Rockwell Automation SMC Dialog Plus User Manual
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Rockwell Automation SMC Dialog Plus User Manual

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User Manual
™
SMC Dialog Plus
Controller
Bulletin 150
5
3
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2 0
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1 7
1 8
1 4
1 5
1 6
1 1
1 2
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3 0
2 9
2 5
2 6
2 7
2 8
2 4
2 1
2 2
2 3

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Summary of Contents for Rockwell Automation SMC Dialog Plus

  • Page 1 User Manual ™ SMC Dialog Plus Controller Bulletin 150...
  • Page 2 Important: Identifies information that is especially important for successful application and understanding of this product. SMC Dialog Plus, SMB, SCANport, and Accu-Stop are trademarks of Rockwell Automation. DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.) For Bulletin 150 SMC Smart Motor Controller technical support on start-up or existing installations, contact your Allen-Bradley representative.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1 Product Overview 1-1 Description ........1-1 Operation .
  • Page 4 toc–iv Table of Contents Dimensions ........2-4 Power Factor Correction Capacitors .
  • Page 5 toc–v Table of Contents Example Settings ........4-13 Undervoltage.
  • Page 6 I/O Mapping ........8-25 SMC Dialog Plus Controller Logic Command Addresses ..8-29 Explicit Messaging.
  • Page 7 Factor Correction Capacitors ....2-9 Figure 2.7 SMC Dialog Plus Controller with Human Interface Module ....2-13 Figure 2.8...
  • Page 8 Figure 3.9 SMC Dialog Plus Controller Control Terminals ..3-6 Figure 3.10 Grounding Provision ..... . . 3-6 Figure 3.11 Typical Wiring Diagram for Standard Controller .
  • Page 9 toc–ix Table of Contents Figure 7.9 SMB Smart Motor Braking Sequence of Operation 7-14 Figure 7.10 Typical Wiring Diagram for the Preset Slow Speed Option ....7-15 Figure 7.11 Typical Retrofit Wiring Diagram .
  • Page 10 toc–x Table of Contents Table 8.A Logic Control Data ......8-1 Table 8.B SMC Status Data ......8-3 Table 8.C Fault Code Cross-reference .

  • Page 11: Chapter 1 Product Overview

    Chapter Product Overview Description The SMC Dialog Plus controller offers a full range of starting modes as standard: • Soft Start with Selectable Kickstart • Current Limit Start with Selectable Kickstart • Dual Ramp Start • Full Voltage Start Other features that offer further user benefit include: •...

  • Page 12: Starting Modes

    The acceleration ramp time is user-adjustable from 0 to 30 seconds. If the SMC Dialog Plus controller senses that the motor has reached the up-to-speed condition during the voltage ramp operation, the output voltage automatically switches to full voltage.

  • Page 13: Selectable Kickstart

    Limit level is user-adjustable from 50 to 600% of the motor full load ampere rating; and the current limit time is user-adjustable from 0 to 30 seconds. If the SMC Dialog Plus controller senses that the motor has reached the up-to-speed condition during the current limit starting mode, the output voltage automatically switches to full voltage.

  • Page 14: Dual Ramp Start

    Product Overview Starting Modes (cont.) Dual Ramp Start ① This starting mode is useful on applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings.

  • Page 15: Energy Saver

    The Energy Saver feature is typically used in applications where the motor is lightly loaded or unloaded for extended periods of time. With the Energy Saver feature enabled, the SMC Dialog Plus controller continuously monitors motor load with its internal feedback circuitry.
  • Page 16 (2) The current sensing capability of the SMC Dialog Plus controller is disabled during bypass operation. Using a Bulletin 825 converter module in these applications is recommended to provide current feedback.

  • Page 17: Figure 1.6 Overload Trip Curves

    Product Overview Figure 1.6 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 10.0 100.0 100.0 100.0 10.0 10.0 10.0 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.

  • Page 18: Stall Protection And Jam Detection

    Product Overview Protection and Diagnostics Stall Protection and Jam Detection (cont.) The SMC Dialog Plus controller provides both stall protection and jam detection for enhanced motor and system protection. • Stall protection is user-adjustable from 0.0 to 10.0 seconds (in addition to the ramp time programmed).

  • Page 19: Open Gate

    0 to 25% with a programmable delay time of 0 to 99 seconds. Underload ③ Utilizing the underload protection of the SMC Dialog Plus controller, motor operation can be halted if a sudden drop in current is sensed. The SMC Dialog Plus controller provides an adjustable underload trip setting from 0 to 99% of the programmed motor full load current rating.

  • Page 20: Excessive Starts/Hour

    Protection and Diagnostics Excessive Starts/Hour (cont.) The SMC Dialog Plus 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.

  • Page 21: Communication

    Product Overview 1-11 Communication A serial interface port (called SCANport™) is provided as standard, which allows connection to the Bulletin 1201 human interface modules and the Bulletin 1203 communication modules. Figure 1.10 SCANport Location SCANport ATTENTION: Only one peripheral device can be connected to the SCANport.

  • Page 22: Control Options

    1-12 Product Overview Control Options The SMC Dialog Plus controller offers the control options described below. Important: The options listed in this section are mutually exclusive and must be specified when ordering. An existing controller may be upgraded to another control option by replacing the control module.

  • Page 23: Pump Control Option

    Product Overview 1-13 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.

  • Page 24: Smb‰ Smart Motor Braking Option

    Control Options (cont.) Smart Motor Braking Option This option can be used in applications that require reduced stopping times. The SMC Dialog Plus controller incorporates a microprocessor-based system that applies braking current to a standard squirrel cage induction motor without any additional equipment.

  • Page 25: Accu-Stop‰ Option

    Product Overview 1-15 Note: All braking current settings in the range of 1–100% will provide 100% braking current to the motor. ATTENTION: SMB Smart Motor Braking is not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements. Accu-Stop™...

  • Page 26: Slow Speed With Braking Option

    1-16 Product Overview Slow Speed with Braking Option The Slow Speed with Braking option provides a jog speed for process set-up and braking-to-stop at the end of the cycle. Figure 1.17 Slow Speed with Braking Option 100% Coast-to-rest Motor Speed 7% or 15% Braking Slow...

  • Page 27: Chapter 2 Installation

    Chapter Installation Receiving It is the responsibility of the user to thoroughly inspect the equipment before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are damaged, it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill.

  • Page 28: General Precautions

    1170 1400 2025 2250 2400 2760 Enclosures The open-style design of the SMC Dialog Plus controller requires that it be installed in an enclosure. The internal temperature of the enclosure must be kept within the range of 0°C to 50°C.

  • Page 29: Ventilated Enclosures

    Non-ventilated Enclosures For Type 12 (IP54) or non-ventilated enclosures, it is recommended that a bypass contactor be used. This will allow the SMC Dialog Plus controller to bring the motor up-to-speed. After the controller is up to full voltage, it is bypassed. Note that the Energy Saver, Phase Rebalance, some metering functions, and some protective features of the controller may no longer be available.

  • Page 30: Mounting

    Installation Mounting The controller is convection cooled. Additionally, units rated for 97A and above are fan cooled. It is important to locate the controller in a position that allows air to flow vertically through the power module. The controller must be mounted with heatsink fins in a vertical plane and have a minimum of six inches (15 cm) free space above and below the controller.

