Rockwell-automation 150 SMC-Flex User Manual User Manual

USER MANUAL FOR SERIES BSMC™-FlexBULLETIN 150

1-2 Product OverviewOperation The SMC-Flex controller can operate standard squirrel-cage induction motors rated 1…1250 A or Star-delta (wye-delta) typ

4-16 ProgrammingExample Settings Undervoltage ➀With Line Voltage programmed for 480V and the Undervoltage level programmed for 80%, the trip value is

Chapter 5MeteringOverview While the SMC-Flex controller operates your motor, it also monitors several different parameters, providing a full function

5-2 Metering The metering values that are displayed on the SMC-Flex can be modified to show your desired values by accessing Main Menu / Preferences.D

Chapter 6Optional HIM OperationOverview The SMC-Flex controller offers a variety of unique control options that provide enhanced motor starting and st

6-2 Optional HIM OperationOption Action OperationPump ControlPump Control The green start button, when pressed, will commence motor acceleration to fu

Chapter 7CommunicationsOverview The SMC-Flex provides advanced communications capabilities that allow it to be started and stopped from multiple sourc

7-2 CommunicationsHuman Interface Module The SMC-FLEX controller can be programmed with the built-in keypad and LCD display or with our optional Bulle

Communications 7-3The control panel provides the operator interface to the controller. All other controls available with the various human interface m

7-4 CommunicationsConnecting the Human Interface Module to the ControllerFigure 7.1 shows the connection of the SMC-Flex controller to a human interfa

Communications 7-5To enable motor control from a connected human interface module or communication module, you must take the following programming ste

Product Overview 1-3Selectable KickstartThis feature provides a boost at startup to break away loads that require a pulse of high torque to get starte

7-6 CommunicationsIf enabling control from the built-in SMC-Flex programmer, the Logic Mask must be set as follows:Table 7.D Logic Mask RequirementsC

Communications 7-7Default Input/Output Configuration The default configuration for I/O is 4 bytes in and 4 bytes out (TX = 4 bytes, RX = 4 bytes). The

7-8 CommunicationsSMC — Flex Bit IdentificationTable 7.G Logic Status WordBit #Status Description15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0X Enabled 1 — C

Communications 7-9Reference/Feedback The SMC-Flex does not offer the analog Reference feature. The analog Feedback feature is supported and will provi

7-10 CommunicationsDisplay Text Unit Equivalents Some parameters have text descriptions when viewed from a HIM or through a communication software pro

Chapter 8DiagnosticsOverview This chapter describes the fault diagnostics of the SMC-Flex controller. Further, this section describes the conditions t

8-2 DiagnosticsClear Fault You can clear a fault using any of several methods:• Program the SMC-Flex controller for a Clear Fault, which can be found

Diagnostics 8-3Fault CodesTable 8.A provides a complete cross-reference of the available fault codes and corresponding fault descriptions.Table 8.A F

8-4 DiagnosticsFault Definitions Table 8.B shows the fault definitions for the SMC-Flex.➀Phase loss, overvoltage, and undervoltage protection are disa

Chapter 9TroubleshootingIntroduction For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with

1-4 Product OverviewDual Ramp Start ➀This starting mode is useful on applications that have varying loads (and therefore varying starting torque requi

9-2 TroubleshootingThe following flowchart is provided to aid in quick troubleshooting.Figure 9.1 Troubleshooting FlowchartSeeTable 10.Aon page10-3See

Troubleshooting 9-3Open Bypass 13, 14, & 15 • Control voltage is low• Inoperable power module bypass• Check control voltage power supply• Replace

9-4 Troubleshooting➀Prestart fault indication.Table 9.B Motor Will Not Start — No Output Voltage to the MotorTable 9.C Motor Rotates (but does not a

Troubleshooting 9-5Table 9.D Motor Stops While RunningTable 9.E Miscellaneous SituationsStarting • Mechanical problems• Inadequate Current Limit set

9-6 TroubleshootingMotor stops too slowly withSoft Stop option• Stopping time setting• Misapplication• Verify the programmed stopping time and correct

Troubleshooting 9-7Power Module Check If a power module needs to be checked, use the applicable procedure that follows.Shorted SCR Test1. Using an ohm

9-8 Troubleshooting

Rockwell Automation Publication 150-UM011A-EN-P - August 2010Appendix ASpecificationsFunctional Design Standard FeaturesInstallationPower Wiring Stand

A-2 SpecificationsElectrical Ratings➀ 690V power is only available with 100…240V control.Device Rating UL/CSA/NEMA IECPower CircuitRated Operation Vol

