Page 2
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).
Page 3
European Communities (EC) If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet Directive Compliance 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.
Page 8
Bulletin 150 SMC-Flex™ Chapter 8 Overview ..................8-1 Communications Communication Ports ..............8-1 Human Interface Module ..............8-1 Keypad Description ..............8-2 Connecting the Human Interface Module to the Controller ..8-3 HIM Control Enable ..............8-4 Control Enable ................8-6 Loss of Communication and Network Faults ........8-6 SMC-Flex Specific Information ............8-6 Default Input/Output Configuration ..........8-7 Variable Input/Output Configuration ..........8-7...
Page 9
Bulletin 150 SMC-Flex™ Appendix A Functional Design Specifications ........... A-1 Specifications Wiring Diagram ................A-2 Electrical Ratings ................A-2 Environmental ................A-4 Mechanical ..................A-5 Other ..................... A-5 Approximate Dimensions and Shipping Weights ......A-6 Open Type Controllers ............A-6 Enclosed Type Line-Connected Controllers ......
Page 10
Bulletin 150 SMC-Flex™ List of Figures Chapter 1 Figure 1.1 Soft Start ..............1-2 Product Overview Figure 1.2 Selectable Kickstart ...........1-3 Figure 1.3 Current Limit Start .............1-3 Figure 1.4 Dual Ramp Start ............1-4 Figure 1.5 Full Voltage Start ............1-4 Figure 1.6 Preset Slow Speed .............1-5 Figure 1.7 Linear Speed Acceleration .........1-6...
Page 11
Bulletin 150 SMC-Flex™ Figure 3.10 Typical Wiring Diagram for Dual Ramp Applications ............3-11 Figure 3.11 Typical Wiring Diagram for Start-Stop Control via DPI Communications ............. 3-12 Figure 3.12 Typical Wiring Diagram for Retrofit Applications ..3-13 Figure 3.13 Typical Wiring Diagram for Isolation Applications (DPI also) ..............
Chapter Product Overview Other Related Documents • Quick Start — Publication 150-QS001_ -EN-P • Renewal Part Instructions — 41053-277-01 (5…85 A) 41053-228-01 (108…480 A) • Selection Guide — Publication 150-SG008_ -EN-P • Application Guide — Publication 150-AT002_ -EN-P Description The SMC-Flex™ controller offers a full range of starting modes as standard: •...
Product Overview Operation The SMC-Flex controller can operate three-phase squirrel-cage motors rated 1…480 A or wye-delta motors rated 1.8…831 A; 200…480V AC or 200…600V AC; 50/60 Hz. Depending upon the catalog number ordered, the controller will accept a control power input of either 100…240V AC or 24V AC/DC.
Product Overview 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.
Product Overview Dual Ramp Start This starting mode is useful on applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings. Figure 1.4 Dual Ramp Start Percent Voltage...
Product Overview 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.
Product Overview Linear Speed Acceleration The SMC-Flex has the ability to control the motor speed during starting and stopping maneuvers. A tach input (0…5V DC) is required to perform this start mode. The start time is selectable from 0…30 seconds and determines the time the motor will ramp from 0 speed to full speed.
Product Overview Soft Stop This option can be used in applications that require an extended coast- to-rest. 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.
Product Overview Control Options 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.
Product Overview Modes of Operation 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.
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 Accu-Stop and Slow Speed with Braking are not ATTENTION...
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;...
Page 24
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 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...
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.
1-14 Product Overview Stall Protection and Jam Detection The SMC-Flex controller provides both stall protection and jam detection for enhanced motor and system protection. • Stall protection is user-adjustable from 0.0…10.0 seconds (in addition to the ramp time programmed). Figure 1.15 Stall Protection 600% Percent Full...
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.
1-16 Product Overview Parameter 75, Gnd Flt 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 Flt Delay, allows the installer to define the time period a ground fault condition must be present before a trip occurs.