  • Page 31: Figure 2.2 Dimensions: 97 And 135 Amp Controllers

    Installation Figure 2.2 Dimensions: 97 and 135 Amp Controllers Power Terminal M10 Bolt 6 Places Ground Screw (M6) Terminals .281 in. (Ø 7.14 mm) 4 Mtg. Holes Approx. Unit Width Height Depth Ship. Wt. 256.2 40.4 10.4 kg Controller 9-49/64 13-15/64 10-3/32 5-3/64...

  • Page 32: Figure 2.3 Dimensions: 180 Through 360 Amp Controllers

    Installation Mounting (cont.) Figure 2.3 Dimensions: 180 through 360 Amp Controllers .281 (7.1) Dia. 6 Mtg. Holes .281 (7.1) Rad. 2 Key Holes Terminal Detail .136 (3.5) Dia. #8-32 UNC-2B .413 (10.5) Dia. 1.02 (25.9) .984 (25) .531 1.161 (13.5) (29.5) 2.250 (57)

  • Page 33: Figure 2.4 Dimensions: 500 Amp Controller

    Installation Figure 2.4 Dimensions: 500 Amp Controller .531 in. (13.5 mm) for 1/2 Bolts Typ. .312 in. (7.9 mm) 6 Mtg. Holes Ground Nut (1/4-20) Approx. Unit Ship. Height Width Depth 588.4 310.7 51.4 50.8 469.9 196.9 393.7 38.9 18.6 17.5 40.8 kg 23-11/64...

  • Page 34: Figure 2.5 Dimensions: 650-1000 Amp Controllers

    Installation Mounting (cont.) Figure 2.5 Dimensions: 650-1000 Amp Controllers .56 Dia. (Ø 14.2) 2 – Lifting Holes .5 Dia. (Ø 12.7) 6 – Holes .105 Steel Sheet (2.67) .75 Dia. (Ø 19.1) 2 – Holes (50.8) (101.6) .688 .515 (17.5) (13.1) Dia.

  • Page 35: Power Factor Correction Capacitors

    Correction Capacitors line side of the controller. This must be done to prevent damage to the SCRs in the SMC Dialog Plus controller. When discharged, a capacitor essentially has zero impedance. For switching, sufficient impedance should be connected in series with the capacitor bank to limit the inrush current.

  • Page 36: Fast Acting Current-Limiting Fuses

    2-10 Installation Fast Acting Short-circuit protection guidelines are provided in Appendix A of this manual. Enhanced SCR protection may be obtained with the use of Current-limiting fast acting current-limiting fuses. Table 2.C provides a listing of Fuses fuses that are coordinated to protect the controller SCRs in the event of a ground fault or short-circuit at the connected load.

  • Page 37: Protective Modules

    Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed. Multi-motor Protection If the SMC Dialog Plus controller is controlling more than one motor, individual overload protection is required for each motor.

  • Page 38: Human Interface Module

    The display panel duplicates the 2-line, 16-character backlit LCD display and programming keypad found on front of the SMC Dialog Plus controller. Refer to Chapter 4 for a description of the programming keys;...

  • Page 39: Connecting The Human Interface Module To The Controller

    2-13 Connecting the Human Interface Module to the Controller Figure 2.7 shows the connection of the SMC Dialog Plus controller to a human interface module. See Figure 3.14 on page 3-10 for the control wiring diagram that enables start-stop control from a human interface module.
  • Page 40 2-14 Installation Human Interface Series A Human Interface Modules Module (cont.) Description Action Display STOPPED — — 0.0 AMPS Press any key to access CHOOSE MODE the Choose Mode _ _ _ _ _ function. Scroll with the Up/Down CHOOSE MODE keys until the Program PROGRAM option appears.
  • Page 41 Installation 2-15 Series B Human Interface Modules Description Action Display STOPPED — — 0.0 AMPS Press any key to access CHOOSE MODE the Choose Mode _ _ _ _ _ function. Scroll with the Up/Down keys until the Control CHOOSE MODE Logic option is CONTROL STATUS presented.

  • Page 42: Communication Modules

    SMC Dialog Plus Controller Converter Modules The Bulletin 825 converter module provides three-phase current feedback to the SMC Dialog Plus controller for metering and overload protection during phase rebalance and bypass operation. Select the converter module based on the motor full load current (FLC) rating.

  • Page 43: Figure 2.9 Converter Module Connection Interface

    The converter module rating must be programmed in the calibration group for proper current measurement scaling. ② Cable length is three meters. Only the cable provided with the converter module is compatible with the SMC Dialog Plus controller. Use of any other cable may result in faulty controller operation.

  • Page 44: Electromagnetic Compatibility (Emc)

    2-18 Installation Converter Modules (cont.) For applications in which the motor’s full load current rating is greater than 360A, three additional current transformers with 5A secondaries are required. The figure below illustrates the connection of the current transformers to the converter module. Figure 2.10 Current Transformer Connection to Converter Module Current Transformer ➀➁...

  • Page 45: Wiring

    Installation 2-19 Wiring Wire in an industrial control application can be divided into three groups: power, control, and signal. The following recommendations for physical separation between these groups is provided to reduce the coupling effect. • Different wire groups should cross at 90° inside an enclosure. •...
  • Page 46 2-20 Installation...

  • Page 47: Chapter 3 Wiring

    Chapter Wiring Terminal Locations The SMC Dialog Plus controller wiring terminal locations are shown in Figure 3.1 through Figure 3.4. Make wiring connections as indicated in the typical connection diagrams. Connect the line to terminals L1/1, L2/3, and L3/5. Connect the load to terminals T1/2, T2/4, and T3/6.

  • Page 48: Figure 3.3 Wiring Terminal Locations (180 To 360 Amp)

    Wiring Terminal Locations (cont.) Figure 3.3 Wiring Terminal Locations (180 to 360 Amp) Control Wiring Access Door Input Power Fan Power Connections Connections Control Circuit Connections Output Power Connections Figure 3.4 Wiring Terminal Locations (500 Amp) Input Power Connections Fan Power Connections Control Circuit Connections...

  • Page 49: Power Wiring

    Wiring Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp) Input and Output Power Connections Control Circuit Connections Fan Power Connections Power Wiring 24–54A The power modules for controllers rated 24A–54A have internal mechanical-type lugs to accept line and load cables. Table 3.A and Table 3.B provide the lug wire capacity and tightening torque requirements.

  • Page 50: Control Power

    1000A (375 lb-in) (400 lb-in) [(2) 1/0–500 AWG] Control Power Control Voltage Depending upon the catalog number ordered, the SMC Dialog Plus controller will accept a control power input of: • 240V AC, (–15/+10%), 1 phase, 50/60 Hz – •...

  • Page 51: Fan Power

    Wiring Fan Power Controllers rated 97A 1000A have heatsink fan(s). Refer to Table 3.D – for the control power VA requirements of the heatsink fans. Fan Terminations See Figure 3.2 to Figure 3.4 for fan power connection locations. ATTENTION: The fan jumpers have been factory installed for 110/120 VAC input.

  • Page 52: Control Terminal Designations

    Wiring Control Terminal As shown in Figure 3.9, the SMC Dialog Plus controller contains 20 control terminals on the front of the controller. Designations Figure 3.9 SMC Dialog Plus Controller Control Terminals Terminal Terminal Description Description Number Number Control Power Input...