Specifications A-3Short Circuit Protection➀ Consult local codes for proper sizing of short circuit protection.➁ Non-time delay fuses: Class K5 - 5…480

Product Overview 1-5Preset Slow Speed This option can be used in applications that require a slow speed jog for general purpose positioning. Preset Sl

A-4 Specifications➀ Heatsink fans can be powered by either 110/120V AC or 220/240V AC.Power RequirementsControl Module, 1…480 A 120…240V ACTransformer

Specifications A-5Environmental➀ The product’s allowable operational ambient temperature must be derated by -3 °C (-27°F) per 1000 m (3280 ft.). Maxim

A-6 SpecificationsOtherApproximate Dimensions and Shipping WeightsOpen Type Controllers Dimensions are in millimeters (inches). Dimensions are not int

Specifications A-7Enclosed Type Line-Connected ControllersFactory-installed options may affect enclosure size requirements.Exact dimensions can be obt

A-8 SpecificationsEnclosed Type Line-Connected Controllers, Continued ➀ Use this row for 460V -58 and 575V -59.➁ Use this row for 460V -59 and 575V -6

Appendix BParameter InformationTable B.1 Parameter List GroupParameterNameParameterNumberUnitsMin./Max.DefaultSettingsParameter DescriptionUserSettin

B-2 Parameter InformationBasic Set UpSMC Option 14StandardBrakePump ControlThis a “read-only” parameter that identifies to the user the type of contro

Parameter Information B-3Dual RampStarting Mode 2 25Full VoltageCurrent LimitSoft StartLinear SpeedPump StartSoft StartWhen the dual ramp mode is sel

B-4 Parameter InformationBasic Set Up/ Accu-StopBraking Current 35 %FLC 0…400 0When the Smart Motor Braking option is installed, this parameter allows

Parameter Information B-5Preset SS/ Accu-StopSlow Speed Sel 39SS LowSS HighSS HighWhen this option is used, this parameter provides the user the abil

1-6 Product OverviewLinear Speed Acceleration ➀The SMC-Flex has the ability to control the motor speed during starting and stopping maneuvers. A tach

B-6 Parameter InformationLinear List OL Shunt Time 48➂ Sec 0…999 0This parameter prevents the overload from accumulating or incrementing the Motor The

Parameter Information B-7Under-voltageUndervolt A Lvl 57 %V 0…99 0Allows the user to set a voltage (% of line Voltage) that will cause an Alarm when t

B-8 Parameter InformationJam Jam A Lvl 69 %FLC 0…1000 0Allows the user to set an instantaneous over current level (% of line FLC) that will cause an A

Parameter Information B-9Restart Restart Attempts 82 0…5 0Allows the user to enable the SMC-Flex to auto-restart for up-to 5 attempts, other than an

B-10 Parameter InformationMotor DataMotor ID 104 0…65535 0Allows the user the ability to assign a specific identification number to a motor and contro

Parameter Information B-11Basic Set UpAux2 Config 110NormalNormal NCUp To SpeedUp To Speed NCFaultFault NCAlarmAlarm NCNetworkNetwork NCExternal Bypas

B-12 Parameter InformationLinear List V Shut Off Level 117➂ % V 0…100 25This parameter provides the user with the ability to manually adjust the level

Parameter Information B-13Linear List Fault 3 126 0…255Fault buffer #3 represents fault history of the device with fault #1 being the current fault an

B-14 Parameter InformationNotes

Appendix CRenewal Parts➀One piece provided per part number.➁ Three-phase power pole structure provided per part no.➂ One-phase power pole provided per

Product Overview 1-7Soft StopThis option can be used in applications that require an extended stop time. The voltage ramp down time is user-adjustable

C-2 Renewal PartsNotes:

Appendix DContactor Replacement Installation Instructions for 625…1250 A units:Prior to beginning the following steps, the front cover must be removed

D-2 Contactor Replacement Installation Instructions for 625…1250 A units12Step BStep C1231

Contactor Replacement Installation Instructions for 625…1250 A units D-31342EIEEIEStep DClick

D-4 Contactor Replacement Installation Instructions for 625…1250 A units12564321100 lb-in11.3 N•m100 lb-in11.3 N•m140 lb-in15.8 N•m100 lb-in11.3 N•m62

Appendix EAccessories➀Requires a 20-HIM-H10 cable.Description Description/Used With Cat. No.Protective Modules 5…85 A, 480V 150-F84108…1250 A, 480V 15

E-2 AccessoriesNotes:

Appendix FRenewal Part Cross ReferenceDescription Controller TypeSMCRatingLineVoltageControl InputVoltageOrderableRenewal Part No.Control Module Cat.

