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SMC-Flex User Manual

1. Parameter No Description Parameter No Description Parameter No Description 1 Volts Phase A B 49 OL Trip Enable Disable 97 Data Out A2 2 Volts Phase B C 50 Overload A Lvl 98 Data Out B1 3 Volts Phase C A 51 Underload F Lvl 99 Data Out B2 4 Current Phase A 52 Underload F Dly 100 Data Out C1 5 Current Phase B 53 Underload A Lvl 101 Data Out C2 6 Current Phase C 54 Underload A Dly 102 Data Out D1 7 Watt Meter 55 Undervolt F Lvl 103 Data Out D2 8 Kilowatt Hours 56 Undervolt F Dly 104 Motor ID 9 Elapsed Time 57 Undervolt A Lvl 105 CT Ratio 10 Meter Reset 58 Undervolt A Dly 106 MV Ratio 11 Power Factor 59 Overvolt F Lvl 107 Aux1 Config 12 Mtr Therm Usage 60 Overvolt F Dly 108 Aux3 Config 13 Motor Speed 61 Overvolt A Lvl 109 Aux4 Config 14 SMC Option 62 Overvolt A Dly 110 Aux2 Config 15 Motor Connection 63 Unbalance F Lvl 111 Language 16 Line Voltage 64 Unbalance F Dly 112 Timed Start 17 Starting Mode 65 Unbalance A Lvl 113 Shut Off Level 18 Ramp Time 66 Unbalance A Dly 114 UTS Level 19 Initial Torque 67 Jam F Lvl 115 Parameter Mgmt 20 Cur Limit Start 68 Jam F Dly 116 Backspin Timer 21 Reserved 69 Jam A Lvl 117 VShut Off Level 22 Kickstart Time 70 Jam A 118 OL Reset Level 23 Kickstart Level 71 Stall Delay 119 Ambient Temp 24 Option Input 2 72 Gnd Fit Enable 120 Notch Position 25 Starting Mode 2 73 Gnd Fit L
2. Controller IP65 Type 4 12 Rating A B Height A Width C Depth Non Combination Controller mm in 6004 406 69 253900 7 25 610 24 406 16 254 10 43 610 24 406 16 254 10 60 610 24 406 16 254 10 85 610 24 406 16 254 10 108 762 30 610 24 305 12 135 762 30 610 24 305 12 201 965 38 762 30 356 14 251 965 38 762 30 356 14 317 1295 51 914 36 356 14 361 1295 51 914 36 356 14 480 1295 51 914 36 356 14 625 2286 90 762 30 508 20 Combination Controllers with Fusible Disconnect 5 610 24 406 16 254 10 25 610 24 406 16 254 10 43 610 24 406 16 254 10 60 610 24 406 16 254 10 85 610 24 406 16 254 10 108 965 38 762 30 356 14 135 965 38 762 30 356 14 201 965 38 762 30 356 14 251 965 38 762 30 356 14 317 1524 60 965 38 356 14 361 1524 60 965 38 356 14 480 1524 60 965 38 356 14 480 2286 90 889 35 508 20 625 2286 90 1397 55 508 20 780 2286 90 1397 55 508 20 Combination Controllers with Circuit Breaker 5 610 24 406 16 254 10 25 610 24 406 16 254 10 43 610 24 406 16 254 10 60 610 24 406 16 254 10 85 610 24 406 16 254 10 108 965 38 762 30 356 14 135 965 38 762 30 356 14 201 965 38 762 30 356 14 251 965 38 762 30 356 14 317 1295 51
3. L1 1 T1 2 3 Phase 7 L2 3 T2 4 Input Power L3 5 T3 6 E Sad MO Mex Controller row L Nyy Control Power 100 240 VAC H A X00 O X00 00X SMC Flex Control Terminals 23 24 25 26 27 28 29 30 31 32 33 34 V J J k E Ground Aux 2 Input Input Fault Customer supplied Aux 3 Aux 4 3 28 Wiring Preset Slow Speed Figure 3 26 and Figure 3 27 show the different wiring for the Preset Slow Speed Figure 3 26 Typical Wiring Diagram for the Preset Slow Speed Control Power Option Command SMC Flex Control Terminals Aux 1 23 2 as 26 27 28 29 30 at a2 33 as ee es Ge PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Slow Speed Note Refer to Chapter 3 for typical power circuits Wiring 3 29 Figure 3 27 Typical Slow Speed Wiring Diagram for Hand Off Auto DPI
4. 3 7 Controllers rated 625 1250 3 7 Control Wire Specifications serene 3 11 Fall M m 3 11 Fan Terminations insan a e a 3 11 Control Terminal Designations eren 3 12 Standard Controller Wiring Diagrams 3 13 Soft Stop Pump Control and SMB Smart Motor Braking 3 24 Preset Slow Speed 3 28 Slow Speed with Braking ccccccscescscssssescssssscssessssssecssesssessesaeseseesesees 3 30 Sequence of Operation eese 3 31 Special Application Considerations seen 3 36 Use of Protective Modules 36 Multi motor Applications esseeseeeeereernnn nnn 3 38 SMC Flex Controller as a Bypass to an AC Drive 3 39 SMC Flex Controller with a Bulletin 1410 Motor Winding Heater 3 40 VervIgw i t te mto tete ee 4 1 Keypad Description eseseseeeeenee rennen 4 1 Programming MENU eseeeeeeneennn nnne nnn nnn nnn nnn nns 4 1 Password encanta ished ee et eee eee 4 5 Parameter Management es
5. SMC Flex Control Terminals Aux 1 Ta TsTsTeTaTsTs Ts TSTS T Ww TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault 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 For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Soft Stop Pump Stop or Brake Aux 4 should be set to normal operation Note Refer to Chapter 3 for typical power circuits 3 26 Wiring Figure 3 24 Typical Wiring Diagram for Applications Requiring an Isolation Contactor Control Power Option Stop Teel Te TS Te Te T SMC Flex Control Terminals Aux 1 sTT TsTToT2 Te sT TeT Aged C U PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Soft Stop Pump Stop or Brake Aux 4 should be set to normal operation Note Refer to Chapter 3 for typical power circuits Wiring 3 27 Figure 3 25 Typical Wiring Diagram for Hand Off Auto DPI Control Soft Stop Braking and Pump Control Only
6. These not orderable catalog numbers they appear on the product label of the orderable part If a control module needs to be ordered reference the control module renewal part no found in Appendix C Control Type Control Voltage Line Voltage Amperes Originally Ordered Renewal Part Cross Reference Internal Control Orderable Power AB Cat No Module Label Poles Pump Control 100 240V 200 480V AC 5 150 F5NBDB B 150 FB1FX 150 FPP5B 25 150 F25NBDB B 150 FB1FX 150 FPP25B 43 150 F43NBDB B 150 FB1FX 150 FPP43B 60 150 F60NBDB B 150 FB1FX 150 FPP60B 85 150 F85NBDB B 150 FB1FX 150 FPP85B 150 F108NBDB B 150 FB1FX 150 FPP108B 150 F135NBDB B 150 FB1FX 150 FPP135B 200 600V AC 150 F5NCDB B 150 FB1FX 150 FPP5C 150 F25NCDB B 150 FB1FX 150 FPP25C 150 F43NCDB B 150 FB1FX 150 FPP43C 150 F60NCDB B 150 FB1FX 150 FPP60C 150 F85NCDB B 150 FB1FX 150 FPP85C 150 F108NCDB B 150 FB1FX 150 FPP108C 150 F135NCDB B 150 FB1FX 150 FPP135C 24V AC DC 200 480V AC 150 F5NBRB B 150 FB2FX 150 FPP5B 150 F25NBRB B 150 FB2FX 150 FPP25B 150 F43NBRB B 150 FB2FX 150 FPP43B 150 F60NBRB B 150 FB2FX 150 FPP60B 150 F85NBRB B 150 FB2FX 150 FPP85B 150 F108NBRB B 150 FB2FX 150 FPP108B 150 F135NBRB B 150 FB2FX 150 FPP135B 200 600V AC 150 F5NCRB B 150 FB2FX 150 FPP5C 150 F25NCRB B 150 FB2FX 150 FPP25C 150 F43NCRB B 150 FB2FX 150 FPP43C 15
7. Control L1 1 3 Phase l 19 3 T2 4 Input Power 195 T3 6 D Branch SMC Flex Protection Controller Hand Start _ Hand Stop Option Command SMC Flex Control Terminals PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Slow Speed Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 4 should be set to normal operation 3 30 Wiring Slow Speed with Braking Figure 3 28 shows the wiring for the Slow Speed with Braking option Figure 3 28 Typical Wiring Diagram for the Slow Speed with Braking with an Isolation Contactor Control Power 9 d SMC Flex Control Terminals Aux 1 Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 4 should be set to normal operation Note Refer to Chapter 3 for typical power circuits Wiring 3 31 Figure 3 29 through Figure 3 34 show the different operation sequences for the Soft Stop Preset Slo
8. eseseseesseeeeenennnnennennn nnne nnns A 5 Other and rre ea re tre ro bi E du ber ls A 6 Approximate Dimensions and Shipping Weights A 6 Open Type Controllers essere A 6 Enclosed Type Line Connected Controllers A 7 Parameter Information essent B 1 Renewal Parts 1 Contactor Replacement Installation Instructions for 625250 A UNIS t e ener ere Ernie tas D 1 ACCeSSOFIGS dedo e ren c ee sates ud ceeds a E 1 Renewal Part Cross Reference F 1 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 328 01 108 135 A 41053 228 01 201 480 A 41053 367 01 625 1250 A Selection Guide Publication 150 8G009 9 EN P e Application Guide Publication 150 AT002_ EN P The SMC Flex controller 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
9. mE e nem p eH 80 Co Q 79 811 FEN TN i 3 14 WY SK H Y 3 2 4 THE N L 44311 m N 174 p 5906 V 409 225 513 18 A 8 858 Approx Ship Wt 201 251A mm 225 560 253 8 150 504 1 157 25 91 189 44 311 79 811 30 4 kg i 8858 22047 9992 5906 19847 62 359 174 314 67 Ib All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings Installation Figure 2 6 Dimensions 317 480 A Controllers 63 5 lt 2 50 32 74 17 1 29 A 67 L O x D Oc L3 5 C 89 276 5 DETAIL A 10 89 M12 x 1 75 SCALE 1 000 8 32 UNC 2B 30 5 aces LE 0 12 522 7 18 49 6535 T 25 1 0 1104 51 ET 27 51 118 938 SEE DETAIL A 23 62 n 1600 21 23 1539 18 Alen radey SUG Fax m _ 7 01 L 177 9381 4 07 i 103 52 2 20 561 U t G 5 x se 13 022 2001 e 11 42 2901 Approx Ship Wt 317 480A mm 290 600
10. 100 N Seconds _ Class 10 gt lass 15 Ue a Class 20 C Class 30 10 Vie 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 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 Commun
11. Kickstart Time 0 0 2 0s A boost current is provided to the motor for the programmed time period Kickstart Level 0 90 of locked rotor torque Adjusts the amount of current applied to the motor during kickstart Stop Input Coast Stop Option Allows the user to select the operation of terminal 18 Stop Input Option 1 Input Allows the user to select the operation of terminal 16 Option Input 1 Disable Coast Stop Option Fault Fault NC Network Option 2 Input Allows the user to select the operation of terminal 15 Option Input 2 Disable Slow Speed Dual Ramp Fault Fault NC Network Clear Fault Stop Mode Allows the user to program the SMC Flex controller for the type of stopping that best fits the application Disable Soft Stop Linear Speed Stop Time This sets the time period which the controller will ramp the voltage during a stopping maneuver 0 0 120s Overload Class Disable 10 15 20 30 Service Factor 0 01 1 99 Motor FLC 1 0 2200 OL Reset Auto Manual Aux1 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 19 and 20 Aux Contacts 1 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux2 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 29 and 30 Aux Cont
12. Pump Stop Time seconds If Pump Stop Selected f Coast to rest Selected vadis BB 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 100 Speed Push Buttons Start Stop Smart Motor Braking Auxiliary Contacts Normal Up to speed Closed Open Figure 3 32 SMB Smart Motor Braking Sequence of Operation Smart Motor Braking Start Run Brake Automatic Zero Speed Time seconds Shut off Closed Open Closed Open If Brake Selected Closed Open Closed a If Coast to rest Selected Open vadis 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 Wiring 3 35 Figure 3 33 Accu Stop Sequence of Operation 100 L Brakin Motor M Speed Slow Speed Braking ra Coast to rest M i N Slow Speed br ES 1 slow es Start Run Accu Stop d Speg Time seconds Push Buttons Start Closed f Open Stop Closed 2 Accu Stop Closed Open EE Slow
13. 625 2286 90 762 30 508 20 780 x 2286 90 762 30 508 20 970 2286 90 762 30 508 20 1250 2286 90 762 30 508 20 970 1250 rated devices are only available as Type 1and require a door mounted fan capable of delivering 240 cfm A 8 Specifications Enclosed Type Line Connected Controllers Continued IP65 Type 4 12 Controller Rating A Rang A Width C Depth Combination Controllers with Fusible Disconnect 5 30 A J 610 24 406 16 254 10 25 30 A J 610 24 406 16 254 10 43 60 A J 610 24 406 16 254 10 60 100 A J 610 24 406 16 254 10 85 100 A J 610 24 406 16 254 10 108 200 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 20 625 2286 90 1387 55 508 20 780 2286 90 1387 55 508 20 970 amp 2286 90 1651 65 508 20 1250 2286 90 1651 65 508 20 Combination Controllers with Circuit Breaker 5 15A 610 24 406 16 254 10 25 30A 610 24 406 16 254 10 43 80A 610 24 406 16 254 10 60 100A 610 24 406 16 254 10 85 125A 610 24 406 16 254
14. T2 4 Input power L3 5 T3 6 SMC Flex Controller SHIELD I1 12 13 14 05 1718 SMC Flex Control Terminals SHIELD BLACK WHITE Customer supplied Q Cat No 825 CBCT or Flex Core Cat No 126 252 Note When connecting the ground fault sensors the secondary of the CT should be shorted until the connection to the Flex control module is completed 1 16 Product Overview 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 GF Inhibit Time has expired e GF Current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay 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 1 250 seconds Parameter 73 Gnd Fit Level allows the installer to define the ground fault current at which the SMC Flex will trip It is adjustable from 1 0 5 0 A or 5 0 25 A depending on the service size Important The ground fault inhibit
15. cccccccssescsssssssscsssessessessssessesseseteeseserees 7 10 Configuring DataLinks sess 7 10 Rules for Using DataLinks esseeeeeennnnnnnnnn 7 10 Updating Firmware seseseeseeneeree rennen 7 10 OVeIVIOW Lid remet teet t rere m 8 1 Protection Programming ccsceccsccssessescsssssssssssssssesseseseeseessesseseseseesers 8 1 Chapter 9 Troubleshooting Appendix A Specifications Appendix B Parameter Information Appendix C Renewal Parts Appendix D Accessories Appendix E Accessories Appendix F Renewal Parts Cross Reference nnn nnns 8 1 db rere i de Ee ns 8 2 Fault Buffer essent 8 2 Fault CODES ntn e t er Qa re Pe mcs UL E 8 3 Fault and Alarm Auxiliary Indication for Fault or Alarm 8 3 Fault Deflnitiorls tds re irte rr e reed vea 8 4 IMHO CUGUION ete ad arte nore p ve Ee OR S E ERAS 9 1 Power Module Check eoe ente hec tds 9 7 Shorted SCR Test eie 9 7 Functional Design Specifications ccccccccescssssssssesssssssssssssserssesssssseesers 1 Electrical Ba ngs eme tad meis A 2 Short Circuit Protection ccccccsssssscssssssscsssssssessessssesesssssecsssessessesanseseeees A 3 Environmental maa teret eie tr cer t m re e Tere Pera A 5 Mechanical
16. 900 323 400 1200 416 1250 533 1600 Trip Classes 10 15 20 and 30 Trip Current Rating 11796 of Motor FLC Number of Poles 3 Certifications Open Type Controllers CE Marked Per Low Voltage Directive 73 23 EEC 93 68 EEC UL Listed File No E96956 Open Type Controllers Dimensions are in millimeters inches Dimensions are not intended for manufacturing purposes Approximate Controller Height 1 Shipping Rating A Weight 5 7 kg 5 85 12 6 Ib 108 135 E 201 251 RUN 45 8 kg 317 480 101 Ib 179 kg 625 780 395 Ib 970 1250 ies E Specifications A 7 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 m A lt C IP65 Type 4 12 Controller Rating A on Rating p Height A Width C Depth Non Combination Controller 5 610 24 406 16 254 10 25 m 610 24 406 16 254 10 43 610 24 406 16 254 10 60 610 24 406 16 254 10 85 610 24 406 16 254 10 108 762 30 610 24 305 12 135 762 30 610 24 305 12 201 965 38 762 30 356 14 251 965 38 762 30 356 14 317 1295 51 914 36 356 14 361 1295 51 914 36 356 14 480 1295 51 914 36 356 14
17. Other features that offer further user benefit include e Expanded protective features e Metering e O Communication capability Innovative starting and stopping options provide enhanced performance e Pump Control e Braking Control e Smart Motor Braking SMB e Accu 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 standard squirrel cage induction motors rated 1 1250 A or Star delta wye delta type motors rated 1 8 1600 A up to 690V AC 50 60 Hz Depending upon the controller type ordered the control power input can range from 100 240V AC to 24V AC DC Please verify voltage on product before applying power Soft Start This mode has the most general application The motor is given an initial torque setting 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 Star
18. Q Input Power Branch Protection SMC Flex Controller SMC Flex Aux 1 Control Terminals Ey 2 Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Two speed consequent pole installations Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Overload must be disabled in SMC Flex 3 22 Wiring Figure 3 20 Typical Wiring Diagram for SMC Off Bypass Control L1 1 T1 2 3 Phase L2 3 T2 4 M Input Power L3 5 T3 6 p Branch El SMC Flex Protection Controller SMC Off Bypass Bypass X M OLO Bypass Connector BC SMC Flex Control Terminals Aux 1 E S dtp PTC TACH Ground Input Input Fault Aux 2 Aux 3 Aux 4 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Wiring 3 23 Figure 3 21 Typical Wiring Diagram for Hand Off Auto Contr
19. Table 3 D SMC Flex 108 1250 A Delta Connection Lug Information for Inside the Delta applications Max No Lugs SMC Suggested Lug Conductor Pole Tightening Torque Rating Cat No Range Line Side Wire Lug Lug Busbar 108 135 1494R N15 25 240 mm 1 42 Nem 23 Nem 4 500 375 Ib in 200 Ib in 201 251 A 1494R N14 50 120 mm 2 31 Nem 23 Nem 1 0 250 MCM 275 Ib in 200 Ib in 317 480 A 150 LG5MC 95 240 mm 1 33 9 Nem 28 Nem 3 0 500 300 Ib in 250 Ib in 625 780 A 25 240 mm 2 42 Nem N A 4 500 MCM 375 Ib in 970 1250 A 25 240 mm 4 42 Nem N A 4 500 MCM 375 Ib in For625 1250 A inside the delta connections terminal blocks are required for line side connections Required terminal blocks are as follows Allen Bradley Part 1492 BG 625 780 A 2 per phase 970 1250 A 4 per phase Short Circuit Protection Fuses Cooper Bussmann Part 16504 2 625 780 A 1 per phase 970 1250 A 2 per phase Short Circuit Protection Circuit breaker Q Load side lug information for inside the delta applications is contained in Table 3 C Control Power Wiring 3 7 Control Wiring Refer to the product nameplate for control terminal wire capacity and tightening torque requirements Each control terminal will accept a maximum of two wires Refer to the product nameplate prior to applying control power Depending on t