  • Page 53: Standard Controller Wiring Diagrams

    Figure 3.11 Typical Wiring Diagram for Standard Controller L1/1 T1/2 3-Phase ➀ L2/3 T2/4 Input Power L3/5 T3/6 Fast-acting ➀ SCR Fuses SMC Dialog Plus Branch (optional) ➀ Protection ➀ Controller ➀ ➀ Stop ➀ Start ➀ ➁ SMC Dialog Plus Control Terminals Internal...

  • Page 54: Programmable Control Interfacing

    Notes: Programmable controller interfacing in this diagram refers to hard-wiring between the PLC’s output contacts and the SMC Dialog Plus controller’s control terminals. For a wiring diagram related to programmable controller interfacing via the SMC Dialog Plus controller’s SCANport, refer to Figure 3.14.

  • Page 55: Dual Ramp Applications

    T1/2 3-Phase ➀ L2/3 T2/4 Input Power L3/5 T3/6 Fast-acting ➀ SCR Fuses Branch SMC Dialog Plus (optional) ➀ Protection ➀ Controller ➀ ➀ Stop ➀ Ramp 1 ➀ Ramp 2 Start ➀ ➁ SMC Dialog Plus Control Terminals Internal...

  • Page 56: Control Via The Scanport

    1203 communication module connected to the SMC Dialog Plus controller’s SCANport. L1/1 T1/2 3-Phase ➀ L2/3 T2/4 Input Power L3/5 T3/6 Fast-acting ➀ SCR Fuses SMC Dialog Plus Branch (optional) ➀ Protection ➀ Controller ➀ ➀ ➁ ➂ SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ①...

  • Page 57: Retrofit Applications

    Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller. ③ Refer to the controller nameplate to verify the rating of the control power input voltage.

  • Page 58: Isolation Applications

    Figure 3.16 Typical Wiring Diagram for Isolation Applications Wiring Diagrams (cont.) L1/1 T1/2 3-Phase ➀ L2/3 T2/4 Input Power L3/5 T3/6 Isolation Fast-acting SMC Dialog Plus Branch Contactor SCR Fuses ➀ Protection ➀ (IC) ➀ (optional) ➀ Controller ➀ ➀ ➀ Stop ➀...

  • Page 59: Bypass Applications

    ① Customer supplied. ② The Bulletin 825 Converter Module is required when the SMC Dialog Plus controller will be providing motor overload protection during bypass operation. ③ Refer to the controller nameplate to verify the rating of the control power input voltage.

  • Page 60: With Isolation Applications

    L1/1 3-Phase ➀ T2/4 L2/3 Input Power T3/6 L3/5 Isolation Fast-acting Contactor Branch SCR Fuses SMC Dialog Plus (IC) ➀ Protection ➀ (optional) ➀ ➀ Controller ➀ ➀ Bypass Contactor (BC) ➀ ➀ Stop ➀ Start ➀ ➁ Auxiliary contacts...

  • Page 61: Shunt Trip Applications

    T1/2 L1/1 3-Phase ➀ T2/4 L2/3 Input Power T3/6 L3/5 Fast-acting ➀ SCR Fuses Branch SMC Dialog Plus (optional) ➀ Protection ➀ Controller ➀ ➀ Stop ➀ Start ➀ ➁ SMC Dialog Plus Control Terminals ➀ Auxiliary contact set for Fault and N.O.

  • Page 62: Speed Reversing Applications

    Figure 3.20 Typical Wiring Diagram for Single Speed Reversing Applications Wiring Diagrams (cont.) L1/1 T1/2 3-Phase ➀ L2/3 T2/4 Input Power L3/5 T3/6 Fast-acting Bulletin 825 SMC Dialog Plus Branch SCR Fuses Protection ➀ Coverter Controller (optional) ➀ ➀ Module (optional) ➀ Reversing Contactors ➀ ➀...

  • Page 63: Two-Speed Applications

    Figure 3.21 Typical Wiring Diagram for Two-speed Applications L1/1 T1/2 3-Phase ➁ L2/3 T2/4 Input Power ➁ L3/5 T3/6 ➀ SMC Dialog Plus Branch Protection ➀ Controller Fast-acting ➀ SCR Fuses (optional) ➀ ➀ ➀ Two-speed Motor Starter ➀ LOL ➀...

  • Page 64: Hand-Off-Auto (Scanport) Control

    Figure 3.22 Typical Wiring Diagram for Hand-Off-Auto (SCANport) Control Wiring Diagrams (cont.) L1/1 T1/2 3-Phase L2/3 T2/4 ➀ Input Power L3/5 T3/6 Fast-acting ➀ SCR Fuses SMC Dialog Plus Branch (optional) ➀ Protection ➀ Controller ➀ ➀ ➀ ➁ SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ①...

  • Page 65: Chapter 4 Programming

    SMC Dialog Plus controller. This chapter also describes programming the controller by modifying the parameters. Keypad Description The keys found on the front of the SMC Dialog Plus controller are described below. Escape Pressing the Escape key causes the programming system to move up one level in the menu structure.

  • Page 66: Figure 4.1 Menu Structure Hierarchy

    ➁ ⑤ GROUP LEVEL ① The SMC Dialog Plus controller does not support EEPROM, Link, Process, or Start-up modes. ② Steps back one level. ③ Control Status and Search are only available when using a Series B Bulletin 1201 human interface module.
  • Page 67 Programming Figure 4.1 (Cont.) Menu Structure Hierarchy Metering Calibrate Linear Basic Setup Advanced Setup Language Faults List Chapter 6 Chapter 5 ➀ ➁ GROUP LEVEL ➀ Volts Phase A–B SMC Option SMC Option Clear Fault Overload Class Volts Phase B–C Starting Mode Starting Mode Fault Buffer #1...

  • Page 68: Parameter Linear List

    Programming Programming Menu (cont.) Table 4.A Parameter Linear List Parameter No. Description Parameter No. Description Volts Phase A–B Slow Speed Dir. Volts Phase B–C Slow Accel Cur. Volts Phase C–A Slow Running Cur. Current Phase A Braking Current Current Phase B Factory Use Current Phase C Factory Use...

  • Page 69: Password

    Programming Password The SMC Dialog Plus controller allows the user to limit access to the programming system through password protection. This feature is a disabled with a factory-set parameter with a default setting of 0. To modify the password or login after a password is programmed, complete the procedure below.

  • Page 70: Parameter Management

    These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode. Electrically Erasable Programmable Read-only Memory (EEPROM) The SMC Dialog Plus controller provides a nonvolatile area for storing user-modified parameter values in the EEPROM.

  • Page 71: Using Parameter Management

    Programming Using Parameter Management Description Action Display Saving to EEPROM To ensure that the newly modified parameters are PARAMETER MGMT not lost if control power is STORE IN EE removed from the controller, store the values into EEPROM. Recalling from EEPROM Parameters stored in EEPROM can be manually PARAMETER MGMT...

  • Page 72: Parameter Modification

    Programming Parameter Modification All parameters are modified using the same method. The basic steps to performing parameter modification are described below. Note: Parameter values modified while the motor is operating are not valid until the next start sequence begins. Description Action Display STOPPED...

