Rockwell Automation Allen-Bradley SMC-Flex 150 User manual

SMC-Flex™
Bulletin 150
User Manual

Important User Information
Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that
each application and use meets all performance and safety requirements,
including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in
this guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Allen-Bradley does not assume responsibility or liability (to include
intellectual property liability) for actual use based upon the examples shown
in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,
Installation and Maintenance of Solid-State Control (available from your
local Allen-Bradley office), describes some important differences between
solid-state equipment and electromechanical devices that should be taken
into consideration when applying products such as those described in this
publication.
Reproduction of the contents of this copyrighted publication, in whole or
part, without written permission of Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
Attention statements help you to:
•identify a hazard
•avoid a hazard
•recognize the consequences
Trademark List
Accu-Stop, Allen-Bradley Remote I/O, RSNetworx, PLC, PowerFlex, SLC, SMC, SMC-2, SMC-Flex, SMC PLUS,
SMC Dialog Plus, SMB, and STC are trademarks of Rockwell Automation. ControlNet is a trademark of ControlNet
International, Ltd. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association
(ODVA). Ethernet is a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation.
Modbus is a trademark or registered trademark of Schneider Automation Inc. Profibus is a registered trademark
of Profibus International.
ATTENTION
!
Identifies information about practices or circumstances
that can lead to personal injury or death, property damage
or economic loss
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.

European Communities (EC)
Directive Compliance
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
the following directives.
EMC Directive
This product is tested to meet the Council Directive 89/336/EC
Electromagnetic Compatibility (EMC) per EN/IEC 60947-4-2.
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 73/23/EEC Low Voltage,
per EN/IEC 60947-4-2.
This equipment is classified as open equipment and must be mounted in an
enclosure during operation to provide safety protection.

Notes

Bulletin 150 SMC-Flex™
ii
Table of Contents
Chapter 1
Product Overview
Other Related Documents .............................................................. 1-1
Description .................................................................................... 1-1
Operation ...................................................................................... 1-2
Modes of Operation (Standard) ...................................................... 1-2
Soft Start................................................................................. 1-2
Selectable Kickstart ................................................................ 1-3
Current Limit Start .................................................................. 1-3
Dual Ramp Start ..................................................................... 1-4
Full Voltage Start .................................................................... 1-4
Preset Slow Speed .................................................................. 1-5
Linear Speed Acceleration ....................................................... 1-6
Soft Stop ................................................................................ 1-7
Control Options .............................................................................. 1-8
Modes of Operation (Pump Control) ............................................... 1-8
Pump Control Option ............................................................... 1-8
Modes of Operation (Braking Control) ............................................ 1-9
SMBSmart Motor Braking Option ........................................ 1-9
Accu-StopOption .............................................................. 1-10
Slow Speed with Braking Option ........................................... 1-10
Protection and Diagnostics .......................................................... 1-11
Overload ............................................................................... 1-11
Underload ............................................................................. 1-11
Undervoltage ........................................................................ 1-13
Overvoltage .......................................................................... 1-13
Unbalance ............................................................................ 1-13
Stall Protection and Jam Detection ....................................... 1-14
Ground Fault ......................................................................... 1-15
Thermistor/PTC Protection .................................................... 1-16
Excessive Starts/Hour ........................................................... 1-17
Overtemperature .................................................................. 1-18
Open Gate ............................................................................ 1-18
Line Faults ............................................................................ 1-18
Metering ...................................................................................... 1-19
Communication ........................................................................... 1-19
Programming .............................................................................. 1-20
Status Indication .......................................................................... 1-20

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Chapter 2
Installation
Receiving .......................................................................................2-1
Unpacking ......................................................................................2-1
Inspecting ......................................................................................2-1
Storing ...........................................................................................2-1
General Precautions .......................................................................2-2
Heat Dissipation .............................................................................2-2
Enclosures .....................................................................................2-2
Enclosures ..............................................................................2-3
Mounting .......................................................................................2-4
Dimensions ....................................................................................2-4
Power Factor Correction Capacitors ................................................2-8
Protective Modules .........................................................................2-9
Motor Overload Protection ..............................................................2-9
Two-speed Motors ..................................................................2-9
Multi-motor Protection ............................................................2-9
Electromagnetic Compatibility (EMC) ............................................2-10
Enclosure ..............................................................................2-10
Wiring ...................................................................................2-10
Recommendations ................................................................2-10
Chapter 3
Wiring
Terminal Locations .........................................................................3-1
Power Structure .............................................................................3-2
Power Wiring ...........................................................................3-3
Control Power ................................................................................3-4
Control Voltage ........................................................................3-4
Control Wiring .........................................................................3-5
Fan Power ......................................................................................3-5
Fan Terminations ....................................................................3-5
Control Terminal Designations ........................................................3-6
Wiring Diagrams ............................................................................3-7
Standard Controller ..................................................................3-7
Soft Stop, Pump Control, and SMB Smart Motor Braking .......3-21
Preset Slow Speed ................................................................3-25
Slow Speed with Braking .......................................................3-27
Sequence of Operation..................................................................3-28
Soft Stop ...............................................................................3-28
Preset Slow Speed ................................................................3-29
Pump Control ........................................................................3-30
SMB Smart Motor Braking Option ..........................................3-31
Accu-Stop .............................................................................3-32
Slow Speed with Braking .......................................................3-33