20. should be turned off Separate overloads are still required to meet the National Electric Code NEC requirements Note The SMC Flex controller s built in overload protection cannot be used in multi motor applications Figure 3 36 Multi Motor Application L1 1 1 2 3 Phase 7 Mot oP otor L2 3 2 4 XW Input Power P v Y Y 13 5 T3 6 DU d m Overload Rel Oil eats SMC Flex elay O L rotection Controller DE 2 pP um eal N Motor Customer Supplied died No2 T AN PA Overload Relay O L SMC Flex Controller as a Bypass to an AC Drive Wiring 3 39 By using the controller as shown in Figure 3 9 a soft start Customer supplied characteristic can be provided in the event that an AC drive is non operational Note Acontrolled acceleration can be achieved with this scheme but speed control is not available in the bypass mode Figure 3 37 Typical Application Diagram of a Bypass Contactor for an AC Drive 1 4 AF AF OL O 3 Phase N VFD Input Power NS 4 2 4 e VFD Branch Protection X X L1A T1 2 l L2 3 T2 4 L3 5 T3 6 IC IC SMC Flex Mechanical interlock required Controller Many VF drives are rated
21. 150 FLA Because the SMC Flex controller can be used for 600 FLA starting separate branch circuit protection may be required Overload protection is included as a standard feature of the SMC Flex controller 3 40 Wiring SMC Flex Controller with a Bulletin Figure 3 38 Typical Application Diagram of SMC Flex Controller with a 1410 Motor Winding Heater Bulletin 1410 Motor Winding Heater IC O L 3 Phase Input Power SMC Flex Controller O HC lt 1 D Bulletin 1410 MWH Customer supplied Overload protection is included as a standard feature of the SMC Flex controller 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 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 o
22. 2 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 7 6 Communications Control Enable Loss of Communication and Network Faults SMC Flex Specific Information If enabling control from the built in SMC Flex programmer the Logic Mask must be set as follows Table 7 D Logic Mask Requirements Mask Code Description 0 No external DPI devices are enabled 4 Only HIM on port 2 is enabled 12 Two HIMs are enabled on ports 2 and 3 32 Only the DPI communication card on port 5 is enabled 36 HIM on port 2 and the DPI communication card on port 5 in enabled 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
23. 20 HIM C3S 20 HIM C5 20 HIM C5S Extension Cables 1202 H03 1202 H10 1202 H30 1202 H90 Splitter Cable 1203 503 Communication DeviceNet 20 COMM D Modules ControlNet 20 COMM C Remote 1 0 20 COMM R Profibus 20COMMP RS 485 20 COMM S InterBus 20 COMM I EtherNet 20 COMM E RS 485 HVAC 20 COMM H ContolNet Fibe 20 COMM Q amp Requires a 20 HIM H10 cable E 2 Accessories Notes Appendix F Description Control Module Renewal Part Cross Reference 230 240V Voltage Voltage Renewal Part No on the Label D Standard 200 600V 100 240V 41391 454 01 S1FX 150 FS1FX 24V AC DC 41391 454 02 S2FX 150 FS2FX 690V 110 120V 41391 454 05 S1FZ 150 FS1FZ 230 240V 200 600V 100 240V 41391 454 01 B1FX 150 FB1FX 24V AC DC 41391 454 02 B2FX 150 FB2FX 690V 110 120V 41391 454 05 B1FZ 150 FB1FZ 230 240V Braking 200 600V 100 240V 41391 454 01 D1AX 150 FD1AX 24V AC DC 41391 454 02 D2AX 150 FD2AX 690V 110 120V 41391 454 05 D1AZ 150 FD1AZ 230 240V 200 600V 100 240V 41391 454 01 D1BX 150 FD1BX 24V AC DC 41391 454 02 D2BX 150 FD2BX 690V 110 120V 41391 454 05 D1BZ 150 FD1BZ 230 240V 200 600V 100 240V 41391 454 01 D1CX 150 FD1CX 24V AC DC 41391 454 02 D2CX 150 FD2CX 690V 110 120V 41391 454 05 D1CZ 150 FD1CZ 230 240V 200 600V 41391 454 02 D1DX 150 FD1DX 230 240V 690V 41391 454 05 D1DZ 150 FD1DZ 230 240V 200 600V 41391 454 02 D1E
24. 276 5 200 539 18 182 25 104 5 55 5 103 5 45 8 kg Controller in 11 42 23 62 10 89 7 87 21 23 7 18 4 11 2 19 4 07 101 Ib All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings 2 10 Installation Figure 2 7 Dimensions 625 780 A Controllers 400 1101 6 1 1 00 254 11921 j 39 pu 130 305 5 1 48 32 UNC2B 1349 1 3X DETAIL A je 790 825 AX 300 1778 2095 17621 9734 4X 275 ter T 1864 ID O O O O e o SEE DETAIL A oltm LJ G 0 9 110414 1 3845 e e 9766 En 2902 9 E 17371 No o o e G9 1 1954 4963 a i o O 13694 1 o o O mE IE G Ir XD FED UA 1 O oO O o 164 vied t L 3 ax 25 1866 1 051 1435 90 13544 1 2169 5509 2350 15969 All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings Installation 2 11 Figure 2 8 Dimensions 970 125
25. 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 delay time is too short for the requirements 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 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 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
26. 59 m 140 31 1 39 135 41 315 bL 81 l R 112 3 ue Ol LY 2 8 xen 6 At 5 5 2 PLACES n 250 16 351 4 PLACES NET BO NET 14 87 mro 1377 81 amp B 12 6 E 321 11 0 7 AlenBrdey SMC Flex 2235575222322 1 a 295 1 51 5 4 1 4 2 PLACES T642 T48 T540 n i ES T2 T2 4 THE LE 9 1 39 81 TT 7 135 41 LH 2 50 ds E E v up be 295 I 2 95 EA m 105 91 ne 117 11 11681 TET TET UNT A 1 43 188 6 NOTE DIMENSIONS IN INCHES MILLIMETERS 2 DIMENSIONS ARE NOT INTENDED TO BE USED FOR MANUFACTURING PURPOSES B H Approx i Ship Wt 5 85A mm 150 1 307 203 1 120 291 119 8 14 1 5 7 kg Controller i 5 91 1209 800 472 1146 472 056 1261b 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 1 Dimensions 108 135 A Controllers 5 10 MEC ON 129 5 1 0
27. 914 36 356 14 361 1295 51 914 36 356 14 480 1295 51 914 36 356 14 625 2286 90 1397 55 508 20 780 2286 90 1397 55 508 20 Usethis row for 460V 58 and 575V 59 Use this row for 460V 59 and 575V 60 and 61 Installation 2 5 Mounting units are fan cooled It is important to locate the controller in a position that allows air to flow vertically through the power module The controller must be mounted in a vertical plane and have a minimum of 15 cm 6 in free space above and below the controller When drilling or installing near the softstarter make sure that adequate measures are taken to protect the device from dust and debris See Figure 2 2 Figure 2 2 SMC Flex Mounting Protection 2 6 Installation Figure 2 3 Dimensions 5 85 A Controllers C 4 12 6 46 11201 11641 I 3 1 101 21 be 412 2 20 112 561 2 PLACES e 1
28. Auxiliary Contacts Speed Normal Up to speed Braking 1 If Coast to rest a Selected When Accu Stop push button is closed start stop function is disabled Ihe 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 36 Wiring 100 Speed Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Brake Closed Open Auxiliary Contacts Normal Closed Open Up to speed Closed Open Special Application Considerations Figure 3 34 Slow Speed with Braking Sequence of Operation Braking Slow Speed i Start Run _ Brake Time seconds i If Coast to rest select d vids BL 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 Use of Protective Modules A protective module see Figure 3 35 containing metal oxide varistors MOVs can be installed to protect the power components from electrical transients and or electrical noise The protective modules clip transients generated on the lines and prevent such surges from damaging the SCRs Wiring 3 37 Figure 3 35 Protective Module There are two general situat
29. C 15 NVS Error 39 No Load A 16 No Load 40 No Load B 17 Line Loss A 410 No Load C 18 Line Loss B 42 0 Line Unbalance 19 Line Loss C 43 Overvoltage 20 V24 Loss 45 Undervoltage 21 V Control Loss 46 Overload 22 Input 1 48 Underload 23 Input 2 49 Jam 24 System Faults 128 209 Table 8 B for definition Auxiliary contacts can be programmed for Fault or Alarm N O or N C indication Parameter setup can be found in the Parameter Motor Protection group when modifying parameters in the Program Mode 8 4 Diagnostics Fault Definitions Table 8 B shows the fault definitions for the SMC Flex Table8 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
30. C A HHH Volt 4 Current Phase A Amps F Gig P 5 Current Phase B Amps F Gi P 6 Current Phase C Amps F Gig P 7 Waitt Meter HEH KW F Gig P 8 Kilowatt Hours H KWH F Gig P 9 Elapsed Time Hour F Gig P 10 Meter Reset No F Gig P 11 Power Factor F 12 Mtr Therm Usage 96MTU The metering values that are displayed on the SMC Flex can be modified to show your desired values by accessing Main Menu Preferences Overview Human Interface Module Chapter 6 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 7 4 for instructions 2 The control terminals must be wired according to Figure 3 14 on page 3 16 or Figure 3 25 on page 3 27 Option Action Operation Standard Soft Stop The green start button when pressed will Current Limit
31. Description PTC Input PTC Input Tach Input Tach Input Ground Fault Transformer Input Ground Fault Transformer Input Aux Contact 420 Aux Contact 20 Aux Contact 300 Aux Contact 300 Aux Contact 40 Aux Contact 40 RC Snubbers are required on loads connected to auxiliary Do not connect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping External Bypass operates an external contactor and overload 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 Control power on units rated 625 1250 A is pre wired internally from terminal block CP1 Wiring 3 13 Standard Controller Wiring Figure 3 11 through Figure 3 22 show typical wiring for the Diagrams SMC Flex controller Figure 3 11 Typical Wiring Diagram for Standard Controller 3 Phase Input Power Protection SMC Flex Controller SMC Flex Control Terminals Aux 1 PTC TACH Ground Aux 2 Aux 43 Aux 4 Input Input Fault Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 3 14
32. This parameter allows for the pump stopping control algorithm to be manually modified It is recommended that you do not make changes to this parameter without specifically talking with Technical Support Linear List Start Delay 1226 Sec 90 An internal on delay timer Ensures that a subsequent start can not be initiated for a preset amount of time Linear List By pass Delay 1236 Sec 15 For applications that routinely see fast spikes of current or overload conditions more than 125 of the SMC s frame rating this parameter can be used to reduce the cycling between SCR and by pass This time delay parameter will allow the SMC to stay under SCR control for the duration of time programmed Linear List Fault 1 124 255 Fault buffer 1 allows display of the current fault A value of 0 indicates that there is no current fault Linear List Fault 2 125 255 Fault buffer 2 represents fault history of the device with fault 1 being the current fault and fault 5 being the oldest fault kept in memory G This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Rockwell Automation technical support if you have Version 4 001 firmware or earlier and need to access this parameter Parameter Information B 13 Table B 1 Parameter List Continued Grou Parameter Parameter Units Min Default Param
33. This parameter identifies the type of control present and is not user programmable Slow Speed Select Low 7 Allows the user to program the slow High 15 speed that best fits the application Slow Accel Current 0 450 of full load Allows the user to program the current required current to accelerate the motor to slow speed operation Slow Running Current 0 450 of full load Allows the user to program the current required current to operate the motor at the slow speed setting Braking Current 0 400 of full load Allows the user to program the current intensity of the braking current applied to the motor Stopping Current 0 400 of full load Allows the user to program the current intensity of the braking current applied to the motor from slow speed operation Programming 4 13 Option Parameter Range Slow Speed SMC Option Braking Control with Braking This parameter identifies the type of control present and is not user programmable Slow Speed Select Low 796 Allows the user to program the slow High 15 speed that best fits the application Slow Accel Current 0 450 of full load Allows the user to program the current required current to accelerate the motor to slow speed operation Slow Running Current 0 450 of full load Allows the user to program the current required current to operate the motor at the slow speed setting Braking Current 0 400 of full lo
34. Time seconds vids ill Accu Stop and Slow Speed with Braking are not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements 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 10000 AN Braking SA N Motor Speed Coast to rest 7 or 15 V N E AN 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 Parameter 12 Motor Thermal Usage an Overload Fault will occur when this value reaches 10096 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 2200A Service Factor 0 01 1 99 Notes 1 The factory default setting for Overload Class which is 10 enables overload protection The motor s full load current rating must be programmed to proper
35. V Control F46 e Sense of control voltage in error e Same as F44 Option Input 1 2 F48 F49 e Fault occurs based on the user e Review the option input fault configuration and clear configuration of the option input the fault condition Varies control module F128 F209 e Control module wiring e Review the control module wiring Ensure ground system faults e Control module defective terminal is secure connected to system earth ground Ensure an RC snubber is connected to all inductive loads in the control circuit refer to input wiring e Replace the control module Prestart fault indication Table 9 B Motor Will Not Start No Output Voltage to the Motor Display Possible Cause Possible Solutions Fault displayed e See fault description e Table 9 A addressing fault conditions Display is blank e Control voltage is e Check control wiring and absent correct if necessary e Failed control module e Replace control module e Cycle control power Stopped e Pilot devices e Check wiring 0 0 Amps e Enable input is e Check wiring open at terminal 13 e Input terminals are not e Check wiring wired correctly e Start Stop control has not been enabled for the human interface Follow the instructions on page 7 4 7 6 to enable control capability module e Control voltage e Check control voltage e Failed control module e Replace control module Starting e Twoorthree power e Check power system phases
36. Wiring Figure 3 12 Typical Wiring Diagram for Two Wire Control with Stopping Control No DPI Control 3 Phase ET T2 4 L3 5 T3 6 Input Power Protection Controller Two Wire Device Am e TISTSTSTSTSTST8Te T Te Te SMC Flex Control Terminals Aux 1 PPP PPP PPE Te Te T LENS 22 Ground Input Input Fault Aux 2 Aux 3 Aux 4 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 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 The OFF state leakage current for a solid state device must be less than 6 mA Wiring 3 15 Figure 3 13 Typical Wiring c for Dual Ramp Applications 3 Phase TET T2 4 L3 5 T3 6 SMC Flex Controller Input Power Branch Protection Q FRESE Te TT Te Te Te Te SMC Flex Control Terminals Aux 1 PPP PP PEPE Te P G 2 e PTC TACH Ground Input Input Fault Aux 2 Aux 3 Aux 4 amp Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1
37. and high ambient temperatures The following table defines the SMC Flex PTC thermistor input and response ratings Table 1 4 Input Ratings Response resistance 3400 Q 150 Q Reset resistance 1600 Q 100 Q Short circuit Trip Resistance 25 Q 100 Maximum Voltage at PTC Terminals 4 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 y 1330 550 250 Ha 4 100 20 10 20 C TNF 20K TNF 15K 0 C TNF 5K TNF 5K TNF PTC Trip The SMC Flex will trip with a PTC indication if other fault currently exists e PTC protection is enabled 1 18 Product Overview 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 Overtemperature The SMC Flex controller monitors the temperature of the SCRs and Bypass by using internal thermistors When the
38. are missing Table 9 C Motor Rotates but does not accelerate to full speed Display Possible Cause Possible Solutions Fault displayed e fault description e Table 9 A addressing fault conditions Troubleshooting 9 5 Starting e Mechanical problems e nadequate Current Limit setting e Failed control module Table 9 D Motor Stops While Running Display Fault displayed Possible Cause e See fault description e Check for binding or external loading and correct e Check motor e Adjust the Current Limit Level to a higher setting e Replace control module Possible Solutions e Table 10 A addressing fault conditions Display is blank e Control voltage is absent e Failed control module e Check control wiring and correct if necessary e Replace control module Stopped e Pilot devices e Check control wiring and 0 0 Amps correct if necessary e Failed control module e Replace control module Starting e Twoorthree power e Check power system phases are missing e Failed control module Table 9 E Miscellaneous Situations e Replace control module Situation Possible Cause Possible Solutions Motor current and e Motor e Verify type of motor as a standard voltage fluctuates squirrel cage induction motor with steady load e Erratic Load e Check load conditions Erratic operation e Loose e Shutoff all power to controller and connections chec