  • Page 73: Soft Start

    Programming Soft Start The following parameters are specifically used to adjust the voltage ramp supplied to the motor. Parameter Option Starting Mode Soft Start, Current Limit This must be programmed for Soft Start. Ramp Time #1 ① This programs the time period that the controller will 0 to 30 seconds ramp the output voltage up to full voltage from the Initial Torque level programmed.

  • Page 74: Dual Ramp Start

    4-10 Programming Dual Ramp Start The SMC Dialog Plus controller provides the user with the ability to select between two Soft Start settings. The parameters below are available in the Advanced Setup programming mode to obtain Dual Ramp control: Parameter...

  • Page 75: Basic Setup

    Displays the type of controller. This is factory set and not Standard adjustable. Starting Mode Allows the user to program the SMC Dialog Plus Soft Start, Current Limit controller for the type of starting that best fits the application. Ramp Time #1...

  • Page 76: Advanced Setup

    While the Basic Setup group allows the user to get started with a minimum number of parameters to modify, the Advanced Setup group allows full access to the SMC Dialog Plus controller’s powerful parameter set. Following is a listing of the additional setup parameters provided.

  • Page 77: Example Settings

    Programming 4-13 Parameter Option Phase Reversal This parameter allows the user to enable phase reversal Off, On protection. Starts Per Hour Allows the user to limit the number of starts during a one 0–99 (0 is the Off setting) hour period. Restart Attempts ①...
  • Page 78 4-14 Programming...

  • Page 79: Chapter 5 Calibration

    Enter the value from the motor’s 0.01–1.99 #.## nameplate. ① Refer to the SMC Dialog Plus controller nameplate for maximum ratings. Exceeding these could result in damage to the controller. ② The controller’s programming system will not allow both HP and kW to be programmed.

  • Page 80: Motor Codes

    Calibration Motor Data Entry (cont.) Parameter Option Display Motor Code Letter ① Enter the value from the motor’s nameplate. If the motor nameplate MOTOR CODE LETTER A–V does not provide this, consult the motor manufacturer. See Table 5.A for code letter definitions.

  • Page 81: Calibration Procedure

    Calibration Procedure For current measurement accuracy, use the procedure below to calibrate the SMC Dialog Plus controller to the connected motor. A clamp-on ammeter, which provides a true rms measurement and has a published accuracy of ±1% (Fluke model 33 or equal), is required to perform this procedure.
  • Page 82 Calibration Calibration Procedure (cont.) Description Action Display You can scroll to the next CURRENT PHASE A parameter to view the current ###.# AMPS measurement in phase A. Scroll to the next parameter to PARAMETER MGMT save the Calibrate group READY settings.

  • Page 83: Chapter 6 Metering

    Chapter Metering Overview While the SMC Dialog Plus controller operates your motor, it also monitors several different parameters, providing a full function metering package. ① Viewing Metering Data To access the metering information, follow the procedure below. Description Action Display AT SPEED —...
  • Page 84 Metering Viewing Metering Data (cont.) Description Action Display Scroll through the Metering VOLTS PHASE A–B parameters with the Up/Down ### VOLTS keys to access the desired information. VOLTS PHASE B–C ### VOLTS VOLTS PHASE C–A ### VOLTS CURRENT PHASE A ###.# AMPS CURRENT PHASE B ###.# AMPS...

  • Page 85: Chapter 7 Options

    Chapter Options Overview The SMC Dialog Plus controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities. (See pages 1-12 through 1-15 for brief descriptions of each option.) Note: Only one option can reside in a controller.
  • Page 86 Options Option Action Operation Preset Slow Speed The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop. The jog button, when pressed, will initiate slow speed motor operation from a “stopped”...

  • Page 87: Programming Parameters

    Options Programming Parameters The following table provides the option-specific parameters that are provided with each control option. These parameters are in addition to those already discussed in the Basic Setup, Advanced Setup, Metering, and Calibration groups. Diagrams supporting the options described below are shown later in this chapter.
  • Page 88 Options Programming Parameters (cont.) SMC Option SMB Smart Motor Braking This parameter identifies the type of SMB Braking control present and is not user programmable. Braking Current ① Allows the user to program the intensity 0–400% of full load current of the braking current applied to the motor.

  • Page 89: Control Wiring For Scanport Control

    Stop, Pump Control, and SMB Smart Motor Braking options. SMB Smart Motor Braking Options Figure 7.1 Typical Wiring Diagram Control Power ➂ Stop ➀ Option Stop ➀ ➁ Start ➀ SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied.

  • Page 90: Figure 7.2 Typical Retrofit Wiring Diagram

    Auxiliary Contacts ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller. ③ Refer to the controller nameplate to verify the rating of the control power input voltage. ④ Soft Stop, Pump Stop, or Brake.

  • Page 91: Requiring An Isolation Contactor

    Contactor Control Power ➁ IC ➀ Stop ➀ Option Stop ➀ ➂ Start ➀ Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.

  • Page 92: Requiring A Bypass Contactor

    Figure 7.4 Typical Wiring Diagram for Applications Requiring a Bypass Contactor Control Power ➁ BC ➀ Stop ➀ Option Stop ➀ ➂ Start ➀ Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals Fanning Strip ➀ Bulletin 825 Internal Converter Auxiliary Module Contacts ①...

  • Page 93: Or Programmable Controller Interfacing

    Options Figure 7.5 Typical Wiring Diagram for Two-wire Control or Programmable Controller Interfacing Control Power ➁ Two-wire device ➀ SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.

  • Page 94: Hand-Off-Auto (Scanport) Control

    SMB Smart Motor Braking Options (cont.) L1/1 T1/2 3-Phase L2/3 T2/4 ➀ Input Power L3/5 T3/6 Fast-acting ➀ SMC Dialog Plus Branch SCR Fuses Protection ➀ (optional) ➀ Controller ➀ ➀ Control Power 100-240 VAC SMC Dialog Plus Internal Control Terminals...

  • Page 95: Soft Stop Option

    Options 7-11 Soft Stop Option Figure 7.7 Soft Stop Option Sequence of Operation 100% Coast-to-rest Motor Speed Start Soft Stop Time (seconds) Push Buttons Start Closed Open Stop Closed Open Soft Stop Closed Open Auxiliary Contacts Soft Stop Operation Normal Coast-to-rest Operation Up-to-speed ATTENTION: The user is responsible for...

  • Page 96: Pump Control Option

    7-12 Options Pump Control Option Figure 7.8 Pump Control Option Sequence of Operation Coast-to-rest 100% Motor Speed Start Soft Stop Time (seconds) Push Buttons Start Closed Open Stop Closed Open Pump Stop Soft Stop Closed Open Auxiliary Contacts Pump Stop Operation Normal Coast-to-rest Operation Up-to-speed...

  • Page 97: Smb Smart Motor Braking Option

    Options 7-13 SMB Smart Motor Braking Option Figure 7.9 SMB Smart Motor Braking Sequence of Operation 100% Smart Motor Braking Coast-to-rest Motor Speed Start Brake Automatic Zero Speed Time (seconds) Shut-off Push Buttons Start Closed Open Stop Closed Open Brake Soft Stop Closed Open...