1-18 Product Overview Overtemperature The SMC-Flex controller monitors the temperature of the SCRs and Bypass by using internal thermistors. When the power poles’ maximum rated temperature is reached, the unit will shut down and restart is inhibited. An overtemperature condition can indicate inadequate ventilation, high ambient temperature, overloading, or excessive cycling.
Product Overview 1-19 Metering Power monitoring parameters include: • Three-phase current • Three-phase voltage • Power in kW • Power usage in kWH • Power factor • Motor thermal capacity usage • 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.
1-20 Product Overview Programming Setup is easy with the built-in keypad and three-line, sixteen character backlit LCD. Parameters are organized in a three-level menu structure, using a text format for straightforward programming. Figure 1.20 Built-in Keypad and LCD Port 5 — DPI Communications Port 2 Ports 2 and 3 when two...
Chapter Installation Receiving 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.
Installation General Precautions In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. The controller contains ESD- (electrostatic ATTENTION discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the assembly.
Page 35
Installation Enclosures For Type 12 (IP54) enclosures, the following guidelines are recommended to limit the maximum controller ambient temperature. There should be a clearance of at least 15 cm (6 in.) above and below the controller. This area allows air to flow through the heatsink. Table 2.B Minimum Enclosure Size IP65 (Type 4/12)
Installation Mounting All units are fan cooled. It is important to locate the controller in a position that allows air to flow vertically through the power module. The controller must be mounted in a vertical plane and have a minimum of 15 cm (6 in.) free space above and below the controller.
Page 37
Installation Figure 2.1 Dimensions: 5…85 A Controllers Approx. Unit Width Height Depth Ship. Wt. 5…85 A 150.1 203.1 119.8 14.1 5.7 kg Controller 5.91 12.09 8.00 4.72 11.46 4.72 0.56 12.6 lb. All dimensions are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings.
Installation Power Factor The controller can be installed on a system with power factor correction (PFC) capacitors. The capacitors must be located on the Correction Capacitors line side of the controller. This must be done to prevent damage to the SCRs in the SMC-Flex controller.
Installation Protective Modules Protective modules containing metal oxide varistors (MOVs) can be installed on controllers rated 5…480 A to protect the power components from electrical transients. The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs.
2-10 Installation Electromagnetic Compatibility (EMC) This product has been designed for Class A ATTENTION equipment. Use of the product in domestic environments may cause radio interference, in which case, the installer may need to employ additional mitigation methods. The following guidelines are provided for EMC installation compliance.
Chapter Wiring Terminal Locations The SMC-Flex controller wiring terminal locations are shown in Figure 3.2. Make wiring connections as indicated in the typical connection diagrams. Incoming three-phase power connections are made to terminals L1/1, L2/3, and L3/5. Load connections to Line motors are made to T1/2, T2/4, and T3/6, while load connections to inside-the-Delta motors are made to T1/2, T2/4, T3/6, T4/8, T5/10, and T6/12.
Wiring Figure 3.2 Wiring Terminal Locations (108…480 A) Table 3.A Wiring Terminal Locations Incoming Line Termination Line Motor Connections Delta Motor Connections Control Terminations Fan Terminations Power Structure 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…480 A units.
Wiring Power Wiring The SMC-Flex can be connected to a Line-controlled motor as shown in Figure 3.3. Current ratings for the motor must be in the range of 1 A…480 A. Figure 3.3 Line Power Wiring diagram 1/L1 3/L2 5/L3 12/T6 8/T4 10/T5...
Page 46
Wiring Figure 3.4 Delta Power Wiring diagram 3/L2 5/L3 12/T6 2/T1 8/T4 4/T2 6/T3 10/T5 Power lugs are available as optional kits. Each kit contains three lugs. The number of terminal lugs required is listed in the table below. Table 3.A also provides the lug wire capacity and the tightening torque requirements.
Wiring Control Power Control Voltage The SMC-Flex controller will accept a control power input of 240V AC, (–15/+10%), 1 phase, 50/60 Hz or 24V AC/DC. … Refer to the product nameplate to verify the control power input voltage. Connect control power to the controller at terminals 11 and 12. The control power requirement for the control module is 75 VA.