39. de 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 daB commence motor acceleration to full speed The red stop button when pressed will amp 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 6 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 opera
40. effective in the run mode It will not Linear List Emergency Run 850 1 Enable Disable override faults prior to starting i e shorted gt SCR This parameter is reset to off disable when control power is recycled 0 Disable This parameter allows the user to override a Linear List Current Loss 869 2 Enable current loss fault This is indicative of the 1 Enable j typical failure mode of a damaged CT Allows the user to enable or disable control Comm from various serial interface ports DPI with a Masks Logic Mask 87 8 bit binary 0 0 setting If a port is set to 1 the port will be allowed to control the SMC and will produce a comm fault if disconnected DataLinks Data In A1 88 0 16 bit Datalink DataLinks Data In A2 89 0 16 bit Datalink DataLinks Data In B1 90 0 16 bit Datalink DataLinks Data In B2 91 0 16 bit Datalink DataLinks Data In C1 92 0 16 bit Datalink DataLinks Data In C2 93 0 16 bit Datalink DataLinks Data In D1 94 0 16 bit Datalink DataLinks Data In D2 95 0 16 bit Datalink DataLinks Data Out A1 96 0 16 bit Datalink DataLinks Data Out A2 97 0 16 bit Datalink DataLinks Data Out B1 98 0 16 bit Datalink DataLinks Data Out B2 99 0 16 bit Datalink DataLinks Data Out C1 100 0 16 bit Datalink DataLinks Data Out C2 101 0 16 bit Datalink DataLinks Data Out D1 102 0 16 bit Datalink DataLinks Data Out D2 103 0 16 bit Datalink This parameter is not viewable without entering a
41. ir b ore n he a n Ha ded PED ds 6 1 Human Interface Module sess 6 1 Standard aeter ee mde ek 6 1 PUMP COMMON retener ette e edet m tente ER thee 6 2 Braking Control i tete tete 6 2 OVeIVIBW ettet theta recitat in d RES 7 1 Communication Ports 22 22 222 7 1 Human Interface Module essen nnne 7 2 c je ree e 7 2 Connecting the Human Interface Module to the Controller 7 4 HIM Control Enable esses 7 4 Control 7 6 Loss of Communication and Network Faults 7 6 SMC Flex Specific Information essere 7 6 Default Input Output Configuration eeeenenennnn 7 1 Variable Input Output Configuration serene 7 7 SMC Flex Bit Identification esee 7 8 Reference Feedback 7 9 Parameter Information 7 9 Scale Factors for PLC Communication esee 7 9 Read Example i tee tete ree ies 7 9 Write Example tmt tete e tete nt ee es 7 9 Display Text Unit Equivalents
42. level of motor thermal usage that will cause an alarm when the level exceeds the setting Underload Underload F Lvl 51 FLC Allows the user to set a current of line FLC that will cause a fault when the motor current falls below this value A zero value is the off setting Underload Underload F Dly 52 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the motor current condition must persist within for the controller to fault Underload Underload A Lvl 53 FLC Allows the user to set a current of line FLC that will cause an Alarm when the motor current falls below this value A zero value is the off setting Underload Underload A Dly 54 Secs Allows the user the ability to prevent some nuisance Alarm conditions by entering a delay period that provides a window that the motor current condition must persist within for the controller to Alarm Under voltage Undervolt F Lvl 55 AV Allows the user to set a voltage of line Voltage that will cause a fault when the voltage falls below this value A zero value is the off setting Under voltage Undervolt F Dly 56 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage condition must persist within for the controll
43. of the stop input This is an additional Elapsed Time Meter that Linear List Elapsed Time 2 1340 Hours 0 0 3000 0 canriot bet reset by theruser Hinerements exactly as the Elapsed Time but cannot be reset This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Rockwell Automation technical support if you have Version 4 001 firmware or earlier and need to access this parameter Parameter Information Description Standard Control Modules Renewal Parts Appendix C Part No For units rated 200 600V AC ponas HER 100 240V AC 24V AC DC 100 240V AC 41391 454 05 S1FZ Pump All All 41391 454 01 S1FX 41391 454 01 B1FX 41391 454 02 S2FX 41391 454 02 B2FX 41391 454 05 B1FZ Braking 5 85 A 41391 454 01 D1AX 41391 454 02 D2AX 41391 454 05 D1AZ 108 251A 41391 454 01 D1BX 41391 454 02 D2BX 41391 454 05 D1BZ 317 480A 41391 454 01 D1CX 41391 454 02 D2CX 41391 454 05 D1CZ 625 780 A 41391 454 01 D1DX N A 41391 454 05 D1DZ 970 1250 A 5A 41391 454 01 D1EX 200 480V 150 FPP5B N A Part No Line Voltage 200 600V 150 FPP5C 41391 454 05 D1EZ 230 690V N A 150 FPP25B 150 FPP25C N A 150 FPP43B 150 FPP43C N A 150 FPP60B 150 FPP60C N A 150 FPP85B 150 FP
44. 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 e Line Fault with phase indication Line voltage loss Missing load connection Shorted SCR Running protection includes e 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 1 0 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 Braking Accu Stop and Slow Speed with Braking control options 2 The elapsed time and k
45. special password in Firmware versions 4 001 or earlier Contact Rockwell Automation technical support if you have Version 4 001 firmware or earlier and need to access this parameter B 10 Parameter Information Table B 1 Parameter List Continued Parameter Parameter _ Default EN User Group Name Number Units Max Settings Parameter Description Settings Allows the user the ability to assign a specific identification number to a motor and Motor controller combination This can be useful for Data Moe ie 009299 0 network applications where you may need to locate a specific motor controller based on a network address Motor Sets the proper current ratio when an external CT Ratio 105 1 1500 current transformer is used for Medium Data Voltage applications Motor Sets the proper feedback scaling when used Data MY Dato 106 tered NDE for Medium Voltage applications Normal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each Up Aux1 Config 107 Fault NC Normal Auxiliary relay contact for a specific operation Alarm Note Normal SMC in RUN Alarm NC Network Network NC External Bypass Normal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each Up Aux3 Config 108 Fault NC Alarm Auxiliary relay contact for a specific operation Alarm Note Normal SMC in RUN Alarm NC Network Network NC External Bypass No
46. 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 Control Option 100 Motor Speed Pump Start Run Pump Stop Time seconds Kickstart is also available with Pump Control Washam Pump stopping is not FETTE Pun soppusdenobin endedigsededassm to be used as an emergency stop Referto the applicable standard for emergency stop requirements Vara ill 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
47. 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 a 100 Ruming Jam gt Time seconds detection is disabled during slow speed and braking operation Q Unit 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 require the use of external sensor Installation of this sensor allows the option of enabling Ground Fault Trip Ground Fault Alarm or both For the 5 480 Amp devices the recommended sensor is a Cat No 825 CBCT core balance current transformer for 1 5 A core balanced ground fault protection For the 625 1250 A devices the recommended sensor is shown below and provides 5 25 A core balanced ground fault protection e Manufacturer Allen Bradley e Description 600 Volt Rated Current Transformer e Catalog Number 1411 126 252 e Ratio 2500 5 Figure 1 17 Branch Livi rive pe L2 3
48. the user the ability to prevent some Ground nuisance faults by entering a delay period that Fault Gnd Fit Delay 74 Secs 0 1 250 0 0 5 provides a window that the ground fault 5 condition must persist within for the controller to fault Ground Allow the user the ability to disable inhibit Fault Gnd Fit Inh Time 75 Secs 0 250 10 ground fault protection for a selected time when starting Ground Disable Enables a ground fault protection Alarm when d Gnd Fit A Enable 76 Disable used with an external core balanced ground Fault Enable fault sensor Ground Allows the user to set a current core balance Gnd Fit A Lvl 77 Amps 1 0 5 0 9 2 0 current that will cause an Alarm when the Fault current is above this value Allows the user the ability to prevent some Ground nuisance Alarms by entering a delay period Gnd Fit A Dly 78 Secs 0 250 10 that provides a window that the ground fault Fault pup condition must persist within for the controller to Alarm Disable Enables PTC based over temperature PTC PTC Enable 79 Enable Disable protection when used with external PTC sensors Allows the user to prevent starting if the Phase Disable incoming line phase sequence is not correct Reversal Phase Reversal 80 Enable Disable The incoming power lines are expected to be in an ABC sequence The controller will fault if power lines are out of the ABC sequence Limits the number of starts that can occur in a one hour period This feature incl
49. 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 GF Inhibit Time has expired 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 or 5 0 25 A depending on the service size 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 0 250 seconds Product Overview 1 17 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 conditions as obstructed cooling
50. voltage 9o of line Voltage that will cause an Alarm when the voltage falls above this value A zero value is the off setting Over voltage Overvolt A Dly 62 Secs Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage condition must persist within for the controller to Alarm Unbalance Unbalance F Lvl 63 Allows the user to set a percentage of line to line Voltages that will cause a fault when the voltage falls above this value A zero value is the off setting Unbalance Unbalance F Dly 64 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage unbalance condition must persist within for the controller to fault Unbalance Unbalance A Lvl 65 Allows the user to set a percentage of line to line Voltages that will cause an Alarm when the voltage falls above this value A zero value is the off setting Unbalance Unbalance A Dly 66 Secs Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage unbalance condition must persist within for the controller to Alarm Jam Jam F Lvl 67 FLC 0 1000 Allows the user to set an instantaneous over current level of line FLC that will cause a fault A zero value is the off s
51. 0 A Controllers 8 32 UNC 2B 13 Be 41 F ail AL te 1 SEE DETAIL A 29 02 A 954 1 454 bes 1 1386 5791 Height Ship Wt 970 1250 mm 596 9 1041 4 346 2 550 9 594 1 214 9 200 4 224 kg Controller in 23 5 410 13 63 21 69 23 39 8 46 7 89 495 Ib All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings 2 12 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 690V 15 cm 6 in diameter coil 8 loops Take care in mounting the coils so that they are not stacked directly on top of each other stacking will cause a cancelling effect Also mount the coils on insulated supports away from metal parts so th
52. 0 F60NCRB B 150 FB2FX 150 FPP60C 150 F85NCRB B 150 FB2FX 150 FPP85C B 150 F108NCRB 150 FB2FX 150 FPP108C 150 F135NCRB 150 FB2FX 150 FPP135C 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 Control Type Braking Control Renewal Part Cross Reference Originally Ordered Internal Control Control Voltage Line Voltage hB Cat No sees Module Label 100 240V 200 480V AC Orderable Power 200 600V AC 24V AC DC 200 480V AC 200 600V AC Poles 150 F5NBDD 150 FD1AX 150 FPP5B 150 F25NBDD 150 FD1AX 150 FPP25B 150 F43NBDD 150 FD1AX 150 FPP43B 150 F60NBDD 150 FD1AX 150 FPP60B 150 F85NBDD 150 FD1AX 150 FPP85B 150 F108NBDD 150 FD1BX 150 FPP108B 150 F135NBDD 150 FD1BX 150 FPP135B 150 F5NCDD 150 FD1AX 150 FPP5C 150 F25NCDD 150 FD1AX 150 FPP25C 150 F43NCDD 150 FD1AX 150 FPP43C 150 F60NCDD 150 FD1AX 150 FPP60C 150 F85NCDD 150 FD1AX 150 FPP85C 150 F108NCDD 150 FD1BX 150 FPP108C 150 F135NCDD 150 FD1BX 150 FPP135C 150 F5NBRD 150 FD2AX 150 FPP5B 150 F25NBRD 150 FD2AX 150 FPP25B 150 F43NBRD 150 FD2AX 150 FPP43B 150 F60NBRD 150 FD2AX 150 FPP60B 150 F85NBRD 150 FD2AX 150 FPP85B 150 F108NBRD 150 FD2BX 150 FPP108B 150 F135NBRD 150 FD2BX 150 FPP135B 150 F5NCRD 150 FD2AX 150 FPP5C 150 F25NCRD 150 FD2AX 150 FPP25C 150 F43NCRD 1
53. 000 85 kA 3200 85 kA 3000 Delta Device Operational Current Rating A 8 7 5 kA 35 5 kA 35 70 kA 17 5 43 5 kA 150 5 kA 150 70 kA 90 74 10 kA 300 10 kA 300 70 kA 150 104 10 kA 400 10 kA 400 70 kA 200 147 10 kA 400 10 kA 400 70 kA 200 187 10 kA 600 10 kA 500 70 kA 300 234 10 kA 700 10 kA 700 70 kA 400 348 18 1000 18 1000 70 kA 600 435 18 kA 1200 18 kA 1200 70 kA 800 549 30 kA 1600 30 kA 1600 69 kA 1000 625 30 kA 1600 30 kA 1600 69 kA 1200 831 42 kA 1600 30 kA 1600 69 kA 1600 850 42 kA 1600 42 2000 74 1600 900 42 1600 42 2000 74 1600 1200 85 3000 85 3200 85 kA 3000 1600 85 3000 85 3200 85 3000 SCCR Performance 690V Type 1 SCCR List Max Ampere Tested North Max Ampere Tested Max Std Available Fault American Style European Style Maximum FLC Device Rating A 108 135 201 251 317 361 480 625 780 970 1250 Consult local codes for proper sizing of short circuit protection Non time delay fuses Class K5 5 480 8 7 831 A devices 70 kA 70 kA 70 kA 70 kA 70 kA 70 kA 70 kA 70 kA 70 kA 85 kA 85 kA A070URD33xxx500 A070URD33xxx500 A070URD33xxx700 A070URD33xxx700 A070URD33xxx900 A070URD33xxx900 070033 1250 A100URD73xxx1250 A070URD33xxx1400 A070URD33xxx1400 2 fuses in parallel A070URD33xxx1250 2 fuses in parallel A070URD33xxx1250 Class L 625 1250 850 1600 A devices High capacity fault rat
54. 10 108 175 A175 A Plug 965 38 762 30 356 14 135 225 A 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 14 625 2286 90 1397 55 508 20 780 2286 90 1397 55 508 20 970 amp 2286 90 1651 65 508 20 1250 2286 90 1651 65 508 20 Use this row for 460V 58 and 575V 59 Use this row for 460V 59 and 575V 60 and 61 970 1250 rated devices are only available as Type 1 and require a door mounted fan capable of delivering 240 cfm Appendix B Table B 1 Parameter List Parameter Information Group Parameter Name Parameter Number Units Min Default Parameter Description Door Max Settings p Settings Metering Volts Phase A B Provides the three phase to phase supply Volt voltage measurements at all times including bypass operation Metering Volts Phase B C Provides the three phase to phase supply Volt voltage measurements at all times including bypass operation Metering Volts Phase C A Provides the three phase to phase supply Volt voltage measurements at all times including bypass operation Metering Current Phase A Provides the three phase motor current measurement This measurement is a
55. 2 G 126 19 y e Tr Qa r 16 57 T 1420 81 E 38251 8 43 214 15 58 E 1385 81 13611 B 14 07 15 32 351 5 3891 oe 17 47 d 443 1 08 2 11 0 295 Jil 17 57 9 2 S 13 54 541 5 10 isi 1129 51 11081 8 35 212 2 0 1 14 196 6 A Approx Ship Wt 108 135 A mm 196 4 443 7 212 2 166 6 367 129 5 26 15 kg Controller in 774 1747 8 35 6 56 1445 5 10 1 02 33 Ib All dimensions are approximate and are not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings 2 8 Installation Figure 2 5 Dimensions 201 251 A Controllers E 508 2 0 249 La 135 980 u li 531 i i a ds uie 25 48 984 1 890 M10X 1 5 M d D i Ns 8 32 UNC 2B DETAIL AA SCALE 1 000 rm 2538 9992 197 776 011 5 ib m 157 25 a ad 6 2 i i i i 1 s 54 J ss 3 59 250 Tm 1 083 e 5 6H 164 126 6 46 i gt LT SEE DETAIL AA o 245 689 24 8 67 Fr ds E il 504 1 I 984 1 o e NEN