  • Page 98: Preset Slow Speed And Accu-Stop Options

    Preset Slow Speed and Accu-Stop options. Accu-Stop Options Figure 7.10 Typical Wiring Diagram for the Preset Slow Speed Option Control Power ➁ Stop ➀ Option Command ➀ ➂ Start ➀ SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied.
  • Page 99 Auxiliary Contacts ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller. ③ Refer to the controller nameplate to verify the rating of the control power input voltage. ④ Slow Speed or Accu-Stop. Note: Refer to Chapter 3 for typical power circuits.

  • Page 100: Requiring An Isolation Contactor

    Contactor Control Power ➁ IC ➀ Stop ➀ Option Command ➀ ➂ Start ➀ Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.

  • Page 101: Requiring A Bypass Contactor

    Figure 7.13 Typical Wiring Diagram for Applications Requiring a Bypass Contactor Control Power ➁ BC ➀ Stop ➀ Option Command ➀ ➂ Start ➀ Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals Fanning Strip ➀ Bulletin 825 Internal Converter Auxiliary Module Contacts ①...

  • Page 102: Hand-Off-Auto (Scanport) Control

    Accu-Stop Options (cont.) L1/1 T1/2 3-Phase ➀ L2/3 T2/4 Input Power L3/5 T3/6 Fast-acting ➀ Branch SMC Dialog Plus SCR Fuses Protection ➀ (optional) ➀ Controller ➀ ➀ Hand Start ➀ Hand Stop ➀ ➀ Option Command ➀ ➁ ➂ Auxiliary contacts...

  • Page 103: Preset Slow Speed Option

    Options 7-19 Preset Slow Speed Figure 7.15 Preset Slow Speed Option Sequence of Operation Option 100% 7 or 15% Motor Speed Slow Start Coast Speed Time (seconds) Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Normal Up-to-speed...

  • Page 104: Accu-Stop Option

    7-20 Options Accu-Stop Option Figure 7.16 Accu-Stop Option Sequence of Operation Braking 100% Motor Speed Slow Speed Braking/Coast Slow Speed Slow Accu-Stop Speed Start Time (seconds) Push Buttons Start Closed Open Stop Closed Open Accu-Stop ➀ Closed Open Auxiliary Contacts Normal If Stopping Current is set to 0%.

  • Page 105: Slow Speed With Braking Option

    Slow Speed with Braking option. Figure 7.17 Typical Wiring Diagram for the Slow Speed with Braking Option Control Power ➁ Stop ➀ Brake ➀ Slow Speed ➀ Start ➀ SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied.

  • Page 106: Slow Speed With Braking Option

    ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller. ③ Refer to the controller nameplate to verify the rating of the control power input voltage. Note: Refer to Chapter 3 for typical power circuits.
  • Page 107 Control Power ➁ Stop ➀ IC ➀ Brake ➀ Slow Speed ➀ Start ➀ Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.
  • Page 108 Figure 7.20 Typical Wiring Diagram for the Slow Speed with Braking Option with a Bypass Contactor Control Power ➁ BC ➀ Stop ➀ Brake ➀ Slow Speed ➀ Start ➀ Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals Fanning Strip ➀ Bulletin 825 Internal Converter Auxiliary Module Contacts ①...

  • Page 109: Of Operation

    Options 7-25 Figure 7.21 Slow Speed with Braking Option Sequence of Operation 100% Braking Motor Speed Slow Start Brake Speed Time (seconds) Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Normal Up-to-speed ATTENTION: 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.

  • Page 110: Chapter 8 Serial Communications

    Logic Control Data The information in Table 8.A provides the logic control information that can be sent to the SMC Dialog Plus controller through the logic controller’s output image table. Table 8.A...

  • Page 111: Control Enable

    Control Enable Per factory programming, “stop” is the only control command active on the SMC Dialog Plus controller when the SCANport is utilized. To enable motor control from a programmable logic controller through a communication module, follow the programming procedure below.

  • Page 112: Smc Status Data

    Dialog Plus controller’s parameters and groups. In addition to the range of adjustments, the parameters’ units are provided. Scale Factor The parameter values of the SMC Dialog Plus controller are stored as unscaled numbers. When reading parameter data in the PLC/SLC’s Conversion input image table, divide this number by the scale factor shown in Appendix B, Table B.1 to arrive at the proper value.

  • Page 113: Display Unit Equivalents

    Processing Time The typical time for the SMC Dialog Plus controller to process a single parameter data request (i.e., block transfer) via the SCANport is approximately 100 msec. Keep this value in mind when determining the message length of multiple parameter value read or write operations.

  • Page 114: Remote I/O Examples

    This example demonstrates discreet control of an SMC Dialog Plus controller from an SLC 500 logic controller. Additionally, the SLC controller reads the Current Phase A from the SMC Dialog Plus controller via the analog feedback word. Many of the selections shown are example-specific.

  • Page 115: 1203-Gd1 Communication Module Switch Settings

    ① ② Datalinks: SW3: Switch 4-8 (Off) ① This configuration requires a 1/4 rack size allocation. ② The SMC Dialog Plus controller does not support Datalinks. Switch Settings Not Used Starting Module Group (0) Block Transfer On Not Used Starting Module Group (0)

  • Page 116: G File Configuration

    SLC programming software. The configuration is based on the devices connected to the R I/O link. For this example, the following G file configuration map for the scanner’s I/O image file of the SMC Dialog Plus controller applies. ① Address...
  • Page 117 Serial Communications Remote I/O Examples (cont.) ① SMC Dialog Plus Controller Logic Control Addresses ② ③ ④ Bit Description I or O Address Slot Word Stop O:1.16/00 Start O:1.16/01 Option Command O:1.16/02 Clear Fault O:1.16/03 ① SMC Dialog Plus Controller Status Addresses ②...

  • Page 118: Example #1 - Ladder Logic Program

    Example #1 - Ladder Logic Program First Rung: When the Machine START push button is pressed, the SLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog Plus controller will start if no STOP command is being issued by the SLC or any other control device. (The start button is a normally open contact in this example.)

  • Page 119: Example #2 - Slc 500 Controller With Block Transfer

    Remote I/O Examples (cont.) Example #2 - SLC 500 Controller with Block Transfer This example demonstrates a block transfer of the SMC Dialog Plus controller’s metering group (parameters 1–11) to an SLC500. Many of the selections shown are example-specific. Some changes by the user may be necessary to apply the concepts of this example to a specific application.
  • Page 120 Serial Communications 8-11 SLC Image Table Map SLC Word Output Image Input Image Rack Size Start at Group ① Block Transfer Block Transfer Logic Command Logic Status ① Set SW2, Switches 1 and 2 to “On.” Switch Settings Starting Module Group (0) Not Used Block Transfer On Not Used...
  • Page 121 Block Transfer Write The sample ladder logic program that follows performs a consecutive parameter value read of the SMC Dialog Plus controller’s metering group (parameters 1–11) by using a BTW/BTR pair. The BTW operation defines to the Bulletin 1203 communication module the type of parameter read/write operation (“Continuous Parameter Value...
  • Page 122 Serial Communications 8-13 BT Control Buffer Layout – The following table maps integer files starting at N10:0 with the associated M0 file location as defined in the sample ladder logic program that follows. BT Control Datafile Control Flags BT Length BT Logical Address ①...
  • Page 123 8-14 Serial Communications Remote I/O Examples (cont.) BTR Datafile Format – A BTR Datafile must also be defined to accept the data read during the BTR operation. For this example, the BTR Datafile will begin at address N10:110. BTR Datafile Header Word PLC Decimal Value Number of Parameter Values to Read...