F-2 Renewal Part Cross Reference➀ These are not orderable catalog numbers. they appear on the product label of the orderable part. If a control module

Renewal Part Cross Reference F-3➀ These are not orderable cat. nos. If a control module needs to be ordered, reference the control module renewal part

1-8 Product OverviewControl Options The SMC-Flex controller offers the control options described below. Important: The options listed in this section

F-4 Renewal Part Cross Reference➀ These are not orderable cat. nos. If a control module needs to be ordered, reference the control module renewal part

Publication 150-UM008H-EN-P — January 2010 PN 40055-218-01 (8)Superecedes Publication 150-UM008G-EN-P — November 2006 Copyright ©2010 Rockwell Automat

Product Overview 1-9Modes of Operation (Braking Control)SMB™ Smart Motor Braking OptionThis option can be used in applications that require reduced st

1-10 Product OverviewAccu-Stop™ OptionThis option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options. For general purp

Product Overview 1-11Protection and Diagnostics The SMC-Flex controller provides the protective and diagnostic features described below.OverloadThe SM

Important User InformationBecause of the variety of uses for the products described in this publication, those responsible for the application and use

1-12 Product OverviewFigure 1.13 Overload Trip CurvesFigure 1.14 Restart Trip Curves after Auto ResetApproximate trip time for 3-phase balancedconditi

Product Overview 1-13Undervoltage ➀Utilizing the undervoltage protection of the SMC-Flex, motor operation can be halted if a sudden drop in voltage is

1-14 Product OverviewStall Protection and Jam DetectionThe SMC-Flex controller provides both stall protection and jam detection for enhanced motor and

Product Overview 1-15Ground FaultIn isolated or high impedance-grounded systems, core-balanced current sensors are typically used to detect low level

1-16 Product OverviewGround Fault TripThe SMC-Flex will trip with a ground fault indication if:• No other fault currently exists• Ground fault protect

Product Overview 1-17Thermistor/PTC ProtectionThe SMC-Flex provides terminals 23 and 24 for the connection of positive temperature coefficient (PTC) t

1-18 Product Overview• The resistance across terminals 23 and 24 is either greater than the relay’s response resistance or less than the short-circuit

Product Overview 1-19Metering Power monitoring parameters include:• Three-phase current• Three-phase voltage•Power in kW• Power usage in kWH•Power fac

1-20 Product OverviewCommunication A serial interface port (DPI) is provided as standard, which allows connection to the Bulletin 20-HIM LCD interface

Product Overview 1-21Status Indication Four programmable hard contact outputs are provided as standard. All auxiliary contacts are programmable for th

European Communities (EC) Directive ComplianceIf this product has the CE mark it is approved for installation within the European Union and EEA region

1-22 Product OverviewNotes

Chapter 2InstallationDegree of Protection The SMC-Flex soft starters have an IP00 or IP2X protection rating, depending on the size. Taking into accou

2-2 InstallationLifting For controllers rated 625…1250 A, the device should only be lifted from designated lifting points. The lifting points are desi

Installation 2-3General Precautions In addition to the precautions listed throughout this manual, the following statements, which are general to the s

2-4 InstallationEnclosures The open-style design of the SMC-Flex controller requires that it be installed in an enclosure. The internal temperature of

Installation 2-5Mounting All units are fan cooled. It is important to locate the controller in a position that allows air to flow vertically through t

2-6 InstallationFigure 2.3 Dimensions: 5…85 A ControllersAll dimensions are approximate and are not intended for manufacturing purposes. Consult your

Installation 2-7Figure 2.4 Dimensions: 108…135 A ControllersAll dimensions are approximate and are not intended for manufacturing purposes. Consult yo

2-8 InstallationFigure 2.5 Dimensions: 201…251 A ControllersAll dimensions are approximate and are not intended for manufacturing purposes. Consult yo

Installation 2-9Figure 2.6 Dimensions: 317…480 A ControllersAll dimensions are approximate and are not intended for manufacturing purposes. Consult yo

Notes

2-10 InstallationFigure 2.7 Dimensions: 625…780 A ControllersAll dimensions are approximate and are not intended for manufacturing purposes. Consult y

Installation 2-11Figure 2.8 Dimensions: 970…1250 A ControllersAll dimensions are approximate and are not intended for manufacturing purposes. Consult

2-12 InstallationPower Factor Correction CapacitorsThe controller can be installed on a system with power factor correction (PFC) capacitors. The capa