56. 2 Parameter Menu Structure 9 Parameter Motor m Monitoring 4 Set Up lt gt Protection lt gt Communications 4 Utility lt gt Linear List Metering Basic Overload Jam Comm Masks Language Linear List Volts Phase A B SMC Option Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase B C Motor Connection Service Factor Jam F Dly Parameter Mgt Parameter Mgt Parameter Mgt Volts Phase C A Line Voltage Motor FLC Jam A Lvl Current Phase A Starting Mode Overload Reset Jam A Dly Current Phase B Ramp Time Overload A Lvl Parameter Mgt poss Beie Current Phase C Initial Torque Parameter Mgt Data In A1 MotorFLC Watt Meter Cur Limit Lvl Stall Data In A2 Motor ID Kilowatt Hours Kickstart Time UEC Data In B1 Parameter Mgt Elapsed Time Kickstart Lvl Stall Dly Data In B2 Meter Reset Stop Input Underload F Lvl Parameter Mgt Data In C1 Power Factor Option 1 Input Underload F Dly Data In C2 Mtr Therm Usage Option 2 Input Underload A Lvl Ground Few Data In D1 Motor Speed Stop Mode Underload A Dly Data In D2 Stop Time Parameter Mgt Gnd Fit Enable Data Out A1 Braking Current Gnd Fit Lvl Data Out A2 Overload Class Gnd Fit Data Out B1 Service Factor Gnd FitInh Time Data Out B2 Motor FLC Undervolt F Lvl Gnd Fit A Enable Data Out C1 Overl
57. 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 25 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 Programming Parameters Programming 4 11 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 SMC Option This parameter identifies the type of control present and is not use
58. 50 FD2AX 150 FPP43C 150 F60NCRD 150 FD2AX 150 FPP60C 150 F85NCRD 150 FD2AX 150 FPP85C 150 F108NCRD 150 FD2BX 150 FPP108C 150 F135NCRD 150 FD2BX 150 FPP135C 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 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 150 UMO008H EN P January 2010 PN 40055 218 01 8 Superecedes Publication 150 UM008G EN P November 2006 Copyright 2010 Rockwell Automation Inc All Rights Reserved Printed in USA
59. 60 Utilization Category AC 15 DC PTC Input Ratings Response Resistance 3400 Q 150 Q Reset Resistance 1600 Q 100 Q Short Circuit Trip Resistance 250 100 Max Voltage at Terminals 4 lt 7 5V Max Voltage at PTC Terminals open 30V Max 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 Heatsink fans can be powered by either 110 120V AC or 220 240V AC Specifications A 5 Environmental Mechanical Operating Temperature Range 5 50 C 23 122 open 5 40 C 23 104 enclosed Storage and Transportation Temperature 20 75 Altitude 2000 m 6560 ft Humidity 5 95 non condensing Pollution Degree 2 product s allowable operational ambient temperature must be derated by 3 C 27 F per 1000 m 3280 ft Maximum operating altitude is 7000 m 23 000 ft Current rating of the SMC Flex does not change for altitudes that require a lower maximum ambient temperature Resistance Operational All 1 0 G Peak 0 15 mm 0 006 in displacement to Vibration Non 5 480 A 2 5 G 0 38 mm 0 015 in displacement Operational 625 1250 A 1 0 G Peak 0 15 mm 0 006 in displacement Resistance Operational 5 85A 15G to Shock 108 480 A 5 5 G 625 1250 A 4G Non 5 85A 30G Operational 108 480 A 25G 625 1250 A 12G Construction P
60. C Flex A DataLink is a mechanism used by 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 Rules for Using DataLinks e Each set of DataLink parameters in an SMC Flex can 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 SMC Flex 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 The latest version of firmware and instructions for the SMC Flex can be obtained from www ab com Overview Fault Display Chapter 8 Diagnostics This chapter describes the fault diagnostics of the SMC Flex controller Further this section describes the conditions that cause various faults to occur Protectio
61. Circuit Rated Operation Voltage 5 480A 100 240V AC or 24V AC DC 625 1250 110 120 AC and 230 240V AC Rated Insulation Voltage All N A 240V Rated Impulse Voltage All N A 3000V Dielectric Withstand All 1600V AC 2000V Operating Frequency All 47 63 Hz Input on state voltage minimum 85V AC 19 2V DC 20 4V AC Input on state current 20 mA 120V AC 40 mA 240V AC 7 6 mA 24V AC DC 50V AC 10V DC 12V AC 10 mA AC 3 mA DC Input off state voltage maximum Input off state current input off state voltage 6901 power is only available with 100 240V control Specifications A 3 Short Circuit Protection SCPD Performance 200 600V Protection Type 1 SCCR List Type Non Time Delay Fuse Circuit Breaker Time Delay Fuse Max Std Max Circuit iae i Fuse meus bu Breaker MER High Fault 5 A A Line Device Operational Current Rating A 5 5 kA 20 5 kA 20 70 kA 10 25 5 kA 100 5 kA 100 70 kA 50 43 10 kA 150 10 kA 150 70 kA 90 60 10 kA 225 10 kA 225 70 kA 125 85 10 kA 300 10 kA 300 70 kA 175 108 10 kA 400 10 kA 300 70 kA 200 135 10 kA 500 10 kA 400 70 kA 225 201 18 600 18 600 70 kA 350 251 18 kA 700 18 kA 700 70 kA 400 317 30 kA 800 30 kA 800 69 kA 500 361 30 kA 1000 30 kA 1000 69 kA 600 480 42 kA 1200 42 kA 1200 69 kA 800 625 42 1600 42 1600 74 1600 780 42 kA 1600 42 kA 2000 74 kA 1600 970 85 kA 2500 85 kA 2500 85 2500 1250 85 kA 3
62. Figure 3 1 Figure 3 2 and Figure 3 3 for fan power connection locations vids Bi The fan jumpers have been factory installed for 110 120V AC input Refer to Figure 3 9 for 220 240V AC fan wiring 5 480A devices only Figure 3 9 Power Terminations 625 1250 A Control Power Fan Terminations 5 480A Fan Terminations CP1 110 120 VAC Factory Set Optional Or 110 120 VAC 220 240 VAC 230 240 VAC 50 60 Hz ONLY 1 1 To To 1 2 Supply 2 Supply x To Jumpers lt Jumper 2 LAN Supply 3 3 Jumpers 3 4l 4 Table 3 G Heatsink Fan Control Power SMC Rating Heatsink Fan VA 5 135A 20 201 251A 40 317 480A 60 625 780A 150 970 1250 150 internally wired 3 12 Wiring 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 Aux Contact 10 Aux Contact 10 Not Used Not Used As shown in Figure 3 10 the SMC Flex controller contains 24 control terminals on the front of the controller Figure 3 10 SMC Flex Controller Control Terminals Terminal Number 23 24 25 26 27 28 29 30 31 32 33 34
63. IM Rev3 002 or later must be utilized with the SMC Flex Note Extension cables are available up to a maximum of 10 m in total length Note A maximum of two HIM modules can be installed Communications 7 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 option maneuver for example Pump Stop yada iil The Bulletin 20 HIM interface module s stop 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 viis BB The external HIM has a similar programming operation to the built in programmer but note that differences do exist other controls available with the various human interface modules are non functional with the SMC Flex controller 7 4 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 7 1 shows the connection of the SMC Flex controller to a human interface module Table 7 C provides a description of e
64. OMM DPI communication module Communications One DPI provided for connection to optional human interface and communication modules Starting and Stopping Modes e SoftStart 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 MW MWH 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 Four fully programmable contacts as normal up to speed network N 0 N C or external bypass N O only 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 controlled position
65. P85C N A 150 FPP108B 150 FPP108C 150 FPP108Z 150 FPP135B 150 FPP135C 150 FPP135Z 150 FPP201B amp 150 FPP201C amp 150 FPP201Z 150 FPP251B 150 FPP251C amp 150 FPP251Z 150 FPP317B amp 150 FPP317C 150 FPP317Z 150 FPP361B 150 FPP361C 150 FPP361Z 150 FPP480B 150 FPP480C 150 FPP480Z 150 FPP625B 150 FPP625C 150 FPP625Z 150 FPP780B 150 FPP780C 150 FPP780Z 150 FPP970B 150 FPP970C 150 FPP970Z 150 FPP1250B 150 FPP1250C 150 FPP1250Z 41391 801 03 41391 801 03 41391 801 01 41391 801 02 0 U9J W nan nD 00 41391 801 04 UJ 41391 801 05 41391 803 01 41391 803 02 Description Power Poles Heatsink Fans 110 120V AC Control Power 230 240V AC Control Power Base Plate By Pass 110 120V AC Contactor Control Power 230 240V AC 100 D180ED11 100 D420ED11 Control Power 100 D180EA11 Dann 100 D420EA11 D00 One piece provided per part number Three phase power pole structure provided per part no One phase power pole provided per part no See Appendix D for special installation instructions C 2 Notes Renewal Parts Appendix D Contactor Replacement Installation Instruction
66. 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 gate 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 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 open or shorted e Check resistance of PTC Troubleshooting 9 3 Table 9 A SMC Fault Display Explanation Continued Display Fault Code Possible Causes Possible Solutions Open Bypass 13 14 amp 15 Control voltage is low Check control voltage power supply e noperable power module bypass Replace power module Check control module TB2 TB4 and TB5 TB7 for Secureness Check Aux 1 2 3 4 configurations are 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
67. USER MANUAL FOR SERIES B DESSEN THINK SOME SM EX BULLETIN 150 Rockwell Allen Bradley RockwellSoftwae Automation 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
68. Up Down keys until the qo e Preferences option is highlighted Diagnostics 3 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 O e Change Password US 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 v Naw Cone the password make a note of it as s 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 after you have S ed ange Password completed modifying the password User Dspy lines Preferences 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 RAM lt ROM Random Access Memory RAM This is the
69. WH 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 The SMC Flex has the ability to accept up to two 2 inputs and four 4 outputs controlled over a network The two inputs are controlled at terminal 16 Option Input 1 and terminal 15 Option Input 2 For these two inputs see Chapter 4 for the parameter settings and see Chapter 7 for the bit identification By using these two terminals as inputs the Stop Input will need to be programmed to meet the desired stop functionality The four 4 outputs are Aux 1 Aux 2 Aux 3 and Aux 4 auxiliary contacts are programmable to the function found on page 4 14 If programmed to Network or Network NC they can be controlled over a Network Please see Table 7 H that defines the Logic Command Word Control 1 20 Product Overview Communication Programming Port 5 DPI Communications Port 2 Ports 2 and 3 when two HIMs are connected with a splitter 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 EN Wars Bil B Two peripheral devices can be connected to the DPI The maximum output current through the DPI is 280 mA Setup is easy with the built in keypad and three line sixteen character
70. X 150 FD1EX 230 240V 690V 110 120V 41391 454 05 D1EZ 150 FD1EZ F 2 Renewal Part Cross Reference Originally Ordered Internal Control Orderable Power Control Type Control Voltage Line Voltage Ld Eg Module Label P les Standard 100 240V 200 480V AC 150 F5NBD 150 FS1FX 150 FPP5B 150 F25NBD 150 FS1FX 150 FPP25B 150 F43NBD 150 FS1FX 150 FPP43B 150 F60NBD 150 FS1FX 150 FPP60B 150 F85NBD 150 FS1FX 150 FPP85B 150 F108NBD 150 FS1FX 150 FPP108B 150 F135NBD 150 FS1FX 150 FPP135B 200 600V AC 150 F5NCD 150 FS1FX 150 FPP5C 150 F25NCD 150 FS1FX 150 FPP25C 150 F43NCD 150 FS1FX 150 FPP43C 150 F60NCD 150 FS1FX 150 FPP60C 150 F85NCD 150 FS1FX 150 FPP85C 150 F108NCD 150 FS1FX 150 FPP108C 150 F135NCD 150 FS1FX 150 FPP135C 24V AC DC 200 480V AC 150 F5NBR 150 FS2FX 150 FPP5B 150 F25NBR 150 FS2FX 150 FPP25B 150 F43NBR 150 FS2FX 150 FPP43B 150 F60NBR 150 FS2FX 150 FPP60B 150 F85NBR 150 FS2FX 150 FPP85B 150 F108NBR 150 FS2FX 150 FPP108B 150 F135NBR 150 FS2FX 150 FPP135B 200 600V AC 150 F5NCR 150 FS2FX 150 FPP5C 150 F25NCR 150 FS2FX 150 FPP25C 150 F43NCR 150 FS2FX 150 FPP43C 150 F60NCR 150 FS2FX 150 FPP60C 150 F85NCR 150 FS2FX 150 FPP85C w w w w w w w w w w w w w w w w w w w vn Ww 150 F108NCR 150 FS2FX 150 FPP108C 150 F135NCR 150 FS2FX 150 FPP135C
71. ach port Note The SMC Flex only supports the use of DPI communication modules and DPI HIM LCD Modules Scanport devices are not supported by the SMC Flex See Figure 3 14 on page 3 16 for the control wiring diagram that enables start stop control from a human interface module Figure 7 1 SMC Flex Controller with Human Interface Module Table 7 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 interface 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 Communications 7 5 To enable motor control from a connected human interface module communication module you must take the following programming steps 1 Disconnect the HIM and allow to power down 2 Reconnect the HIM On Initializing screen the bottom right 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
72. acts 2 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux3 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 31 and 32 Aux Contacts 3 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux4 Config Contact is provided as standard with the SMC Flex controller This contact is located at terminals 33 and 34 Aux Contacts 4 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Parameter Mgmt Recall of factory default parameter values Ready 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 Programming 4 15 vui helm Foroverload protection it is critical that the data be Motor Protection entered as it appears on the motor nameplate 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 sett
73. ad Allows the user to program the current intensity of the braking current applied to the motor Al braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor 4 14 Programming 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 Limit Full Voltage Linear Allows the user to program the SMC Flex controller for the type of starting that best fits the application Speed Ramp Time 0 30s This sets the time period during which the controller will ramp the output voltage Initial Torque The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter 0 90 of locked rotor torque Current Limit Level The current limit level that is applied for the Ramp Time selected 50 600 FLC
74. aking Option 1 10 Protection and Diagnostics 1 11 Overload 3 reete Tete te dee nene 1 11 WMO OA i ient ete Re etc Ee tere 1 11 Undervoltage n nri ette 1 13 Overvoltage ce REC RR Decet 1 13 3 adil coh Abit add 1 13 Stall Protection and Jam Detection 1 14 Ground et ere 1 15 Ground Fault Trip niitit eiti a deett 1 16 Ground Fault Alarm nennen 1 16 Thermistor PTC Protection sese 1 17 PUG THp ore pe Nan 1 17 Excessive Starts Hour sse nnn nnne 1 18 OvertemperatUre eese nnn nnn nnns 1 18 Open Gale ss eee ee 1 18 LANG FANS ze ire teinte tte ete erre ne cea 1 18 Metering tc RO TETUR 1 19 See cS oh iri tette emendet ntn Echte ide 1 19 COMMUNICATION 2 22 5 2 3 et eet tette rte diee 1 20 Program Ming eie 1 20 Status Indication esses nnne nnne 1 21 Degree of Protection 2 1 ReCelVIfig een e ee C He d 2 1 UNPACKING M 2 1 Inspecting tdt teet tee cete titan 2 1 STONO a Ae 2 1 Chapter 3 Wiring Chapter 4 Progra
75. ally 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 7 10 Communications Display Text Unit Equivalents Configuring DataLinks Updating Firmware 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 7 1 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 7 1 Text Descriptor Numerical Equivalent Disabled 0 Class 10 1 Class 15 2 Class 20 3 Class 30 4 DataLinks are supported in the SM
76. ar Speed Allows the user to select the type of stop Up Stop Mode 2 SMB Soft Stop provided with the installed controller Accu Stop Basic Set Allows the user to select the length of U Stop Time 33 Secs 0 120 0 Stopping time when a stopping mode is p selected Only available with Pump Control option Allows the ability to manually adjust the pump algorithm slightly for different applications The purpose of this parameter is to allow the Linear List Pump Pedestal 34 pump stop algorithm to be more aggressive earlier in the ramp If experiencing overload trips during stopping either reduce the stopping time or try increasing this by units of 5 Try not to exceed a value of 40 Q 625 780 970 and 1250 A units the min max is 5 0 25 and the default value is 5 0 Amps B 4 Parameter Information Table B 1 Parameter List Continued Group Parameter Name Parameter Number Units Min Max Default Settings Parameter Description User Settings Basic Set Up Accu Stop Braking Current 35 FLC 0 400 When the Smart Motor Braking option is installed this parameter allows the user the ability to adjust the braking current level applied to the motor Smart Motor Braking and Accu Stop has the capability to apply braking current to the motor from the at speed condition With Smart Motor Braking the braking maneuver continues until the motor comes to re
77. 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 Status Indication Product Overview 1 21 Four programmable hard contact outputs are provided as standard auxiliary contacts are programmable for the following states Normal N O N C e Up to Speed N O N C Alarm N O N C Fault N O N C e Network Control N O N C e External Bypass N O Figure 1 21 Control Terminals Opt Start Input 2 Inpu Aux 1 SMC Flex Control Terminals 23 24 25 26 27 28 29 30 31 32 83 34 CRUS RA EN A PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Network inputs can be obtained through proper programming of Option Input 1 and Option Input 2 1 22 Product Overview Notes Degree of Protection Receiving Unpacking Inspecting Storing Chapter 2 Installation The SMC Flex soft starters have an IPOO or IP2X protection rating depending on the size Taking into account the ambient conditions the device must be installed in IP54 Type 2 switchgear cabinets Make sure that no dust liquids or conductive parts can enter the soft starter Soft starter operation produces waste heat heat loss See Table 2 A or Specification