  • Page 124: Example #2 - Ladder Logic Program

    Serial Communications 8-15 Example #2 – Ladder Logic Program Rung 2:0 This rung clears the Virtual BT Command word on the first scan. First Scan S : 1 MOVE Source Dest N10:0 Rung 2:1 Copy the BT Status Bits from the 1747-SN into the Virtual BT Status Buffer. MOVE Source M1:1.100...
  • Page 125 8-16 Serial Communications Remote I/O Examples (cont.) Example #2 – Ladder Logic Program (cont.) Rung 2:4 This rung sets up the BT buffer for a BTR and sets the Virtual BT_Enable. User BTR_Avail Virtual Logic BTW = 0 BTR = 1 B3:0 I:1.0 N10:0...
  • Page 126 Serial Communications 8-17 The information in the data table listed below was obtained from a 150 Hp motor, 1800 RPM rated at 480 volts. The motor has been operating continuously for a period of 72 hours. Parameter Parameter Display Parameter Parameter Display Description...

  • Page 127: Example #3 - Plc 5/20, 5/40, 5/60, And 5/80

    Remote I/O Examples (cont.) Example #3 – PLC 5/20, 5/40, 5/60, and 5/80 This example demonstrates PLC control of an SMC Dialog Plus controller with the Pump Control option. Use of the Option Command bit to initiate the pump stop maneuver is also shown.

  • Page 128: 1203-Gd1 Communication Module Switch Settings

    ① ② Datalinks: SW3: Switch 4-8 (Off) ① This configuration requires a 1/4 rack size allocation. ② The SMC Dialog Plus controller does not support Datalinks. Switch Settings Not Used Starting Module Group (0) Block Transfer On Not Used Starting Module Group (0)
  • Page 129 (BTR_AVAIL) Block Transfer Wait I:020/13 (BT_WAIT) Block Transfer Error I:020/14 (BT_ERROR) Block Transfer Write Available I:020/15 (BTW_AVAIL) ① SMC Dialog Plus Controller Logic Control Addresses ③ Bit Description I or O Rack Group Address Stop O:021/00 Start O:021/01 Option Command...

  • Page 130: Block Transfer Instructions

    Serial Communications 8-21 Block Transfer Instructions Block transfer operations with the 1203-GD1 communication module require coordinated block transfer write (BTW) and block transfer read (BTR) instructions to achieve successful data transmissions. BLOCK TRNSFR WRITE BLOCK TRNSFR WRITE (EN) (EN) Rack: Rack: Group: Group:...

  • Page 131: Block Transfer Datafiles

    8-22 Serial Communications Remote I/O Examples (cont.) Block Transfer Datafiles The tables below provide the necessary data file configuration for a parameter value read of the SMC Dialog Plus controller’s Fault Buffer #1. BTW Datafile: Message Length PLC Decimal Value...

  • Page 132: Example #3 Ladder Logic Program

    Example #3 Ladder Logic Program First Rung: When the Machine START push button is pressed, the PLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog Plus controller will start if no STOP command is being issued by the PLC or any other control device. (The start button is a normally open contact in this example.)

  • Page 133: Devicenet Examples

    DeviceNet Examples Example #1 SLC 500 Controller with Explicit Messaging This example demonstrates discreet control of the SMC Dialog Plus controller in addition to use of the explicit messaging function for transferring parameter data to an SLC500. The DeviceNet Manager (revision 3.001) software is used in this example for network and...

  • Page 134: Example Information

    Input Data Logic Command Logic Status ① ② Reference Feedback ① The SMC Dialog Plus controller does not utilize this feature; a value of zero should be given. ② The feedback word is the value of parameter 4, Current Phase A.
  • Page 135 After you have your network “project” configured in the DeviceNet Manager software, perform a Network Who; the following screen will appear: Notice that the SMC Dialog Plus controller is identified as node 13, which was configured by setting the DIP switches on the 1203-GK5 communication module.
  • Page 136 The left Yes indicates that input data is mapped from the SMC Dialog Plus controller to the SLC-500. The right Yes indicates that output data from the SLC-500 is mapped to the SMC Dialog Plus controller. Configure the 1747-SDN if “No” is displayed.

  • Page 137: Smc Dialog Plus Controller Logic Command Addresses

    8-28 Serial Communications This indicates that the SMC Dialog Plus controller’s input data is mapped to words 7 and 8. By clicking the radio button next to Output, the output data mapping can be seen; the following screen will appear: This indicates that the SLC-500’s output data associated with the...

  • Page 138: Explicit Messaging

    Serial Communications 8-29 SMC Dialog Plus Controller Status Addresses ② Bit Description Address Enabled I:1.7/00 Running I:1.7/01 Starting I:1.7/04 Stopping I:1.7/05 Fault I:1.7/07 At Speed I:1.7/08 ② Refer To Table 8.B Explicit Messaging: The 1747-SDN scanner module uses the M0 and M1 file areas for data transfer.

  • Page 139: Explicit Message Response (Get Attribute Multiple)

    8-30 Serial Communications Explicit Message Response (Get Attribute Multiple) TXID STATUS word 0 PORT SIZE SERVICE MAC ID PARAMETER DATA “ word 31 Transmission ID (TXID): The scanner uses this value to track the transaction to completion, and returns the value with the response that matches the request downloaded by the SLC-500 processor.

  • Page 140: Examples

    Serial Communications 8-31 Attribute: This code identifies the specific characteristic of the object towards which the transaction is directed. The Attribute data size is one word. Examples The following table lists the most common codes for each given transaction type: ①...

  • Page 141: Setting Up The Data File

    In this example, the data file for the Explicit Message Request begins at N11:0. Following is the structure for a Get Attribute Multiple of the SMC Dialog Plus controller’s Metering group parameters (1 - 11). Please note that the data shown is in a hexadecimal format. The first...

  • Page 142: Example Ladder Logic Program

    Enable Rung 1: When the START command is initiated at the RSView station the SLC processor sets the output bit mapped to the SMC Dialog Plus controller’s logic control word start bit. The branch provides a logic “latched” circuit which exerts the START command until input from the SMC Dialog Plus controller’s status word indicates that it has received the command and has responded appropriately.
  • Page 143 Serial Communications Rung 3: When the FAULT RESET command is initiated at the RSView station, the SLC processor sets the output bit mapped to the SMC Dialog Plus controller’s logic control word clear faults bit. The branch provides a logic “latched” circuit which exerts the FAULT RESET command until input from the SMC Dialog Plus controller’s status word indicates that it has received the comand and has responded appropriately.

  • Page 144: Chapter 9 Diagnostics

    Chapter Diagnostics Overview This chapter describes the fault diagnostics of the SMC Dialog Plus controller. Further, this section describes the conditions that cause various faults to occur. Protection Programming Many of the protective features available with the SMC Dialog Plus controller can be enabled and adjusted through the programming parameters provided.

  • Page 145: Fault Buffer

    Usage, parameter 11, value is below 75%. See page 1-7 for further details. Fault Buffer The SMC Dialog Plus controller stores in memory the five most recent faults. Display the fault buffer by selecting the Faults group and scrolling through the fault buffer parameters. The information is stored as fault codes.