Wiring Control Wiring Table 3.B provides the control terminal wire capacity, the tightening torque requirements, and the wire strip length. Each control terminal will accept a maximum of two wires. Table 3.B Control Wiring and Tightening Torque Wire Size Torque Wire Strip Length 0.6 N•m (5 lb.-in.) 5.6…8.6 mm (0.22…0.34 in.)
Wiring Control Terminal Designations As shown in Figure 3.6, the SMC-Flex controller contains 24 control terminals on the front of the controller. Figure 3.6 SMC-Flex Controller Control Terminals Terminal Terminal Description Description Number Number Control Power Input PTC Input Control Power Common PTC Input Controller Enable Input Tach Input...
Wiring Standard Controller Wiring Figure 3.7 through Figure 3.18 show typical wiring for the SMC-Flex controller. Diagrams Figure 3.7 Typical Wiring Diagram for Standard Controller L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller Stop Start SMC-Flex Aux #1 Control Terminals...
Page 51
Wiring Figure 3.8 Typical Wiring Diagram for Two-Wire Control with No Stopping Control (No DPI Control) L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller Two-Wire Device SMC-Flex Control Terminals Aux #1 Normal/Up-to-Speed/ Bypass TACH Aux #2 Ground Fault Alarm...
Page 52
3-10 Wiring Figure 3.9 Typical Wiring Diagram for Two-Wire Control with Stopping Control (No DPI Control) L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller Two-Wire Device SMC-Flex Aux #1 Control Terminals Normal/Up-to-Speed/ Bypass TACH Ground Aux #2 Fault Alarm...
3-12 Wiring Figure 3.11 Typical Wiring Diagram for Start-Stop Control via DPI Communications Note: Use this wiring diagram when start-stop will come from either a Bulletin 20-HIM LCD interface module or a Bulletin 20-COMM communication module connected to the SMC-Flex. Note: Logic mask must be properly configured, see Chapter 8.
3-18 Wiring Figure 3.17 Typical Wiring Diagram for SMC-Off-Bypass Control L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller Bypass X X X Bypass Connector (BC) Stop X X X Start SMC-Flex Control Terminals Aux #1 Normal/Up-to-Speed/ Bypass TACH...
Wiring 3-19 Figure 3.18 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control with no Stopping Control L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller SMC-Flex Aux #1 Control Terminals Normal/Up-to-Speed/ Bypass TACH Aux #2 Ground Fault Alarm Input Input...
Page 62
3-20 Wiring Figure 3.19 Typical Wiring Diagram for Hand-Off-Auto (PLC) Control with Stopping Control L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller SMC-Flex Control Terminals Aux #1 Normal/Up-to-Speed/ Bypass TACH Aux #2 Ground Fault Alarm Input Input Fault...
Wiring 3-21 Soft Stop, Pump Control, and Figure 3.20 through Figure 3.23 show the different wiring for the Soft Stop, Pump Control, and SMB Smart Motor Braking options. SMB Smart Motor Braking Figure 3.20 Typical Wiring Diagram Control Power Stop Start Option Stop SMC-Flex...
3-22 Wiring Figure 3.21 Typical Retrofit Wiring Diagram Control Power Stop Start Option Stop SMC-Flex Control Terminals Aux #1 Normal/Up-to-Speed/ Bypass TACH Ground Aux #2 Fault Alarm Input Input Normal Fault Contact Contact 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.
3-24 Wiring Figure 3.23 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control (Soft Stop, Braking, and Pump Control Only) L1/1 T1/2 3-Phase L2/3 T2/4 Input Power L3/5 T3/6 Branch SMC-Flex Protection Controller Control Power 100-240 VAC SMC-Flex Aux #1 Control Terminals Normal/Up-to-Speed/ Bypass TACH...
Wiring 3-25 Preset Slow Speed Figure 3.24 and Figure 3.25 show the different wiring for the Preset Slow Speed. Figure 3.24 Typical Wiring Diagram for the Preset Slow Speed Control Power Stop Option Command Start SMC-Flex Aux #1 Control Terminals Normal/Up-to-Speed/ Bypass TACH...