78. ble 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 added to the DeviceNet cable near the SMC Flex control module The recommended cores are TDK ZCAT2023 0930H and TDK ZCAT2035 0930 or equivalent All cores specified are the split type cores and can be added to existing connections Chapter 3 Wiring Terminal Locations The SMC Flex controller wiring terminal locations are shown in Figure 3 1 and 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 Wye 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 Wiring 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 Contr
79. d 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 4 8 Programming 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 0 90 locked rotor torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter Kickstart Time 0 0 2 0s A boost of current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time Ifthe 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 Option Starting Mode Current Limit This must be programmed for Current Limit Ramp Time 0 30s This programs the time period that the controller will hold the fixed reduced output voltage before s
80. 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 requirements 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 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 Replace control module Reset default values Line Loss 41 42 43 e Line distortion Check supply voltage for capability to start stop motor High impedance connection Check for loose connections on line side or motor side of power wires 9 4 Troubleshooting Table 9 A SMC Fault Display Explanation Continued Display Fault Code Possible Causes Possible Solutions V24 Recovery F44 e Control module internal 24V control e Check control power Make sure it is within the power stays low after closing bypass operating parameters of the SMC contactor e Check control power connections including ground to the control module e Replace control module V24 Loss F45 e Control module internal 24V supply e Same as F44 out of normal range
81. educes motor cooling efficiency Consult motor manufacturer for motor limitations Smart Motor Braking option Check duty cycle Consult motor manufacturer for motor limitations Motor short circuit Winding fault Identify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure Power Module Check Troubleshooting 9 7 If a power module needs to be checked use the applicable procedure that follows ATTENTION 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 vais MdB Make 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 9 8 Troubleshooting 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 C
82. er to fault This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Rockwell Automation technical support if you have Version 4 001 firmware or earlier and need to access this parameter Parameter Information B 7 Table B 1 Parameter List Continued Group Parameter Name Parameter Number Units Min Max Default Settings Parameter Description User Settings Under voltage Undervolt A Lvl 57 Allows the user to set a voltage 9o of line Voltage that will cause an Alarm when the voltage falls below this value A zero value is the off setting Under voltage Undervolt A Dly 58 Secs Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage condition must persist within for the controller to Alarm Over voltage Overvolt F Lvl 59 0 199 Allows the user to set a voltage of line Voltage that will cause a fault when the voltage falls above this value A zero value is the off setting Over voltage Overvolt F Dly 60 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage condition must persist within for the controller to fault Over voltage Overvolt A Lvl 61 0 199 Allows the user to set a
83. eter Description User p Name Number Max Settings p Settings Fault buffer 3 represents fault history of the device with fault 1 being the current fault and fault 5 being the oldest fault kept in memory Linear List Fault 3 126 0 255 Fault buffer 4 represents fault history of the device with fault 1 being the current fault and fault 5 being the oldest fault kept in memory Linear List Fault 4 127 0 255 Fault buffer 5 represents fault history of the device with fault 1 being the current fault and fault 5 being the oldest fault kept in memory Linear List Fault 5 128 0 255 This parameter provides the user with the ability to extend the ramp time beyond the initial range of 0 30 seconds To use this parameter parameter 18 must be set to 0 Linear List Ramp Time E 1299 Sec 0 999 0 Allows for the second ramp time to also be Linear List Ramp Time 2E 1306 Sec 0 999 0 extended To use this parameter parameter 26 must be set to 0 Allows the stop time be extended beyond the Linear List Stop Time E 1316 Sec 0 999 0 limit of 120 seconds Parameter 33 must be set to 0 for this parameter to be active Disable Coast Basic Set Stop Option Provides the user with the ability to define the Up Option Input ne Fault Stop Option function of option Input 1 Fault NC Network Basic Set Coast Provides the user with the ability to define the Up Stop Input 133 Stop Option Coast function
84. etting Jam Jam F Dly 68 Secs Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the motor over current condition must persist within for the controller to fault B 8 Parameter Information Table B 1 Parameter List Continued Parameter Parameter _ Default EN User Group Name Nuribor Units Max Settings Parameter Description Settings Allows the user to set an instantaneous over Jam Jam A Lvl 69 FLC 0 1000 0 current level of line FLC that will cause an Alarm A zero value is the off setting Allows the user the ability to prevent some nuisance Alarms by entering a delay period Jam Jam A Dly 70 Secs 0 99 0 that provides a window that the motor over current condition must persist within for the controller to Alarm This feature allows the user to program the amount of time beyond the initial start Stall Stall Delay 71 Secs 0 0 10 0 0 maneuver for the motor to be at speed A setting of zero means that the stall detection feature is disabled Ground Disable Enables ground fault protection when used Gnd Fit Enable 72 Disable with an external core balanced ground fault Fault Enable sensor Ground Allows the user to set a current core balance Gnd Fit Level 73 Amps 1 0 5 0 9 2509 current that will cause a fault when the Fault 3 8 current is above this value Allows
85. evel 121 Notch Maximum 26 Ramp Time 2 74 Gnd Fit Delay 122 Start Delay 27 Initial Torque 2 75 Gnd Fit Inh time 123 By pass Delay 28 Cur Limit Level 2 76 Gnd Fit A Enable 124 Fault 1 29 Reserved 77 Gnd Fit A Level 125 Fault 2 30 Kickstart Time 2 78 Gnd Flt A Delay 126 Fault 3 31 Kickstart Level 2 79 PTC Enable 127 Fault 4 32 Stop Mode 80 Phase Reversal 128 Fault 5 33 Stop Time 81 Start Per Hour 129 Ramp Time E 34 Pump Pedestal 82 Restart Attempts 130 Ramp Time 2E 35 Braking Current 83 Restart Delay 131 Stop Time E 36 Braking Time 84 Line Fault Disable 132 Option Input 1 37 Load Type 85 Emergency Run 133 Stop Input 38 High Eff Brake 86 Current Loss 134 Elapsed Time 2 39 Slow Speed Sel 87 Logic Mask 40 Slow Speed Dir 88 Data In A1 41 Slow Accel Cur 89 Data In A2 42 Slow Running Cur 90 Data In B1 43 Stopping Current 91 Data In B2 44 Overload Class 92 Data In C1 45 Service Factor 93 Data In C2 46 Motor FLC 94 Data In D1 47 Overload Reset 95 Data In D2 48 OL Shunt Time 96 Data Out A1 Programming 4 5 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 complete the procedure below Description Action Display 1 Press the ESC key to go from the Main Menu Diagnostics status display to the Main menu Parameter i i Main Menu 2 Scroll with the
86. ey 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 9 Typical Wiring Diagram for Power Factor Correction Capacitors r 1 Li 3 Phase H 1 12 3 T2 4 Input Power f 1 135 T36 i 5 SMC Flex rotection Controller 9 9 5 Customer Supplied Overload protection is included as a Power Factor standard feature of the SMC Flex controller Correction Capacitors Figure 2 10 Typical Wiring Diagram for Power Factor Correction Capacitors and Contactor au 3 Phase 1123 T2 4 Input Power I 1 1 S 1 L3 5 36 p IO rp MUSS Bran SMC Flex Protection Controller Customer Supplied Overload protection is included as a standard feature of the SMC Flex controller Power Factor 9 Energize 1 2 second before start command to SMC Correction Capacitors Open contactor after stopping method is complete Alternate Energize contactor after up to speed Open contactor before initiating a stop Protective Modules Motor Overload Protection Installation 2 13 Protective modules containing metal oxide varistors MOVs can be installed on controllers rated 5 1250 A and 200 600V to protect the power components fro
87. f 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 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 Lang Select language being displayed OPERATION LEVEL Choose Mode A d MAIN MENU Qo Devi M Parameter 4 gt Storage Preferences 4 4 Log In Diagnostics gt i i o o o e o o Monitoring SMC FLEX Reset to Defaults Change Password Enter Password Alarms Set Up User Dspl Line Faults Motor Protection User Dspl Time Device Revision Communications User Dspl Video Utility Reset User Display Linear Llst Esc l GROUP MENU Parameter menu continued in Figure 4 2 TheSMC Flex controller does not support EEPROM Link Process or Start up modes Q Steps back one level Only displayed if a password other than 0 is entered Programming 4 3 Figure 4
88. ging in 3 Use the Sel key to highlight a single digit Description Action Display m Amps a vo La 9eMTU 1 Press the ESC key to go from the status display to the Main menu 2 Scroll with the Up Down keys Main Menu until the Parameter option is O highlighted Memory Storage 3 the Enter key to access the e Set Up 4 Scroll with the Up Down keys GP File until the option you want to use G2 rg Monitoring Motor Protection etc is highlighted For this example Set Up will be used 5 Press Enter to select the Set Up group eS i G 6 a Basic Set Up and press O e e DM roup 7 Scroll to the Starting Mode Parameter parameter by using the Up Down e e ceu keys and press Enter 8 Press Enter to select the option F ai 17 Scroll to the option of your O e choice by using the Up Down keys For this example we will choose Current Limit 9 the Enter key to accept the new setting 10 Scroll to the next parameter by F dii P 18 using the Down key Continue e cane the process until all desired settings are entered 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 user display will indicate that the secon
89. he ability to control the motor speed during starting and stopping maneuvers 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 Start Run Stop Time seconds Kickstart is also available with Linear Speed Acceleration vais MN 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 stop time The 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 Coast to rest Soft Stop Initial L Torque Soft Stop Start Run Time seconds vadis Ml Soft Stop is not intended to be used as an emergency stop Refer to
90. he specific application additional control circuit transformer VA capacity may be required Controllers rated 5 480 A The SMC Flex controllers rated 5 480 A accept control power input of 100 240V AC or 24V AC DC 10 15 single phase 50 60 Hz A control power source of 125 VA is required The control power requirement for the control module is 75 VA The control power requirement for the fans is 20 or 50 VA The control module and fans are separately wired The control module requirements are shown in Table 3 E The fans require additional power as defined in Table 3 G Table 3 E Control Module Requirements 120 240V AC Transformer 75 V 24V AC Transformer 130 VA Inrush Current 5A Inrush Time 250 ms 24V DC Transient Watts 60W Transient Time 500 ms Steady State Watts 24W Minimum Allen Bradley Power Supply 1606 XLP50E Controllers rated 625 1250 A For controllers rated 625 1250 A common control is required for proper operation Control power is connected to the product through terminal block CP1 at terminals 1 and 4 This single connection point feeds the control module contactors and fans Control power must be supplied as 110 120 VAC or 230 240 VAC 50 60 Hz only A control power source of at least 800 VA is required The control power requirements include the control module 75 VA bypass contactors 526 VA max and fan power 150 VA Depending on the specific application addi
91. hed full speed prior to the ramp time completion Also refer to Parameter 129 When using the soft start mode this Basic Set Initial Torque 19 LRT 0 90 70 parameter allows the user to adjust the initial Up torque level applied to the motor at the beginning of the start maneuver When using the current limit starting mode Basic Set Cur Limit Start this parameter allows the user to adjust the Up Level 20 205600 e current level applied to the motor during the start maneuver Reserved 21 Reserved When programmed with a non zero value Basic Set Kickstart Time 22 Secs 00 20 00 this parameter provides a torque pulse for the Up programmed time period at the beginning of the starting maneuver 0 0 2 0 s When the Kickstart Time is programmed this Basic Set Kickstart Level 23 ALRT 0 90 0 parameter provides the user with the ability to Up set the level of the torque pulse applied to the motor approx 0 90 Disable Preset Slow Speed Basic Set Dual Ramp Provides the user with the ability to define the U Option Input 2 24 Fault Disable function of option Input 2 disable coast Fault NC stop option fault fault N C network Network Clear Fault Devices rated 625 1250 Amps are only programmable to the whole digit ampere There are no decimal points for any current based parameters Parameter Information B 3 Table B 1 Parameter List Continued Para
92. ication 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 e Stall protection is user adjustable from 0 0 10 0 seconds in addition to the ramp time programmed Figure 1 15 Stall Protection 60096 Percent i Full Load Current Programmed Start Time Stall Time seconds e 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 100046 of
93. ing 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 Determines the trip level as a percentage of motor full load current and delay period Stall Allows the user to set the stall delay time Ground Fault Allows the user to enable the ground fault level in amps delay time and inhibit time Motor PTC 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 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 Overvo
94. ing when used with time delay class CC J or L fuses 6 9 gRB 73xxx400 6 6URD33xxx500 6 9 gRB 73xxx400 6 6URD33xxx500 6 9 gRB 73xxx630 6 6URD33xxx700 6 9 gRB 73xxx630 6 6URD33xxx700 6 9 gRB 73xxx800 6 6URD33xxx900 6 9 gRB 73xxx800 6 6URD33xxx900 9 URD 73xxx1250 6 6URD33xxx1250 6 6URD33xxx1400 6 6URD33xxx1 400 2 fuses in parallel 6 6URD33xxx1250 2 fuses in parallel 6 6URD33xxx1250 Specifications Power Requirements Control Module 1 480 A Transformer 75 VA 24V AC Transformer 130 VA Inrush Current 5A Inrush Time 250 ms Transient Watts 60 W Transient Time 500 ms Steady State Watts 24W Minimum Allen Bradley Power Supply Control Module 625 1250 A 751 VA recommended 800 VA 5 135 A 20 VA Heatsink Fan s A 201 251 A 40 VA 317 480 A 60 VA 625 1250 A 150 VA Steady State Heat Dissipation with Control and Fan Power W Controller Rating A 5 70 25 70 43 81 60 97 85 129 108 91 135 104 201 180 251 198 317 225 361 245 480 290 625 446 780 590 970 812 1250 1222 Auxiliary Contacts e 19 20 Aux tH e 31 32 Aux 3 e 29 30 Aux 2 e 33 24 Aux 4 Type of Control Circuit Electromagnetic relay Number of Contacts 1 Type of Contacts programmable N O N C Type of Current AC Rated Operational Current 3A Q 120V AC 1 5 A 240V AC Conventional Thermal Current Zp AC DC 5A Make Break VA 3600 3