  • Page 146: Fault Definitions

    Phase loss • Load loss • Shorted SCR Line fault with no phase indication is displayed when one of the following conditions occurs while the SMC Dialog Plus controller is in the run mode. • Phase loss • Load loss •...

  • Page 147: Voltage Unbalance

    ② Jam Detection Jam detection operates when the SMC Dialog Plus controller status is “at speed.” The controller will shut down when the motor current reaches the user-defined trip level, which is based on a percentage of the programmed motor full load current rating.

  • Page 148: Open Gate

    Open gate indicates that an abnormal condition that causes faulty firing (i.e., open SCR gate) has been sensed during the start sequence. The SMC Dialog Plus controller will attempt to start the motor a total of three times before the controller shuts down.
  • Page 149 Diagnostics...

  • Page 150: Chapter 10 Troubleshooting

    ATTENTION: Hazardous voltage is present in the motor circuit even when the SMC Dialog Plus controller is off. To avoid shock hazard, disconnect main power before working on the controller, motor, or control devices such as Start-Stop push buttons.
  • Page 151 10-2 Troubleshooting The following flowchart is provided to aid in quick troubleshooting. Figure 10.1 Troubleshooting Flowchart Fault Displayed? Define Nature of Trouble Motor rotates Motor will not start — Motor stops while Miscellaneous but does not no output voltage to running situations accelerate to full...
  • Page 152 • Replace control module • Communication disconnection at the serial • Check for a communication cable Comm Fault port disconnection to the SMC Dialog Plus controller F128 & • Internal control module hardware failure • Replace control module System Faults...
  • Page 153 10-4 Troubleshooting Table 10.B Motor Will Not Start — No Output Voltage to the Motor Display Possible Cause Possible Solutions • See fault description • See Table 10.A Fault displayed addressing fault conditions • Control voltage is • Check control wiring and Display is blank absent correct if necessary...
  • Page 154 Troubleshooting 10-5 Table 10.E Miscellaneous Situations Situation Possible Cause Possible Solutions Motor current and • Motor • Verify type of motor as a standard voltage fluctuates squirrel cage induction motor with steady load • Energy Saver • Set Energy Saver Off, then restart. –...