Wiring 3-27 Slow Speed with Braking Figure 3.26 shows the wiring for the Slow Speed with Braking option. Figure 3.26 Typical Wiring Diagram for the Slow Speed with Braking with an Isolation Contactor Control Power Stop Brake ...
3-28 Wiring Sequence of Operation Figure 3.27 through Figure 3.32 show the different operation sequences for the Soft Stop, Preset Slow Speed, Pump Control, SMB Smart Motor Braking, Accu-Stop, and Slow Speed with Braking options. Figure 3.27 Soft Stop Sequence of Operation 100% Coast-to-rest Soft Stop...
Wiring 3-29 Figure 3.28 Preset Slow Speed Sequence of Operation 100% Coast-to-rest Soft Stop Motor Speed 7 or 15% Slow Speed Start Coast Time (seconds) Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Closed Normal Open Closed...
3-30 Wiring Figure 3.29 Pump Control Sequence of Operation 100% Coast-to-rest Motor Speed Pump Start Pump Stop Time (seconds) Push Buttons Start Closed Open Stop Closed Open Pump Stop Closed Open If Pump Stop Selected Auxiliary Contacts Closed Normal Open If Coast-to-rest Selected Up-to-speed Closed...
Wiring 3-31 Figure 3.30 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 Smart Motor Braking Closed Open If Brake Selected Auxiliary Contacts Closed Normal...
Wiring 3-33 Figure 3.32 Slow Speed with Braking Sequence of Operation 100% Coast-to-Stop Motor Speed Braking Slow Speed Start Brake Time (seconds) Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Brake Closed Open Brake Auxiliary Contacts Closed Normal Open...
Chapter 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.
Programming Figure 4.1 Menu Structure Hierarchy Power-up and Status Display Lang Select language being displayed OPERATION LEVEL Choose Mode MAIN MENU Memory Device Parameter Preferences Diagnostics Storage Select Monitoring SMC-FLEX Reset to Defaults Change Password Alarms Set Up Save to EEProm User Dspl Line Faults Motor Protection...
Programming Figure 4.2 Parameter Menu Structure Parameter Parameter Motor Communications Utility Linear List Monitoring Set Up Protection Metering Basic Overload Comm Masks Language Linear List Volts Phase A-B Motor Connection Overload Class Jam F Lvl Logic Mask Language All parameters Volts Phase B-C Line Voltage Service Factor...
Page 80
Programming Table 4.A Parameter Linear List Parameter Parameter Description Description Parameter No. Description Volts Phase A-B Slow Speed Dir PTC Enable Volts Phase B-C Slow Accel Cur Phase Reversal Volts Phase C-A Slow Running Cur Starts Per Hour Current Phase A Stopping Current Restart Attempts Current Phase B...
Programming Password The SMC-Flex controller allows the user to limit access to the programming system through password protection. This feature is disabled with a factory-set default of 0. To modify the password or login after a password is programmed, complete the procedure below. Description Action Display...
Programming Parameter Management Before you begin programming, it’s important to understand how the controller memory is: • structured within the SMC-Flex controller • used on power-up and during normal operation Refer to Figure 4.3 and the explanations below. Figure 4.3 Memory Block Diagram EEPROM Random Access Memory (RAM) This is the work area of the controller after it is powered up.
Programming Using Parameter Management with DPI HIM Memory Storage and Parameter Management perform the same function of saving programmed settings. Description Action Display Saving to EEPROM Memory Storage: To ensure that the newly modified parameters Save EEPROM Recall EEPROM are not lost if control power is removed from the controller, store the values into EEPROM.
Programming Parameter Modification All parameters are modified using the same method. The basic steps to performing parameter modification are described below. Notes: (1) Parameter values modified while the motor is operating are not valid until the next time that operation occurs. (2) If the password is set, parameters cannot be adjusted without logging in.
Programming Soft 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…30 s This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed.