Installation 2-13Protective Modules Protective modules containing metal oxide varistors (MOVs) can be installed on controllers rated 5…1250 A and 200…

2-14 InstallationElectromagnetic Compatibility (EMC)The following guidelines are provided for EMC installation compliance.EnclosureInstall the product

Chapter 3WiringTerminal Locations The SMC-Flex controller wiring terminal locations are shown in Figure 3.1 and Figure 3.2. Make wiring connections as

3-2 WiringFigure 3.2 Wiring Terminal Locations (108…480 A)4153233Table 3.A Wiring Terminal Locations1 Incoming Line Termination2 Line Motor Connectio

Wiring 3-3Figure 3.3 Wiring Terminal Locations (625…1250 A)Power Structure The SMC-Flex product has an integrated mechanical run contactor on each pha

3-4 WiringLine ConnectedThe SMC-Flex by default is programmed to be connected to a line controlled motor as shown in Figure 3.4. These motors typicall

Wiring 3-5Power Lugs Power lugs are required for devices rated 108..1250 A. In some cases these lugs are sold in kits. Each kit contains three lugs. T

Table of ContentsChapter 1Product OverviewOther Related Documents ... 1-1Descr

3-6 WiringTable 3.C SMC-Flex 5…1250 A, Line Connection Lug Information ➀The 1250 A device requires one (1) each of the 100-DL630 and 100-DL860.Table

Wiring 3-7Control Power Control WiringRefer to the product nameplate for control terminal wire capacity and tightening torque requirements. Each contr

3-8 WiringFigure 3.6 230V Control Undervoltage Relay Settings for 625…1250 A DevicesSEE NAMEPLATE FOR STATUSLED240208220PICK-UP% NOMINALVOLTAGENOMINAL

Wiring 3-9Figure 3.7 Internal Wiring and 230V Control Undervoltage Relay Connection Diagram for 625…1250 A Devices178 24653CP114132221A2CA1CONTACTOR A

3-10 WiringFigure 3.8 Internal Wiring and 120V Control Connection Diagram for 625…1250 A DevicesCP1CONTACTOR A SM C FLEXCONTROLMODULECONTACTORBCONTACT

Wiring 3-11Control Wire SpecificationsTable 3.F provides the control terminal wire capacity, the tightening torque requirements, and the wire strip le

3-12 WiringControl Terminal Designations As shown in Figure 3.10, the SMC-Flex controller contains 24 control terminals on the front of the controller

Wiring 3-13Standard Controller Wiring DiagramsFigure 3.11 through Figure 3.22 show typical wiring for the SMC-Flex controller.Figure 3.11 Typical Wiri

3-14 WiringFigure 3.12 Typical Wiring Diagram for Two-Wire Control with Stopping Control (No DPI Control) ➀Customer supplied.➁ Refer to the controller

Wiring 3-15Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications➀Customer supplied.➁ Refer to the controller nameplate to verify the rating of

Lifting ...2-2General Precautions ...

3-16 WiringFigure 3.14 Typical Wiring Diagram for Start-Stop Control via DPI CommunicationsNote: Use this wiring diagram when start-stop will come f

Wiring 3-17Figure 3.15 Typical Wiring Diagram for Retrofit Applications➀Customer supplied.➁ Overload protection should be disabled in the SMC-Flex con

3-18 WiringFigure 3.16 Typical Wiring Diagram for Isolation Applications (DPI also)➀Customer supplied.➁ Refer to the controller nameplate to verify th

Wiring 3-19Figure 3.17 Typical Wiring Diagram for Shunt Trip Applications➀Customer supplied.➁ Refer to the controller nameplate to verify the rating o

3-20 WiringFigure 3.18 Typical Wiring Diagram for Single-Speed Reversing Applications➀Customer supplied.➁ Refer to the controller nameplate to verify

Wiring 3-21Figure 3.19 Typical Wiring Diagram for Two-speed Applications➀Customer supplied.➁ Two-speed, consequent pole installations.➂ Refer to the c

3-22 WiringFigure 3.20 Typical Wiring Diagram for SMC-Off-Bypass Control➀Customer supplied.➁ Refer to the controller nameplate to verify the rating of

Wiring 3-23Figure 3.21 Typical Wiring Diagram for Hand-Off-Auto Control with Stop Option and Start/Stop Push Buttons ➀Customer supplied.➁ Refer to the

3-24 WiringSoft Stop, Pump Control, andSMB Smart Motor BrakingFigure 3.22 through Figure 3.25 show the different wiring for the Soft Stop, Pump Contro

Wiring 3-25Figure 3.23 Typical Retrofit Wiring Diagram➀Customer supplied.➁ Overload protection should be disabled in the SMC-Flex controller.➂ Refer t

Current Limit Start ...4-8Dual Ramp Start ...