  • Page 155: Control Module Removal

    10-6 Troubleshooting Control Module Removal ATTENTION: To avoid shock hazard, disconnect main power before working on the controller, motor, or control devices (such as Stop/Start push buttons). ATTENTION: Make sure that wires are properly marked and that programmed parameter values are recorded.
  • Page 156 Troubleshooting 10-7 180–360 Amp Refer to Figure 10.3 for control module reference. 1. Remove controller access door and serial port cable. 2. Remove controller cover. 3. Remove all control wires and loosen six control module mounting screws. 4. Unplug control module from the interface board by pulling for- ward.
  • Page 157 10-8 Troubleshooting Figure 10.3 Removal of Control Module (180–360A)
  • Page 158 Troubleshooting 10-9 500–1000 Amp Refer to Figure 10.4 for control module removal reference. 1. Disconnect all control wires to control modules. 2. Loosen six control module screws. 3. Unplug control module from interface board by pulling forward. Figure 10.4 Removal of Control Module (500–1000A)
  • Page 159 10-10 Troubleshooting Control Module Replacement The gold interconnection pins on the power modules and interface boards are protected with a special contact lubricant. Do not clean or wipe these pins. ATTENTION: When installing the control module, make sure the power module or interface board pins are not bent.
  • Page 160 Troubleshooting 10-11 MOV Fuse 500–1000 Amp Replacement ATTENTION: To avoid shock hazard, disconnect mainpower before working on the controller, motor, or control devices such as Start/Stop push buttons. ATTENTION: Replacement of the fuse with anything other than the recommended part number may cause physical damage to the controller.
  • Page 161 10-12 Troubleshooting Power Module and Interface 24–135 Amp Board Resistance Check (cont.) Remove the control module per the instructions beginning on page 10-6. Refer to Figure 10.7 for power module pin identification. Shorted SCR Test 1. Using an ohmmeter, measure the resistance between the line and load terminals of each phase on the controller.
  • Page 162 Troubleshooting 10-13 180-1000 Amp Remove the control module per the instructions beginning on page 10-6. Refer to Figure 10.8 for interface board pin identification. Shorted SCR Test Using an ohmmeter, measure the resistance between the line and load terminals of each phase on the controller. Resistance should be greater than 10,000 ohms.
  • Page 163 10-14 Troubleshooting Power Module and Interface 2. Measure resistance between: Board Resistance Check (cont.) • pins J14 and J15 for phase L1/T1 • pins J9 and J10 for phase L2/T2 • pins J1 and J2 for phase L3/T3 The resistance should be approximately 100Ω. If any of the resistances measure greater than 100Ω, recheck the resistance values directly at the gate lead connectors as shown in Figure 10.9.
  • Page 164 Appendix Specifications Electrical Ratings UL/CSA/NEMA Power Circuit Method of Connection Motor in delta or star, SCRs between windings and supply Number of Poles Equipment designed for three phase loads only 200–480 VAC (–15%, +10%) 200–415VY (–15%, +10%) Rated Operation Voltage (Ue) 200–600 VAC (–15%, +10%) 200–500VY (–15%, +10%) Rated Insulation Voltage (Ui)
  • Page 165 Specifications Electrical Ratings UL/CSA/NEMA Control Circuit 100–240 VAC (–15%, +10%) 100–240 V~ (–15%, +10%) ① 24 VAC (–15%, +10%) Rated Operation Voltage 24 V~ (–15%, +10%) 24 VDC (–20%, +10%) 24 VDC (–20%, +10%) Rated Insulation Voltage 240 V~ Rated Impulse Voltage 3000 V Dielectric Withstand 1600 VAC...
  • Page 166 Specifications Electrical Ratings UL/CSA/NEMA Control Circuit 100–240 VAC (–15%, +10%) 100–240 V~ (–15%, +10%) ① 24 VAC (–15%, +10%) Rated Operation Voltage 24 V~ (–15%, +10%) 24 VDC (–20%, +10%) 24 VDC (–20%, +10%) Rated Insulation Voltage 240 V~ Rated Impulse Voltage 3000 V Dielectric Withstand 1600 VAC...
  • Page 167 Assumes the Bulletin 825 converter module is utilized. ② The SMC Dialog Plus controller calculates the current values to two decimal place resolution while displaying only to tenths of Amps. The display accuracy provided is, therefore, reduced by the truncation. The affect of truncation on accuracy will be dependent on the magnitude of the value.
  • Page 168 Specifications Environmental Ratings UL/CSA/NEMA 0°C–50°C (open) Operating Temperature Range 0°C–40°C (enclosed) Storage and Transportation –20°C–+75°C Temperature Range Altitude 2000 meters Humidity 5%–95% (nonñcondensing) Pollution Degree...
  • Page 169 Specifications...
  • Page 170 Appendix Parameter Information Table B.1 Parameter List Parameter Parameter Display Scale Default User Group Minimum Maximum Description Number Units Factor Setting Setting Voltage Volts — — — — Phase A–B Voltage Volts — — — — Phase B–C Voltage Volts —...
  • Page 171 Parameter Information Table B.1 (cont.) Parameter List Parameter Parameter Display Scale Default User Group Minimum Maximum Description Number Units Factor Setting Setting Stall Delay Seconds 10.0 0 (Off) Energy Saver — — Off, On Aux. Contacts — — Normal, Up-to-speed Normal 1 and 2 Aux.
  • Page 172 Parameter Information Table B.1 (cont.) Parameter List Parameter Parameter Display Scale Default User Group Minimum Maximum Description Number Units Factor Setting Setting Slow Speed with Braking Slow Speed — — Low, High High Select Slow Accel % FLC Basic Setup Current (cont.) Slow...
  • Page 173 Parameter Information Table B.1 (cont.) Parameter List Parameter Parameter Display Scale Default User Group Minimum Maximum Description Number Units Factor Setting Setting Overload — — Off, 10, 15, 20, and 30 Class Overload — — Manual-Auto Manual Reset Motor HP 6,553.5 Rating Motor kW...
  • Page 174 Parameter Information Table B.2 Parameter Text/Display Unit Cross Reference Parameter Number Description Setting Text Display Unit Standard Soft Stop Pump Control SMC Option Preset Slow Speed Smart Motor Braking Accu-Stop Slow Speed with Braking ETM Reset Ready Default Init Parameter Mgmt. Recall From EE Store In EE Clear Fault...
  • Page 175 Parameter Information Table B.2 (cont.) Parameter Text/Display Unit Cross Reference Parameter Number Description Setting Text Display Unit Motor Code Letter None Converter Rating 50:5 75:5 100:5 150:5 200:5 250:5 CT Ratio 300:5 400:5 500:5 600:5 700:5 800:5 1000:5 1200:5 Manual Overload Reset Auto...
  • Page 176 Appendix Renewal Parts Part Number ① Description SMC Rating Input Control Voltage Standard 40888-490-01-S1FX Soft Stop 40888-490-01-A1FX Pump Control 40888-490-01-B1FX Preset Slow Speed 40888-490-01-C1FX 24–54A 40888-490-01-D1AX 97–135A 40888-490-01-D1BX 180–360A 40888-490-01-D1CX 500–650A 40888-490-01-D1DX 720–1000A 40888-490-01-D1EX 24–54A 120–240V AC 40888-490-01-E1AX 97–135A 40888-490-01-E1BX Accu-Stop 180–360A 40888-490-01-E1CX...
  • Page 177 Renewal Parts ① Description SMC Rating Line Voltage Part Number 200–480V 40382-899-02 200–480V3 40382-899-03 200–480V 40382-899-03 200–480V 40382-806-01 135A 200–480V 40382-806-03 180A 200–480V 40382-809-03 240A 200–480V 40382-809-05 360A 200–480V 40382-809-07 500A 200–480V 40382-810-01 650A 200–480V 40382-818-01 720A 200–480V 40382-818-03 850A 200–480V 40382-819-01 1000A...
  • Page 178 Renewal Parts Part Number ① Description SMC Rating Line Voltage 24–500A 200–480V 650A 200–480V 40382-811-01 720A 200–480V 40382-811-03 850A 200–480V 40382-812-03 1000A 200–480V 40382-812-01 Individual SCRs 24–500A 200–600V 650A 200–600V 40382-811-02 720A 200–600V 40382-811-04 850A 200–600V 40382-812-04 1000A 200–600V 40382-812-02 24–135A 180–360A 40382-805-01...
  • Page 179 Renewal Parts...
  • Page 180 Appendix Accessories Description Description/Used With Cat. No. 24–54A, 480V 150-N84 24–54A, 600V 150-N86 Protective Modules 97–360A, 480V 150-N84L 97–360A, 600V 150-N86L 97–360A 199-LF1 Terminal Lugs 500–720A 199-LG1 850–1000A 199-LJ1 97–135A 150-NT1 IEC Terminal Covers 180–360A 150-NT2 IP30 (Type 1) Door Mount Bezel Kit 1201-DMA IP30 (Type 1) Programmer Only 1201-HAP...
  • Page 181 Glossary Alternating current. AC Contactor An alternating current (AC) contactor is designed for the specific purpose of estab- lishing or interrupting an AC power circuit. Ambient Temperature Ambient temperature is the temperature of air, water, or a surrounding medium where equipment is operated or stored. American Wire Gauge A standard system used for designing the size of electrical conductors.
  • Page 182 Glossary-2 DH-485 Link Data Highway 485 link. An Allen-Bradley token-passing baseband link for a local area network based on the RS-485 standard. Disable To inhibit logic from being activated. Duty Cycle The relationship between the operating and rest times or repeatable operation at different loads.
  • Page 183 Glossary-3 Port On a communication link, the logic circuitry or software at a station that determines its communication parameters for a particular communication channel. Power Factor A measurement of the time phase difference between the voltage and current in an AC circuit.
  • Page 184 Glossary-4 Status The condition at a particular time of any numerous entities within a system. These conditions may be represented by values in a status line. Surge Protection The process of absorbing and clipping voltage transients on an incoming AC line or control circuit.

  • Page 185: Control Module Replacement

    Index control power, 3-4 control voltage, 3-4 accessories, D-1 control wiring, 3-4 Accu-Stop option, wiring diagrams, 7-14, 7-15, control terminals, 3-6 7-16, 7-17 controller overview, 1-1 Accu-Stop, description of, 1-15 controller setup, 4-11 Accu-Stop option advanced setup, 4-12 programming parameters for, 7-4 sequence of operation, 7-20 controller temperature (temp), 9-5 current limit start...
  • Page 186 I–2 Index fan power, 3-5 inspection, 2-1 fan terminations, 3-5 installation, 2-1 180A–500A, 3-5 interfacing, 8-4 650A–1000A, 3-5 97A and 135A, 3-5 fault jam detection, 9-4 auxiliary contact, 9-2 buffer, 9-2 codes, 9-2 definitions keypad description, 1-11, 4-1 comm fault, 9-5 controller temp, 9-5 excess starts/hour, 9-5 jam detection, 9-4...

  • Page 187: Protective Cover Removal

    I–3 Index underload, 1-9, 9-4 parameter protective cover removal, 10-10 electrically erasable programmable read- protective modules, 2-11 only memory (EEPROM), 4-6 pump control option listing of, 4-4, 8-3, B-1 description of, 1-13 management of, 4-6 programming parameters for, 7-3 modifying of, 4-8 sequence of operation, 7-12 random access memory (RAM), 4-6 wiring diagrams, 7-5, 7-6, 7-7, 7-8, 7-9,...
  • Page 188 I–4 Index programming parameters for, 7-3 trip curves, 1-7 sequence of operation, 7-11 troubleshooting, 10-1 wiring diagrams, 7-5, 7-6, 7-7, 7-8, 7-9, fault display explanation, 10-3 7-10 flowchart, 10-2 soft stop/pump control/SMB smart motor braking troubleshooting tables, 10-4, 10-5 options, wiring diagrams, 7-5, 7-6, 7-7, 7-8, specifications, A-1 underload, 1-9, 9-4 stall protection, 9-4...
  • Page 189 Publication 0150-5.3 - October 1998 40055-145-01(C) © 1998 Rockwell International. All Rights Reserved. Printed in USA Supersedes Publication 0150-5.3 - September 1996...

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