4-10 Programming Dual Ramp Start The SMC-Flex controller provides the user with the ability to select between two Start settings. The parameters below are available in the Set Up programming mode. To obtain Dual Ramp control, Ramp #1 is located in the Basic Set Up and Ramp #2 is located in the Option 2 Input (Dual Ramp).
Programming 4-11 Full Voltage Start The SMC-Flex controller may be programmed to provide a full voltage start (output voltage to the motor reaches full voltage within 1/4 second) with the following programming: Parameter Option Starting Mode Full Voltage This must be programmed for Full Voltage. Linear Speed The SMC-Flex provides the user the ability to control the motor speed during starting and stopping maneuvers.
4-12 Programming Programming Parameters The following table provides the option-specific parameters that are provided with each control option. These parameters are in addition to those already discussed in the Basic Set Up and Metering groups. Diagrams supporting the options described below are shown later in this chapter.
Page 89
Programming 4-13 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…120 s Allows the user to set the time period for the pump stopping function.
Page 90
4-14 Programming 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: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...
Programming 4-15 Basic Set Up The Basic Set Up programming group provides a limited parameter set, allowing quick start-up with minimal adjustment. If the user is planning to implement some of the advanced features (e.g., Dual Ramp, or Preset Slow Speed), then the Setup programming group should be selected.
4-16 Programming Motor Protection While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify, the Motor Protection group allows full access to the SMC-Flex controller’s powerful parameter set. Following is a listing of the additional setup parameters provided.
Programming 4-17 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. With Motor FLC programmed for 150 A and the Jam level programmed for 400%, the trip value is 600 A.
Chapter Motor Information Overview The Basic Set Up and Overload programming group allows the user to set parameters indicating to the controller the motor that is connected. It is important to correctly input the data to achieve the best performance from your controller. For overload protection, it is critical that the data be ATTENTION entered as it appears on the motor nameplate.
Chapter Metering Overview While the SMC-Flex controller operates your motor, it also monitors several different parameters, providing a full function metering package. Viewing Metering Data To access the metering information, follow the procedure below. Description Action Display — — ##.# Amps Volt %MTU...
Page 96
Metering Description Action Display Scroll through the Metering P# 1 parameters with the Up/Down keys to Volts Phase A-B Volt access the desired information. Press P# 2 the Enter key to view that parameter. Volts Phase B-C Volt P# 3 Volts Phase C-A Volt P# 4...
Chapter Optional HIM Operation Overview 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. Human Interface Module The control buttons available with the Bulletin 20-HIM LCD Human interface modules are compatible with the SMC-Flex controller’s...
Page 98
Optional HIM Operation Option Action Operation Pump Control Pump 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.
Chapter Communications Overview 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...
Communications Keypad Description The functions of each programming key are described below. Table 8.B Keypad Descriptions Escape Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm. Select Select a digit, select a bit, or enter edit mode in a parameter screen.
Page 101
Communications 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.
Communications Connecting the Human Interface Module to the Controller Figure 8.1 shows the connection of the SMC-Flex controller to a human interface module. Table 8.C provides a description of each port. See Figure 3.11 on page 3-12 for the control wiring diagram that enables start-stop control from a human interface module.
Page 103
Communications Series A 1. Disconnect the HIM and allow to power down. 2. Reconnect the HIM. On Initializing screen, the bottom right cor- ner of LCD shows Port X. Note this port number. 3. Go to Logic Mask, found as follows: Main Menu: Parameter/Communications/Comm Mask/Logic Mask 4.
Communications Only one HIM on port 2 is enabled Two HIMs are enabled on ports 2 and 3 Only the DPI communication cared on port 5 is enabled One HIM on port 2 and the DPI communication card on port 5 in enabled Two HIMs on ports 2 and 3 and the DPI communication card on port 5 is enabled...
Communications Default Input/Output Configuration The default configuration for I/O is 4 bytes in and 4 bytes out (TX = 4 bytes, RX = 4 bytes) and is arranged according to the following table. Table 8.E Produced Data (Status) Consumed Data (Control) Logic Status Logic Command Word 0...