95. ions that may occur which would indicate the need for using the protective modules 1 Transient spikes may occur on the lines feeding the SMC Flex controller or feeding the load from the SMC Flex controller Spikes are created on the line when devices are attached with current carrying inductances that are open circuited The energy stored in the magnetic field is released when the contacts open the circuit Examples of these are lightly loaded motors transformers solenoids and electromechanical brakes Lightning can also cause spikes The second situation arises when the SMC Flex controller is installed on a system that has fast rising wavefronts present although not necessarily high peak voltages Lightning strikes can cause this type of response Additionally if the SMC Flex con troller is on the same bus as other SCR devices AC DC drives induction heating equipment or welding equipment the firing of the SCRs in those devices can cause noise Note protective modules may be placed on the line load or both sides of the SMC However protective modules must NOT be placed on the load side of the SMC when using inside the delta motor connections or with pump linear speed or braking control 3 38 Wiring Multi motor Applications The SMC Flex controller will operate with more than one motor connected to it To size the controller add the total nameplate amperes of all of the connected loads The stall and jam features
96. is 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 30s 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 30s 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 Kickstart can be programmed for both start modes 0 90 locked rotor torque 4 10 Programming Full Voltage Start Linear Speed The SMC Flex controller may be programmed to provide a full voltage start output voltage to the motor reaches full voltage within 1
97. k for loose connections Accelerates too fast Starting time e starting time e initial torque e Lower initial torque setting e Current limit e Decrease current limit setting setting e Kickstart e Lower kickstart time or turn off Accelerates too e Starting time e Decrease starting time slow Initial torque e Increase initial torque setting Current limit e current limit setting setting e Kickstart e Increase kickstart time or turn off Fan does not e Wiring e Check wiring and correct if operate necessary Failed fan s e Replace fan module Motor stops too e Time setting e Verify the programmed stopping quickly with time and correct if necessary Soft Stop option 9 6 Troubleshooting Motor stops too slowly with Soft Stop option Stopping time setting Misapplication Verify the programmed stopping time and correct if necessary The Soft Stop option is intended to extend the stopping time for loads that stop suddenly when power is removed from the motor Fluid surges with pumps still occur with the Soft Stop option Misapplication Soft Stop ramps voltage down over a set period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately suited Refer to Publication 150 911 Motor overheats Duty cycle Preset Slow Speed and Accu Stop options Extended operation at slow speeds r
98. load protection should be disabled in the SMC Flex controller Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 4 should be set for normal operation 3 18 Wiring Figure 3 16 Typical Wiring Diagram for Isolation Applications DPI also 3 Phase E 128 2 4 Input Power 135 73 6 En SMC Flex IC Controller PTD Tel TS Te TS Te Te SMC Flex Aux 1 Control Terminals s sTsT8TsT T8 Ts Ts TT3 T Ww TACH Ground Aux 2 Aux 43 Aux 4 9 Input Input Fault Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 4 should be set for normal operation Wiring 3 19 Figure 3 17 Typical Wiring Diagram for Shunt Trip Applications 3 Phase E T2 4 L3 5 T3 6 Input Power Branch Protection SMG Flex Controller PTSPTHSTSESTSTSESTTE SMC Flex Control Terminals Ts TsT8Te Ta T2 T Ts Te TsT 2 e WY PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For uni
99. ltage 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 Enable Phase Reversal Restarts Per Hour Restart Attempts Restart Delay 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 17 4 16 Programming Example Settings Undervoltage With Line Voltage programmed for 480V and the Undervoltage level programmed for 80 the trip value is 384V Overvoltage With Line Voltage programmed for 240V and the Overvoltage level programmed for 115 the trip value is 276V Jam oo With Motor FLC programmed for 150 A and the Jam level programmed for 400 the trip value is 600 A Underload 2 With Motor FLC programmed for 90 A and the Underload level programmed for 6046 the trip value is 54 A average value of the three phase to phase vo
100. ltages is utilized Q Thelargest value of the three phase currents is utilized The SMC Flex will self protect Chapter 5 Overview Viewing Metering Data Metering While the SMC Flex controller operates your motor it also monitors several different parameters providing a full function meteringo package To access the metering information follow the procedure below Description Action Display 2 Amps Volt MTU Main Menu 1 Press any of the following keys to Memory Storage access the Main Menu O v 2 Scroll with the Up Down keys until e Main Menu ini Parameter the Parameter option is shown IX 3 Press the Enter key to select the Parameter option 4 Scroll with the Up Down keys until v GP File the Monitoring option is displayed Set Up 5 Press the Enter key to access the Monitoring group 6 Press the Enter key to access the e FIP Group Metering group Refer to Metering page 1 19 or Figure 4 2 on page 4 3 for details on the metering functions Metering 7 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 F Gig P 1 Volts Phase A B HHH Volt F Gig P 2 Volts Phase B C HHH Volt F Gig Volts Phase
101. lways line current regardless of the motor connection Wye or Delta Amps Metering Current Phase B Provides the three phase motor current measurement This measurement is always line current regardless of the motor connection Wye or Delta Amps Metering Current Phase C Provides the three phase motor current measurement This measurement is always line current regardless of the motor connection Wye or Delta Amps Metering Watt Meter Provides the power usage of the connected motor This value is calculated from the voltage current and power factor measurements KW MW Metering Kilowatt Hours Provides the power usage over time of the KWH MWH connected motor Metering Elapsed Time Indicates the total time of motor operation in Hours hours The accumulated time is updated continuously during run time Metering Meter Reset 10 NO Provides the user the capability to reset the ETM Reset NO value stored in the elapsed time 9 and KWH Reset kilowatt hours 8 meters to zero Metering Power Factor 11 Provides the operational displacement power 00 099 factor measurement of the connected motor Metering Mtr Therm Usage 12 Provides the theoretical model of motor heating as a percentage value At 100 MTU MTU 0 100 the controller will fault on overload This model is based on the motor thermal overload calculation Metering Mot
102. ly set 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 e e 2 Approximate Trip Time seconds Approximate Trip Time seconds Approximate Trip Time seconds Approximate Trip Time seconds 01 1 2 3 4 5678910 1 2 3 4 567890 1 2 3 4 5678910 1 2 3 4 5678910 Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC Approximate trip time for 3 phase balanced Approximate trip time for 3 phase balanced condition from cold start condition from hot start Figure 1 14 Restart Trip Curves after Auto Reset 100000 1000 Ww
103. m electrical transients The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs vui iil B When installing orinspecting 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 Wada iil B 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 14 Installation Electromagnetic Compatibility EMC vais iil 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 mitigatio
104. mask can be disconnected without causing a fault I d iP Y HE 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 Flex can be used with all LCD applicable DPI interface Regardless of the type of interface being used the information below can be used to configure the rest of the system Communications 7 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 The total size may very when used with a communication card The default configuration is arranged according to the following table Table 7 E Consumed Data Control Word 0 Logic Status Logic Command Word 1 Feedback Reference feedback word is always Current in Phase A The reference word is not used with the SMC Flex however the space must be reseverd Note The total size produced or consumed may vary dependi
105. med via software or a hand held DPI HIM The on board HIM cannot be used to address the communication card Keypad Description The functions of each programming key are described below Table 7 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 e 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 Ifahuman interface module is disconnected from the SMC Flex controller while the Logic Mask is set to 1 a Coms Loss fault will occur 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 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 Bulletin 20 H
106. meter Parameter Min Default Mv User Group Name Number Units Max Settings Parameter Description Settings Full Voltage When the dual ramp mode is selected this Dual current Limit arameter allows the user to select the type Starting Mode2 25 Soft Start Soft Start P of ramp mode used for the second ramp Linear Speed rofile Pump Start When the dual ramp mode is selected this Dual parameter allows the user to program the Ramp Time 2 26 Secs 0 30 10 time 0 30 s that the controller performs the starting maneuver for profile 2 Also refer to Parameter 130 When using the soft start mode for profile 2 Dual this parameter allows the user to adjust the Ramp Initial Torque 2 2 ird 03 30 10 initial torque level applied to the motor at the beginning of the start maneuver When using the current limit starting mode for Dual A profile 2 this parameter allows the user to Ramp Levelg E 90 1600 adjust the current level applied to the motor during the start maneuver Dual Ramp Reserved 29 Reserved Dual This parameter provides a torque pulse for the Ram Kickstart Time 2 30 Secs 0 0 2 0 0 0 programmed time period at the beginning of the starting maneuver for ramp profile 2 This parameter provides the user with the Dual 0 ability to set the level of the torque pulse Ramp Kickstart Levelz 31 Vo 0 applied to the motor approx 0 to 90 for ramp profile 2 Soft Stop Basic Set Line
107. mming etic AO E E EE E EE 2 2 General Precautions iinn ioci te tereti te eee dette 2 3 Heat Dissipation ccccccscescsssssssssssesssessesessscsessesessesseseesaesesseseesaesasseseseesers 2 3 Enclosures 3 ret tete dee de Un 2 4 MOUNTING iit ete nete EORR eee 2 5 Power Factor Correction Capacitors 2 12 Protective Modules niniin enana atenarna 2 13 Motor Overload Protection 2 13 Two speed Motors 2 13 Multi motor Protection eeeseeeeenennnnnn nnn 2 13 Electromagnetic Compatibility 2 14 Enclosure cscsccescsseseseessessessseessessssccsnseeseeseeaseeeseeseesesaseessessesanseeass 2 14 R 2 14 Additional Requirements 2 14 Terminal Locations essere nnne nnne 3 1 Power SITUCEIUre onde caede teet ipee te eee 3 3 Power 3 3 Line Connected nugas dee 3 4 Delta Connected essen 3 4 emen tes 3 5 CONO POWOTF end te ER CR n tts 3 7 Control Wiring 5 2 5 3 7 Controllers rated 5 480
108. n 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 8 1 Fault Display Faulted Fault amp 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 press 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 8 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 J fahuman interface module is connected to the controller press the Stop button Note A stop signal from HIM will always stop the motor and clear the fault regardless of Logic Mask e Ifa RESET push button is presen
109. n methods The following guidelines are provided for EMC installation compliance Enclosure Install the product in a grounded metal enclosure Wiring Wire in an industrial control application can be divided into three groups power control and signal The following recommendations for physical separation between these groups is provided to reduce the coupling effect Different wire groups should cross at 90 inside an enclosure e Minimum spacing between different wire groups in the same tray should be 16 cm 6 in Wire runs outside an enclosure should be run in conduit or have shielding armor with equivalent attenuation e Different wire groups should be run in separate conduits e 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 INO01 A EN P Additional Requirements e f 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 e Ground fault CT must be inside or within 3 m of metal enclosure To meet product susceptibility requirements ferrite cores need to be added to the communication lines When using an external HIM or DPI interface a core should be added to the HIM ca
110. ndition See Chapter 4 for additional information on programming Line Connected The SMC Flex by default is programmed to be connected to a line controlled motor as shown in Figure 3 4 These motors typically have 3 leads and must be rated between 1 1250 amps An optional isolation contactor can be added to the circuit to provide galvanic isolation of the motor and final electro mechanical removal of power Figure 3 4 SMC Flex Ik WT 513 I 10 75 Ic T M 1 32 ec 472 3 8 74 p qt 2m 12 T6 Delta Connected The SMC Flex can be programmed and connected to a delta controlled motor as shown in Figure 3 5 These motors typically have 6 or 12 leads and must be rated between 1 8 1600 amps It is recommended that an isolation contactor be added to the circuit to provide galvanic isolation of the motor and final electro mechanical removal of power Figure 3 5 Power Lugs Wiring 3 5 SMC Flex 513 6 T3 10 75 a eT Vut 2m 12 76 Power lugs are required for devices rated 108 1250 A In some cases these lugs are sold in kits Each kit contains three lugs The number and type of lugs required is listed in the following tables Table 3 C lists the recommended lugs for the SMC when configured as a line connection Table 3 D lists the recommended lugs when using the SMC Flex with a delta connection Note tha
111. ng on the communication card being used For more information refer to the User Manual for the communication card 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 7 F Rx Tx Logic Status Reference DataLinks Size Size Command FeedBack 16 bit 16 bit A B C 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 7 10 7 8 Communications SMC Flex Bit Identification Table 7 G Logic Status Word Bit 4 Status Description 15 14 13 12 11 10 9 8 7 Enabled 1 Control Power Applied 0 No Control Power Running 1 Power Applied 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 Isolati
112. oad Reset Undervolt F Dly Gnd Fit A Lvl Data Out C2 Aux1 Config Undervolt A Lvl Gnd Fit A Dly Data Out D1 Aux2 Config Undervolt A Dly Parameter Mgt Data Out D2 Aux3 Config Parameter Mgt Parameter Mgt Aux4 Config Backspin Timer wills Parameter Mgt Enable Dual Ramp Option 2 Input Dual Ramp Starting Mode 2 Ramp Time 2 Initial Torque 2 Cur Limit Lvl 2 Kickstart Time 2 Kickstart Lvl 2 Parameter Mgt Preset SS Option 2 Input Preset SS Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur Parameter Mgt Overvolt F Lvl Parameter Mgt Overvolt F Dly Overvolt A Lvl Overvolt A Dly Parameter Mgt Phase Reversal Phase Reversal Parameter Mtg Unbalance Unbalance F Lvl Restart Unbalance F Dly Starts Per Hour Option 2 Input Accu Stop Slow Speed Sel Slow Accel Cur Slow Running Cur Braking Current Stopping Current Parameter Mgt Unbalance A Lvl Restart Attempts Unbalance A Dly Restart Dly Parameter Mgt Parameter Mtg Q Steps back one level For further information on parameters see Appendix B For further information on parameter management see page 4 6 See page 4 4 for all SMC Flex parameters available by the Linear List Depending upon SMC option selected some parameters may not appear in product display Programming Table 4 A Parameter Linear List
113. ol Terminations 5 Fan Terminations Wiring 3 3 Power Structure Figure 3 3 Wiring Terminal Locations 625 1250 A Table 3 B Wiring Terminal Locations 1 Incoming Line Terminations 2 Line Motor Connections 3 Terminal Block CP1 Common Control Power Connections Fans Contactors and Control Modules The SMC Flex product has an integrated mechanical run contactor on each phase of the motor to minimize heat generation during run time These contacts are pulled in sequentially in the 108 1250 A units In the 5 85 A units these contacts are pulled in all at once The SMC Flex product also has a Current Transformer CT built in on each phase of the motor to provide current readings Power Wiring Refer to the product nameplate or User Manual for power lug termination information including Lug wire capacity e Tightening torque requirements Lug kit catalog numbers 108 1250 A 3 4 Wiring ATTENTION Failure of solid state power switching components can cause overheating due to a single phase condition in the motor To prevent injury or equipment damage the following is recommended Use of an isolation contactor or shunt trip type circuit breaker on the line side of the SMC This device should be capable of interrupting the motor s lock rotor current Connection of this isolation device to an auxiliary contact on the SMC Flex The auxiliary contact should be programmed for the normal co