3-26 WiringFigure 3.24 Typical Wiring Diagram for Applications Requiring an Isolation Contactor➀Customer supplied.➁ Refer to the controller nameplate

Wiring 3-27Figure 3.25 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control (Soft Stop, Braking, and Pump Control Only)➀Customer supplied.11 1213141

3-28 WiringPreset 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 th

Wiring 3-29Figure 3.27 Typical Slow Speed Wiring Diagram for Hand-Off-Auto (DPI) Control➀Customer supplied.➁ Slow Speed.➂ Refer to the controller name

3-30 WiringSlow 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

Wiring 3-31Sequence of Operation Figure 3.29 through Figure 3.34 show the different operation sequences for the Soft Stop, Preset Slow Speed, Pump Con

3-32 WiringFigure 3.30 Preset Slow Speed Sequence of Operation StartRun100%MotorSpeedTime (seconds)Up-to-speedAuxiliary ContactsPush ButtonsNormalSlow

Wiring 3-33Figure 3.31 Pump Control Sequence of OperationCoast-to-Rest100%Up-to-SpeedNormalPump Stop (Stop Option)StopMotor SpeedPush ButtonsClosedOpe

3-34 WiringFigure 3.32 SMB Smart Motor Braking Sequence of Operation100%Up-to-SpeedNormalSmart Motor BrakingStopMotor SpeedPush ButtonsClosedOpenClose

Wiring 3-35Figure 3.33 Accu-Stop Sequence of Operation➀When Accu-Stop push button is closed, start/stop function is disabled.Start Run100 %Motor Speed

Fault Display ...8-1Clear Fault ...

3-36 WiringFigure 3.34 Slow Speed with Braking Sequence of OperationSpecial Application Considerations Use of Protective Modules A protective module (

Wiring 3-37Figure 3.35 Protective ModuleThere are two general situations that may occur which would indicate the need for using the protective modules

3-38 WiringMulti-motor Applications The SMC-Flex controller will operate with more than one motor connected to it. To size the controller, add the tot

Wiring 3-39SMC-Flex Controller as a Bypass to an AC DriveBy using the controller as shown in Figure 3.37, a soft start characteristic can be provided

3-40 WiringSMC-Flex Controller with a Bulletin 1410 Motor Winding HeaterFigure 3.38 Typical Application Diagram of SMC-Flex Controller with a Bulletin

Chapter 4ProgrammingOverview This chapter provides a basic understanding of the programming keypad built into the SMC-Flex controller. This chapter al

4-2 ProgrammingFigure 4.1 Menu Structure Hierarchy➀The SMC-Flex controller does not support EEPROM, Link, Process, or Start-up modes.➁ Steps back one

Programming 4-3Figure 4.2 Parameter Menu Structure➀ Depending upon SMC option selected, some parameters may not appear in product display.➁ Steps back

4-4 ProgrammingTable 4.A Parameter Linear ListParameter No. Description Parameter No. Description Parameter No. Description1 Volts Phase A-B 49 OL Tr

Programming 4-5Password The SMC-Flex controller allows the user to limit access to the programming system through password protection. This feature is

Chapter 1Product OverviewOther Related Documents • Quick Start — Publication 150-QS001_①-EN-P• Renewal Part Instructions — 41053-277-01 (5…85 A)41053

4-6 ProgrammingParameter Management Before you begin programming, it’s important to understand how the controller memory is: • structured within the S

Programming 4-7Parameter Modification All parameters are modified using the same method. The basic steps to performing parameter modification are desc

4-8 ProgrammingSoft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor.➀If the controller senses th

Programming 4-9Dual Ramp Start The SMC-Flex controller provides the user with the ability to select between two Start settings. The parameters below a

4-10 ProgrammingFull Voltage Start The SMC-Flex controller may be programmed to provide a full voltage start (output voltage to the motor reaches full

Programming 4-11Programming Parameters The following table provides the option-specific parameters that are provided with each control option. These p

4-12 ProgrammingOption Parameter RangePump ControlPump Control SMC OptionThis parameter identifies the type of control present and is not user program

Programming 4-13➀All braking/stopping current settings in the range of 1…100% will provide 100% braking current to the motor.Option Parameter RangeSlo

4-14 ProgrammingBasic Set Up The Basic Set Up programming group provides a limited parameter set, allowing quick start-up with minimal adjustment. If

Programming 4-15Motor Protection While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify, the Motor