Communications SMC — Flex Bit Identification Table 8.G Logic Status Word Bit # Status Description Enabled 1 — Control Power Applied 0 — No Control Power Running 1 — Power Applied to Motor 0 — Power not Applied to Motor Phasing 1 —...
Communications Reference/Feedback The SMC-Flex does not offer the analog Reference feature. The analog Feedback feature is supported and will provide Parameter 1, Current in Phase A, automatically as the feedback word. Parameter Information A complete listing of the SMC-Flex parameters is located in Appendix B.
8-10 Communications Rules for Using DataLinks • 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. • Parameter settings in the SMC determine the data passed through the DataLink mechanism.
Chapter Diagnostics Overview This chapter describes the fault diagnostics of the SMC-Flex controller. Further, this section describes the conditions that cause various faults to occur. Protection Programming Many of the protective features available with the SMC-Flex controller can be enabled and adjusted through the programming parameters provided.
Diagnostics Clear Fault You can clear a fault using any of several methods: • Program the SMC-Flex controller for a Clear Fault, which can be found in Main Menu/Diagnostics/Faults. • If a human interface module is connected to the controller, press the Stop button.
Diagnostics Fault Codes Table 9.A provides a complete cross-reference of the available fault codes and corresponding fault descriptions. Table 9.A Fault Code Cross-reference Fault Code Fault Code Line Loss A Line Loss B Stall Line Loss C Phase Reversal Shorted SCR A Coms Loss P2 Shorted SCR B Coms Loss P3...
Diagnostics Fault Definitions Table 9.B shows the fault definitions for the SMC-Flex. Table 9.B Fault Definitions Fault Description Line Loss F1, F2, F3 The SMC-Flex can determine if a line connection has been lost, and will indicate this accordingly. Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the SMC-Flex.
Chapter Troubleshooting Introduction 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.
Page 114
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 115
Troubleshooting 10-3 Table 10.A SMC Fault Display Explanation (Continued) Display Fault Code Possible Causes Possible Solutions Open Bypass 13, 14, & 15 • Control voltage is low • Check control voltage power supply • Inoperable power module bypass • Replace power module •...
Page 116
10-4 Troubleshooting Table 10.B Motor Will Not Start — No Output Voltage to the Motor Display Possible Cause Possible Solutions Fault displayed • See fault description • See Table 10.A addressing fault conditions Display is blank • Control voltage is •...
Page 117
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 • Erratic Load • Check load conditions Erratic operation •...
10-6 Troubleshooting Power Module Check If a power module needs to be checked, use the applicable procedure that follows. To avoid shock hazard, disconnect main power ATTENTION before working on the controller, motor, or control devices such as Start/Stop push buttons. Make sure that wires are properly marked and ATTENTION programmed parameter values are recorded.
Appendix 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.
Page 121
Specifications UL/CSA/NEMA Short Circuit Protection SCPD Performance Type 1 SCPD List Max. Max. Max. Max. Available Fuse Available Circuit Fault Fault Breaker (A) Line Device Operational Current 10 kA 10 kA Rating (A) 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA...
Specifications UL/CSA/NEMA Steady State Heat Dissipation (W) Controller Rating (A) Auxiliary Contacts • 19/20 (Normal/Up-to-Speed/External Bypass) • 31/32 (Alarm) • 29/30 (Fault) • 33/34 (Normal) Type of Control Circuit Electromagnetic relay Number of Contacts Type of Contacts N.O. Type of Current Rated Operational Current 3 A @ 120V AC, 1.5 A @ 240V AC Conventional Thermal Current I...
Specifications Mechanical Resistance to Operational 1.0 G Peak, Vibration 0.15 mm (0.006 in.) displacement Non-Operational 2.5 G, 0.38 mm (0.015 in.) displacement Resistance to Operational 5.5 G Shock Non-Operational 25 G Construction Power Poles 5…85 A Heatsink thyristor modular design 108…480 A Heatsink hockey puck thyristor modular design...