114. ol with Stop Option and Start Stop Push Buttons Control Power Q E SMC Flex Control Terminals Aux 1 PTC TACH Ground Input Input Fault Aux 2 Aux 3 Aux 4 Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 3 24 Wiring Soft Stop Pump Control and SMB Smart Motor Braking Figure 3 22 through Figure 3 25 show the different wiring for the Soft Stop Pump Control and SMB Smart Motor Braking options Figure 3 22 Typical Wiring Diagram F Control Power Stop Start Option Stop ar SMC Flex Control Terminals Aux 1 23 24 25 26 27 28 29 30 31 32 33 34 LL ae ae PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Soft Stop Pump Stop or Brake Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Note Refer to Chapter 3 for typical power circuits Wiring 3 25 Figure 3 23 Typical Retrofit Wiring Diagram Control Power
115. on Contactor Enabled Isolation 0 Start Isolation Contactor Disabled X Bypass 1 External Bypass Contactor Enabled 0 External Bypass Contactor Disabled X Ready 1 Ready 0 Not Ready X Option 1 1 Input Active Input 0 Input Inactive X Option 2 1 Input Active Input 0 Input Inactive Bits 14 and 15 Not Used Communications 7 9 Table 7 H Logic Command Word Control Bit 4 Status Description 15 14 13 12 11 10 8 7 51413121110 X Stop 1 Stop Inhibit 0 No Action X Start 1 Start 0 No Action X Option 1 1 Stop Maneuver Inhibit Input 0 No Action X Clear 1 Clear Faults Faults 0 No Action X Option 42 1 Perform Option 2 function Input 0 No Action p Bits 5 10 Not Used X Aux 1 Use Aux 1 Aux 4 Enable 0 Ignore Aux 1 Aux 4 X Aux 1 1 Aux 1 Active 0 Aux 1 Inactive X Aux 2 1 Aux 2 Active 0 Aux 2 Inactive X Aux 3 1 Aux 3 Active 0 Aux 3 Inactive X Aux 4 1 Aux 4 Active 0 Aux 4 Inactive Reference Feedback The SMC Flex does not offer the analog Reference feature The Parameter Information Scale Factors for PLC Communication analog Feedback feature is supported and will provide Parameter 1 Current in Phase A automatic
116. or Speed 13 Indicates the operating percentage of motor 0 100 base speed when linear ramp is selected and an external tachometer is used B 2 Parameter Information Table B 1 Parameter List Continued Grou Parameter Parameter Units Min Default Parameter Description User p Name Number Max Settings p Settings Basic Set This a read only parameter that identifies to SMC Option 14 Brake Up the user the type of control module installed Pump Control This parameter allows the user the ability to Basic Set Motor select the power wiring configuration of the 15 Line Delta Line attached motor WYE or DELTA A fault Up Connection 1 controlled means of disconnecting the line should always be use in the DELTA mode This parameter sets the base voltage for the Basic Set under over voltage protective features For Line Voltage 16 Volt 0 10000 480 medium voltage applications the controller Up te has internal capabilities set of multipliers that correspond to the line voltage dividers Full Voltage Current Limit MELLE Sti sostat cmc coetu Linear Speed 9 i Pump Start Allows the user to program the time 0 30 s that the controller performs the starting Basic Set maneuver The starting maneuver will U Ramp Time 18 Secs 0 30 10 automatically transition to bypass and full p voltage if the controller senses that the motor has reac
117. ower 5 85A Heatsink thyristor modular design Poles 108 1250 A Heatsink hockey puck thyristor modular design Control Modules Thermoset and Thermoplastic Moldings Metal Parts Plated Brass Copper or Painted Steel Terminals Power 5 85A Cable size Terminals Line Upper 2 5 95 mm 14 3 0 AWG Line Lower 0 8 2 5 mm 18 14 AWG Load Upper 2 5 50 mm 14 1 AWG Load Lower 0 8 2 5 mm 18 14 AWG Tightening torque 14 7 Nem 130 Ib in Wire strip length 18 20 mm 0 22 0 34 in 108 135A One M10 x 1 5 diameter hole per power pole 201 251A Two M10 x 1 5 diameter holes per power pole 317 480A Two M12 x 1 75 diameter holes per power pole 625 1250A Two 13 5 mm 0 53 in diameter holes per power pole Power Terminal Markings NEMA CENELEC EN50 012 Control Terminals M 3 screw clamp clamping yoke connection A 6 Specifications Other Approximate Dimensions and Shipping Weights EMC Emission Conducted Radio Frequency a Class A Levels Emissions Radiated Emissions Class A EMC Immunity Electrostatic Discharge 8 kV Air Discharge Levels Radio Frequency Electromagnetic Field POr ENIES GOSEA Fast Transient Per EN IEC 60947 4 2 Surge Transient Per EN IEC 60947 4 2 Overload Current Range Delta Characteristics 1 7 9 8 6 43 14 8 75 20 8 104 29 4 147 47 187 59 234 116 348 145 435 183 549 208 625 277 831 283 850 260 300
118. programming the e Overload class Overload reset Motor FLC Service factor Refer to Chapter 5 for more information on Motor Protection Phase Reversal 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 Other settings could also cause this fault see Table 7 D 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 5 480 A devices only 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 S
119. quirements Dual Ramp Start allows the user to select between two separate start profiles with separately adjustable ramp times and initial torque settings Figure 1 4 Dual Ramp Start Percent Voltage 100 Initial Torque 2 Initial Torque 1 Start 1 Run 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 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 high settings in the forward direction Reverse can also be programmed and offers 1096 of base speed low and 20 of base speed high settings Figure 1 6 Preset Slow Speed 100 Motor Speed Forward ro 15 High 2 7 Low Time seconds Start ES Run 10 Low N b 20 High Reverse Wada ill 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 t
120. r programmable 0 120s Standard Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 forward 1096 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 4 12 Programming Option Parameter Range Pump Control Pump Control SMC Option Pump Control This parameter identifies the type of control present and is not user programmable Pump Stop Time 0 120s Allows the user to set the time period for the pump stopping function Starting Mode Pump Start Soft Start Allows the user to program the Current Limit Start SMC Flex controller for the type of starting that best fits the application 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 0 400 of full load Allows the user to program the current intensity of the braking current applied to the motor Accu Stop SMC Option Braking Control
121. ramming information refer to the user manual for the communication interface being used A list of available interfaces is located below Table 7 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 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 RS485 HVAC 20 COMM H 20COMM UM0090 EN P ControlNet Fiber 20 COMM Q 20COMM UM0030 EN P Denotes revision level of user manual Example Publication 20700MM UMOO2C EN P is at revision C The SMC Flex 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 communication cards listed above to the internal DPI comm card connection 7 2 Communications Human Interface Module The SMC FLEX controller can be programmed with the built in keypad and LCD display or with our optional Bulletin 20 HIM LCD human interface modules Parameters are organized in a three level menu structure and divided into programming groups Note Node addressing of the DPI communication card can be program
122. reversing contactor Provides the user the ability to program the Preset SS current to slow speed operation for both the Slow Accel Cur 41 FLC 0 450 0 Preset Slow Speed and Accu Stop control Accu Stop j 3 options This setting is typically load dependent Provides the user the ability to program the operating current of slow speed operation for PIRSA Sor Running 42 FLC 0 450 0 both the Preset Slow Speed and Accu Stop Accu Stop Cur a control options This setting is typically load dependent Provides adjustment capability for the braking A intensity from slow speed operation to the Accu Stop Stopping Current 43 JoFLC 0 400 0 stopped condition for the Accu Stop control option Disable Allows the user to select the time to trip for Basic Set voee the built in overload This selection is based Up Overload Class 44 Class 15 Class 10 irm on the type of motor being used and the Overload ARCA application it is being applied too Class 30 pp URBE Basic Set Up Service Factor 45 0 01 1 99 ios Motor fameplata valle d Ue d to determine the ultimate overload trip current Overload Sets the base current for use with all the Basic Set current based protection features jam over Up Motor FLC 46 Amps 1 0 2200 0 1 0 under load motor overload The motor Overload nameplate FLA is to be used regardless of the configuration WYE or DELTA Basic Set Up Overload Reset 47 Manual Manual Allows
123. rmal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each Up Aux4 Config 109 Fault NC Normal relay contact for a specific operation Alarm Note Normal SMC in RUN Alarm NC Network Network NC External Bypass Parameter Information B 11 Table B 1 Parameter List Continued Parameter Parameter _ Default EN User Group Name Number Units Max Settings Parameter Description Settings Normal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each U Aux2 Config 110 Fault NC Fault Auxiliary relay contact for a specific operation Alarm Note Normal SMC in RUN Alarm NC Network Network NC External Bypass English French Spanish Allows the user to change the text display to Language Language us German English one of the available options Portuguese Mandarin This parameter can be used to force the starting profile to complete its entire time 0 Disable period and ignore an early up to speed Timed start 1120 1 Enable peeve detection The default is set to Disabled so that the SMC can determine when the motor is at speed This parameter adjusts the level of current at which the SMC determines that the SCR has turned off Since this parameter has the 0 Linear List Shut Off 1136 current 0 37 0 potential to modify the SCR control
124. s for 625 1250 A units ATTENTION Remove all power to the unit before proceeding with replacement procedures Prior to beginning the following steps the front cover must be removed Contactor Replacement Installation Instructions for 625 1250 A units D 2 0 09 Contactor Replacement Installation Instructions for 625 1250 A units Read and understand this equipment service instruction before servicing i replacement contactor coil control EI Contactor Replacement Installation Instructions for 625 1250 A units D 4 625 780A 100 Ib in 11 3 Nem 140 Ib in 970 1250A 15 8 Nem BA De V 30 Ib in 3 4 Nem 55 Ib in o 6 2 Nem 625 780 A 970 1250 140 Ib in Appendix E Accessories Description Description Used With Cat No 7 Protective Modules 5 85A 480V 15084 108 1250 A 480V 150 F84L 5 85 A 600V 150 F86 108 1250 A 600V 150 F86L Teminllug 108 251A 199Fl 317 480 A 199 LG1 100 DL860 IEC Terminal Covers 108 135 A 150 TC1 201 250A 150102 317 480A 150 TC3 HIM Hand Held 20 HIM A2 20 HIM A3 20 HIM A4 20 HIM A5 Door Mounted 20 HM C3 includes cable
125. s on page A 1 for details 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 noncondensing e Do not store equipment where it could be exposed to a corrosive atmosphere e Do not store equipment in a construction area 2 2 Lifting Installation For controllers rated 625 1250 A the device should only be lifted from designa
126. scheme it is important that adjustments be made with the help of Technical Support The SMC has the ability to automatically determine if the motor is up to speed If there is a problem with detecting the up to speed condition this parameter can be modified to compensate Rule of thumb is this number up to should be increased on high efficiency motors Linear List UTS Level 1146 oup 0 100 75 experiencing problems If the SMC is speed detecting the up to speed condition too late or not at all this number should be decreased on very low efficiency motors Note Be careful when adjusting this level Improper adjustment can cause the SMC to start at full voltage Ready Allows the user to load factory default values A Parameter Mgmt 115 Load Default Ready for all parameters Basic Set Only available with the Pump Control option Up Backspin Timer 116 Secs 0 999 0 Ensures that a specific amount of time passes between a stop and start sequence This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Rockwell Automation technical support if you have Version 4 001 firmware or earlier and need to access this parameter B 12 Parameter Information Table B 1 Parameter List Continued Group Parameter Name Parameter Number Units Min Max Default Settings Parameter Description User Settings Linear List V Sh
127. sent nnns 4 6 Random Access Memory RAM 4 6 Read only Memory 4 6 Electrically Erasable Programmable Read only Memory EEPROM 4 6 Parameter Modification sessi 4 7 4 8 Chapter 5 Metering Chapter 6 Optional HIM Operation Chapter 7 Communications Chapter 8 Diagnostics Current LIMITE Start retten rts 4 8 Dual rne erede irm eet esed 4 9 Full Voltage Start sess 4 10 Linear Speed ses tees tit ee reditus 4 10 Programming Parameters sese 4 11 Standard tu ated eite nis 4 11 PUMP COMM 4 12 Braking Control eet debe Pe txt td 4 12 Basic Seb Up 5 ente cerent nam eed ae ERE 4 14 Motor Protection esee nnn nnns 4 15 Example Settings ieu eet hende eicere e rece a n 4 16 Undervoltage cccesccscsssssssssssssesceessessesessessesaesessessesaeseseeseesansassteeseess 4 16 Overvoltage odis 2 recen ict See tide edes sete bed 4 16 Stach SE E LL S 4 16 Underload eee vi rite eti 4 16 VeIVIeW cisci 5 1 Viewing Metering Data seeseeseeeerenrn nnns 5 1 OVeIVIeW dated
128. st at which point the controller automatically ceases braking action Note that high braking currents can introduce excessive vibration to the motor couplings and or gearing and additional heating in the motor Linear List Braking Time SMB 369 Sec 0 999 This parameter provides the ability to over ride the SMB function zero speed detection and set an exact time in which the braking current is applied to the motor This can be used for applications where detecting zero speed is difficult or when the purpose is to reduce the number of overload trips associated with driving the motor to a complete stop Setting this to a specific value will turn off the braking at a set time each time a stopping maneuver is performed An ideal setting can be accomplished through trial and error and should always allow for some small coast time Setting this value to long will cause braking current to be applied to a stopped motor and likely result in overload trips Linear List Load Type SMB 376 0 Standard 1 Hi Inertia 2 Hi Friction 3 Ramp 89 0 Standard Allows the user the ability to modify the braking profile to match a particular load type This parameter is designed to only be used with the SMB algorithm and not with timed brake For the majority of applications the standard profile will work sufficiently Adjusting this parameter should really only be used when some type of problem d
129. stallation start up and subsequent maintenance of the system Failure to do this may result in personal injury and or equipment damage vais Mild E Hazardous voltages that can cause shock burn or death are present on L1 L2 L3 T1 T2 T3 T4 T5 and 6 Power terminal covers can be installed to prevent inadvertent contact with terminals Disconnect the main power before servicing the motor controller or associated wiring Pii 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 5A 25 43A 60 85 108A 135A 201A 251A 317A 361A 480A 625A 700A 970A 1250A Rating Max 70 70 81 97 129 104 180 198 225 245 290 446 590 812 1222 Watts 2 4 Installation 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 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
130. 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 Run 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 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 a Speed 7 or 15 Slow Speed Braking Coast to rest T er ow Speed x Start Run Brake Slow Speed
131. stopping During stopping braking torque is applied to the motor until it reaches preset slow speed 796 or 1596 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 Electrical Ratings Device Rating UL CSA NEMA IEC Power Circuit Rated Operation Voltage 200 480V AC 15 10 d 200 600V AC 600V C1596 10 200 500V 690V 230 600V AC 230 690V Y 71595 10 71595 10 Rated Insulation Voltage 480V 500V N A 500V 690V Rated Impulse Voltage 6000V Dielectric Withstand 2200V AC 2500V 690V Repetitive Peak Inverse 480V 1400V Voltage Rating 600V 1600V 690V 1800V Operating Frequency All 47 63 Hz Utilization Category 5 480A MG 1 AC 53B 3 0 50 1750 625 1250 MG 1 AC 53B 3 0 50 3550 Protection Against Electrical 5 85A IP20 Shock 108 480 A N A IP2X with terminal covers 625 1250 A IP00 open Device DV DT Protection 480V amp 600V RC Snubber Network 690V None Transient Protection 480V amp 600V Metal Oxide Varistors 220 Joules 690V None Control
132. sulation 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 programmed 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 9 2 Troubleshooting The following flowchart is provided to aid in quick troubleshooting Figure 9 1 Troubleshooting Flowchart YES b Fault Displayed NO 3 NC x f lt Define Nature gt of Trouble Motor rotates but does not Motor stops while Miscellaneous ae accelerate to full running situations speed See See See See See Table 9 A Table 9 B Table 9 C Table 9 D Table 9 E Table 9 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
133. t 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 Selectable Kickstart 100 rL pM H Coast to rest Soft Stop Initial Torque Start ma Run Soft Stop Time seconds Current Limit 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 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 5a 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 re
134. t the N O push button auxiliary contact can be connected to Option Input 2 terminal 15 Option Input 2 must be programmed for Clear Fault e Cycle control power to the SMC 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 8 A Diagnostics 8 3 Fault Codes Table 8 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 8 A Fault Code Cross reference Fault and Alarm Auxiliary Indication for Fault or Alarm Fault Code Fault Code Line Loss A 1 Stall 25 Line Loss B 2 Phase Reversal 26 Line Loss C 3 Coms Loss P2 27 Shorted SCR A 4 Coms Loss P3 28 Shorted SCR B 5 Coms Loss P5 29 Shorted SCR C 6 Network P2 30 Open Gate A 7 Network P3 31 Open Gate B 8 Network P5 32 Open Gate C 9 Ground Fault 33 PTC Pwr Pole 10 Excess Starts 34 SCR Overtemp 11 Power Loss A 35 Motor PTC 12 Power Loss B 36 Open Bypass A 13 Power Loss C 37 Open Bypass B 14 Hall ID 38 Open Bypass
135. t devices rated 625 1250 A require the use of a power distribution block when used with a delta connection wees il B Terminal covers are available for units rated 108 480 A which can make the product deadfront IP2X safe See Appendix D for the appropriate catalog numbers for ordering 3 6 Wiring Table 3 C SMC Flex 5 1250 A Line Connection Lug Information 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 85 18 20 25 85 mm 11 3 Nem 14 3 0 AWG 100 Ib in 108 135A 199 LF1 18 20 mm 16 120 mm 1 1 31 Nem 23 Nem 6 250 275 lb in 200 Ib in 201 251 199 LF1 18 20 mm 16 120 mm 2 2 31 Nem 23 Nem 6 250 275 lb in 200 Ib in 317 480A 1994161 18 25 mm 25 240 mm 2 2 42 Nem 28 Nem 4 500 375 lb in 250 Ib in 625 780A 100 DL630 32 mm 64 mm 70 240 mm 2 2 45 Nem 68 Nem 2 0 500 400 Ib in 600 Ib in 970A 100 DL860 26 mm 48 mm 120 240 mm 1 1 45 Nem 68 Nem 4 0 500 MCM 400 Ib in 600 Ib in 100 DL630 32 mm 64 mm 70 240 mm 1 1 1250 A 2 0 500 MCM 45 Nem 68 Nem 100 DL860 26 mm 48mm 120 240 mn 1 1 400 Ib in 600 Ib in 4 0 500 MCM 1250 A device requires one 1 each of the 100 DL630 and 100 DL860
136. tage Directive This product is tested to meet Council Directive 73 23 EEC Low Voltage per EN IEC 60947 4 2 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection Notes Chapter 1 Product Overview Chapter 2 Installation Table of Contents Other Related Documents essen 1 1 Description 4 dte de BR RS 1 1 Operation c eie E eid bestes 1 2 Modes of Operation Standard sess 1 2 NISI MD 1 2 Selectable Kickstart esses enean tentes 1 3 Current Limit Start essen 1 3 Dual Ramp Start 200 4 2 1 au recie terret 1 4 Full Voltage Start essen nnns 1 4 Preset Slow Speed esses esee nente sten te atenta nni nes 1 5 Linear Speed 1 6 SOfESTOD in A a ea nt a det ite 1 7 Control OPTIONS caves exes ges sentence seve im ete cede edite eit EN dg 1 8 Modes of Operation Pump Control esee 1 8 Pump Control Option eren m dtm ntes 1 8 Modes of Operation Braking Control ener 1 9 SMB Smart Motor Braking Option eene 1 9 Accu Stop Option ccccccssesssssssssssssscsessessesessesseseesesseseesansasenseseeses 1 10 Slow Speed with Br
137. tarting 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 overvoltage and undervoltage protection are disabled during braking operation detection and underload protection are disabled during slow speed and braking operation Introduction Chapter 9 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 70E Part II in the United States Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments vais Mil a 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 wees eal Disconnect the controller from the motor before measuring insulation resistance IR of the motor windings Voltages used for in
138. ted lifting points The lifting points are designed to accept a 2 13 threaded hoist ring capable of lifting 2500 pounds These points are identified in Figure 2 1 Avoid equipment damage Hoist at proper lift points Refer to User Manual for lifting procedure Figure 2 1 Lifting Points Lifting Points Uu T E UC z 3 le a 1 r I I ences 4 iei Loma o 1 J Installation 2 3 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 vais iil B The controller contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to applicable ESD protection handbooks vui il 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 vui hng Only personnel familiar with the controller and associated machinery should plan or implement the in
139. terminals 1 amp 4 Note The Dual Ramp feature is available only with the standard control version 3 16 Wiring Figure 3 14 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 YET T2 4 L3 5 T3 6 Input Power Branch Protection SMG Flex Controller PTSSISPTHETSTTSTS TE SMC Flex Control Terminals Aux 1 PPP PPP s Ts Te Te Ww Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Wiring 3 17 Figure 3 15 Typical Wiring Diagram for Retrofit Applications X nnm un Lex L2 3 3 Phase Input Power En er a _ Branch Existing Motor SMC Flex Protection Starter Controller 4 OL Start Stop MO Jm PTSTSTTSTSTSTSTSTS T Te SMC Flex Control Terminals Aux 1 sTSTSTsTeTeTSTSTSTsTsT wo Ground Aux 2 Aux 3 4 Input Input Fault Customer supplied Over
140. the user to select between an auto and Overload Auto manual reset mode for all Overload faults Devices rated 625 1250 Amps are only programmable to the whole digit ampere There are no decimal points for any current based parameters B 6 Parameter Information Table B 1 Parameter List Continued Group Parameter Name Parameter Number Units Min Max Default Settings Parameter Description User Settings Linear List OL Shunt Time 480 Sec 0 999 This parameter prevents the overload from accumulating or incrementing the Motor Thermal Usage MTU during the programmed shunt time This function is allowable under some electrical codes for loads which have long acceleration times i e High inertia As a general rule of thumb this time should never exceed the programmed start time Setting this parameter longer than necessary can result in motor overheating that is not being accounted for in the thermal model Linear List OL Trip Enable Disable 499 0 Disable 1 Enable Enable This parameter disables the overload from tripping during slow speed pump stopping and braking maneuvers Motor Thermal Usage MTU continues to increment during these maneuvers Setting this parameter to disable can result in motor overheating or potential damage Overload Overload A Lvl 50 MTU 0 100 Allows the user to set an overload
141. this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss 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 I O 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 Vol
142. tion 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 acceleration 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 qs 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 Chapter 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 ScanPort devices are not supported by 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 prog
143. tional control circuit transformer V capacity may be required Wiring Figure 3 6 230V Control Undervoltage Relay Settings for 625 1250 A Devices SEE NAMEPLATE FOR STATUS LED C PICK UP NOMINAL VOLTAGE X 7 85 A SEC 240 0 1 7 TIME DELAY __ NOMINAL PICK UP VOLTAGE 10 208 SEC 95 0 1 TIME DELAY DROP OUT DROP OUT PICK UP 0 GENERAL NOTES 1 SET ALL RELAY POTENTIOMETERS PER ILLUSTRATION 3 9 Wiring Figure 3 7 Internal Wiring and 230V Control Undervoltage Relay Connection Diagram for 625 1250 A Devices 1 FNI Q z FAN B Lee 1 UV RELAY 8 See Figure 3 6 for setting information Wiring 3 10 Figure 3 8 Internal Wiring and 120V Control Connection Diagram for 625 1250 A Devices FL FAN H EE I Fan Power Wiring 3 11 Control Wire Specifications Table 3 F 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 F Control 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 1250 A have heatsink fan s Refer to Table 3 G for the control power VA requirements of the heatsink fans Fan Terminations See
144. 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 contacts 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 Vy 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
145. ts rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 2 should be set to fault operation 3 20 Wiring Figure 3 18 Typical Wiring Diagram for Single Speed Reversing Applications 7 Lit T1 2 3 Phase M 12 3 T2 4 Input Power L3 5 T3 6 p Branch SMC Flex Protection Controller Reversing Contactors 1 16 17 18 19 20 21 22 SMC Flex Aux 1 Control Terminals 23 24 25 26 27 28 29 30 31 32 33 34 Tamam PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Q Referto the controller nameplate to verify the rating of the control power input rating For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 No braking manuever allowed in wiring diagram Maintained pushbutton Notes 1 Minimum transition time for reversing direction is 1 2 second 2 Phase Reversal protection must be disabled in reversing applications Wiring 3 21 Figure 3 19 Typical Wiring Diagram for Two speed Applications Two Speed Motor Starter 1 RC 3 Phase
146. udes a Restart I Starts Fer Hour 8 Don sliding window for the one hour time period 625 780 970 and 1250 A units the min max is 5 0 25 and the default value is 5 0 Amps Parameter Information B 9 Table B 1 Parameter List Continued Grou Parameter Parameter Units Min Default Parameter Description User P Name Number Max Settings p Settings Allows the user to enable the SMC Flex to auto restart for up to 5 attempts other than Restart Restart Attempts 82 0 5 0 an SCR overtemp or motor overload fault The start signal must remain active for a restart to occur Provides a delay time between restart Restart Restart Delay 83 Secs 0 60 0 attempts to allow for the condition to be removed This parameter gives the user the ability to selectively disable specific fault codes such as F1 F2 F3 and F41 F42 F43 These faults 1 are used to detect problems with incoming 0 Disable 7 Line Fault 1 Disable F1 power and the detection of appropriate zero Linear List 849 Enable F1 or the firing of the SCRs based on Disable 2 DisableF41 Do 3 lt Fnable the current and voltage characteristics associated with the SCR turning off F41 These faults can only occur during starting or stopping and are usually related to the incoming power condition This parameter defeats all running faults and 0 Disable is only
147. uring braking is being encountered Linear List High Eff Brake SMB 386 of Stopping Time This parameter is used to extend the SMB braking time by a percentage of the typical stopping time The need to adjust this parameter can occur when braking is applied to high efficiency motors and relates to the counter EMF produced by these motors This setting should never really exceed 50 Nuisance overload faults will likely occur is set incorrectly This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Rockwell Automation technical support if you have Version 4 001 firmware or earlier and need to access this parameter Parameter Information B 5 Table B 1 Parameter List Continued Parameter Parameter Min Default or User Group Name Number Units Max Settings Parameter Description Settings When this option is used this parameter provides the user the ability to select see Slow Speed Sel 39 n SS High between the Low and High settings for 9 both the Preset Slow Speed and Accu Stop control options Provides the user the ability to program the motor s direction of rotation Note that with Preset SS SS FWD the Preset Slow Speed option the controller Accu Stop slow pend Di 4 SS REV has the capability to operate the motor in the reverse direction during slow speed operation without the use of a
148. ut Off Level 1176 V 100 25 This parameter provides the user with the ability to manually adjust the level for the controller s voltage shut off detection Since this parameter has the potential to modify the SCR control scheme it is important that adjustments be made with the help of Technical Support It is important that you do not disable both parameter 113 and this one at the same time otherwise SCR firing instability can occur Linear List OL Reset Level 1186 9 99 75 Sets the level at which the motor overload is allowed to be reset Once the TCU has dropped below the program level the device can be reset manually or will auto reset if programmed for auto reset operation Linear List Ambient Temperature 1199 60 50 Provides the ability to compensate for a lower or higher ambient temperature condition The ambient temperature programmed should be representative of the actual nominal temperature or worst case condition since improper programming can result in nuisance tripping or SCR damage due to true SCR overheating Linear List Notch Position 1206 9 40 0 100 0 87 5 This parameter allows for the starting control algorithm to be manually modified It is recommended that you do not make changes to this parameter without specifically talking with Technical Support Linear List Notch Maximum pump control 1219 50 70 70
149. w Speed Pump Control SMB Smart Motor Braking Accu Stop and Slow Speed with Braking options Figure 3 29 Soft Stop Sequence of Operation Coast to rest Soft Stop Soft Stop Start Run Time seconds If Soft Stop Selected Sequence of Operation 10096 Speed Push Buttons Start Closed Open Stop Closed Open Soft Stop Closed Open Auxiliary Contacts Normal Closed Open vadis BB 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 100 Speed Push Buttons Start Slow Speed Auxiliary Contacts Normal Up to speed Closed Open Open Closed Open Closed Open Closed Open Figure 3 30 Preset Slow Speed Sequence of Operation Coast to rest Soft Stop L 7 or 15 Slow Speed Start Run 1 Coast 4d Time seconds 100 Speed Push Buttons Start Stop Pump Stop Auxiliary Contacts Normal Up to speed Closed Open Closed Open Closed Open Closed Open Closed Open Wiring 3 33 Figure 3 31 Pump Control Sequence of Operation Coast to rest F Pump Start _
150. witching to full voltage Current Limit Level 50 600 full load current This parameter provides adjustability for the reduced output voltage level provided to the motor Kickstart Time 0 0 2 0s A boost of current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time Ifthe controller senses that the motor has reached full speed before completing the current limit start it will automatically switch to providing full voltage to the motor Programming 4 9 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 torque combination is determined by a hard contact input to terminal 15 When th
151. work area of the controller after it is powered up The SMC Flex uses an Auto Store feature when programming parameters When parameters are modified in the program mode the new values are stored immediately in RAM and then in EEPROM once the enter key has been pressed If control power is lost prior to the enter key being pressed these values will be lost When the device first powers up the values from the EEPROM area of memory are copied into RAM Read only Memory ROM The SMC Flex controller comes with factory default parameter values These settings are stored in non volatile ROM and are displayed the first time you enter the Program mode At any time you can restore defaults by accessing the memory storage menu Description Display Memory Storage Reset to Defaults Electrically Erasable Programmable Read only Memory EEPROM The SMC Flex controller provides a non volatile area for storing user modified parameter values in the EEPROM Recalling Defaults After parameter values have been modified factory default settings can still be re initialized Programming 4 7 Parameter Modification 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 log

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