Specifications Approximate Dimensions and Open Type Controllers Shipping Weights Dimensions are in millimeters (inches). Dimensions are not intended for manufacturing purposes. Controller Height Width Depth Weight Rating (A) 5…85 5.7 kg (12.6) (5.9) (8.0) (12.6 lb.) 108…251 253.8 30.4 kg (22.05) (8.86) (9.99)
Page 127
Appendix Parameter Information Table B.1 Parameter List Parameter Parameter Min./ Default User Group Units Description Number Max. Settings Settings Metering Volts Phase A-B Metering Volts Phase B-C Metering Volts Phase C-A Metering Current Phase A Metering Current Phase B Metering Current Phase C Metering Watt Meter...
Page 128
Parameter Information Table B.1 Parameter List (Continued) Parameter Parameter Min./ Default User Group Units Description Number Max. Settings Settings Dual Ramp Kickstart Time 2 0.0…2.0 Dual Ramp Kickstart Level2 %LRT 0…90 Basic Set Up Stop Mode Disable Disable Soft Stop Linear Speed Accu-Stop Basic Set Up...
Page 129
Parameter Information Table B.1 Parameter List (Continued) Parameter Parameter Min./ Default User Group Units Description Number Max. Settings Settings Stall Stall Delay 0.0…10.0 Ground Fault Gnd Flt Enable Disable Disable Enable Ground Fault Gnd Flt Level 1.0…5.0 Ground Fault Gnd Flt Delay 0.1…250.0 Ground Fault Gnd Flt Inh Time...
Page 130
Parameter Information Table B.1 Parameter List (Continued) Parameter Parameter Min./ Default User Group Units Description Number Max. Settings Settings Basic Set Up Aux2 Config Language Language English English French Spanish German Portuguese Mandarin Parameter Mgmt Ready Ready User Recall User Store Factory Default Basic Set Up Backspin Timer...
Page 131
Appendix Renewal Parts Description SMC Rating Input Control Voltage Part No. Control Modules Standard 120…240V AC 41391-454-01-S1FX Pump Control 41391-454-01-B1FX Braking Control 5…85 A 41391-454-01-D1AX 108…251 A 41391-454-01-D1BX 317…480 A 41391-454-01-D1CX Standard 24V AC/DC 41391-454-02-S2FX Pump Control 41391-454-02-B2FX Braking Control 5…85 A 41391-454-02-D2AX 108…251 A...
Appendix Accessories Description Description/Used With Cat. No. Protective Modules 5…85 A, 480V 150-F84 108…480 A, 480V 150-F84L 5…85 A, 600V 150-F86 108…480 A, 600V 150-F86L Terminal Lugs 108…251 A 199-LF1 317…480 A 199-LG1 IEC Terminal Covers 108…251 A 150-TC2 317…480 A 150-TC3 Hand-Held 20-HIM-A2...
Appendix Renewal Part Cross Reference Orderable Control Module Line Input Description Allen-Bradley Internal Cat. No. Rating Voltage Voltage Renewal Part No. Label Standard — 100…240V 41391-454-01-S1FX 150-FS1FX — 41391-454-02-S2FX 150-FS2FX Pump Control — 100…240V 41391-454-01-B1FX 150-FB1FX — 41391-454-02-B2FX 150-FB2FX Brake Control 5…85 A —...
Renewal Part Cross Reference Originally Ordered Internal Control Orderable Power Control Type Control Voltage Line Voltage Amperes Series AB Cat. No. Module Label Poles Pump Control 100…240V 200…480V AC 150-F5NBDB 150-FB1FX 150-FPP5B 150-F25NBDB 150-FB1FX 150-FPP25B 150-F43NBDB 150-FB1FX 150-FPP43B 150-F60NBDB 150-FB1FX 150-FPP60B 150-F85NBDB 150-FB1FX...
Page 135
Glossary Alternating current. AC Contactor An alternating current (AC) contactor is designed for the specific purpose of establishing 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.
Glossary-II 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 137
Glossary-III 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 138
Glossary-IV 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.
Need help?
Do you have a question about the Allen-Bradley SMC-Flex 150 and is the answer not in the manual?
Questions and answers