Bulletin 150 SMC-Flex™
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Chapter 4
Programming
Overview ....................................................................................... 4-1
Keypad Description ........................................................................ 4-1
Programming Menu ....................................................................... 4-1
Password ...................................................................................... 4-5
Parameter Management ................................................................ 4-6
Random Access Memory (RAM) .............................................. 4-6
Read-only Memory (ROM) ....................................................... 4-6
Electrically Erasable Programmable Read-only Memory
(EEPROM) ............................................................................... 4-6
Using Parameter Management with DPI HIM ........................... 4-7
Parameter Modification ................................................................. 4-8
Soft Start ....................................................................................... 4-9
Current Limit Start ......................................................................... 4-9
Dual Ramp Start .......................................................................... 4-10
Full Voltage Start ......................................................................... 4-11
Linear Speed ............................................................................... 4-11
Programming Parameters ............................................................ 4-12
Basic Set Up ................................................................................ 4-15
Motor Protection .......................................................................... 4-16
Example Settings ......................................................................... 4-17
Undervoltage ......................................................................... 4-17
Overvoltage ........................................................................... 4-17
Jam....................................................................................... 4-17
Underload.............................................................................. 4-17
Chapter 5
Motor Information
Overview ....................................................................................... 5-1
Motor Data Entry ........................................................................... 5-1
Chapter 6
Metering
Overview ....................................................................................... 6-1
Viewing Metering Data .................................................................. 6-1
Chapter 7
Optional HIM Operation
Overview ....................................................................................... 7-1
Human Interface Module ............................................................... 7-1

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Chapter 8
Communications
Overview ........................................................................................8-1
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
SMC — Flex Bit Identification ........................................................8-8
Reference/Feedback ......................................................................8-9
Parameter Information ...................................................................8-9
Scale Factors for PLC Communication ............................................8-9
Read Example .........................................................................8-9
Write Example .........................................................................8-9
Display Text Unit Equivalents ..........................................................8-9
Configuring DataLinks ....................................................................8-9
Rules for Using DataLinks ......................................................8-10
Updating Firmware........................................................................8-10
Chapter 9
Diagnostics
Overview ........................................................................................9-1
Protection Programming ..........................................................9-1
Fault Display ..................................................................................9-1
Clear Fault .....................................................................................9-2
Fault Buffer ....................................................................................9-2
Fault Codes .............................................................................9-3
Fault and Alarm Auxiliary Contact ...................................................9-3
Fault Definitions .............................................................................9-4
Chapter 10
Troubleshooting
Introduction ..................................................................................10-1
Power Module Check ...................................................................10-6

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Appendix A
Specifications
Functional Design Specifications ................................................... A-1
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 ............................. A-6
Enclosed Type Delta-Connected Controllers ............................ A-7
Appendix B
Parameter Information
Appendix C
Renewal Parts
Appendix D
Accessories
Appendix E
Renewal Part Cross Reference

Bulletin 150 SMC-Flex™
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List of Figures
Chapter 1
Product Overview
Figure 1.1 Soft Start ...................................................................1-2
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
Figure 1.8 Soft Stop ...................................................................1-7
Figure 1.9 Overload Trip Curves .................................................1-9
Figure 1.10 Restart Trip Curves after Auto Reset ..........................1-9
Figure 1.11 Stall Protection ........................................................1-11
Figure 1.12 Jam Detection ➀➁ ....................................................1-11
Figure 1.13 Overload Trip Curves ................................................1-12
Figure 1.14 PTC Sensor Characteristics per IEC-34-11-2 ...........1-14
Figure 1.15 DPI Location ............................................................1-16
Figure 1.16 Built-in Keypad and LCD ..........................................1-17
Figure 1.17 Control Terminals ....................................................1-17
Figure 1.18 Pump Control Option ................................................1-18
Figure 1.19 SMB Smart Motor Braking Option ...........................1-19
Figure 1.20 Accu-Stop Option .....................................................1-20
Figure 1.21 Slow Speed with Braking Option ..............................1-20
Chapter 2
Installation
Figure 2.1 Dimensions: 5…85 A Controllers ...............................2-5
Figure 2.2 Dimensions: 108…251 A Controllers .........................2-6
Figure 2.3 Dimensions: 317…480 A Controllers .........................2-7
Figure 2.4 Typical Wiring Diagram for Power Factor Correction
Capacitors .................................................................2-8
Figure 2.5 Typical Wiring Diagram for Power Factor Correction
Capacitors and Contactor ...........................................2-8
Chapter 3
Wiring
Figure 3.1 Wiring Terminal Locations (5…85 A) .........................3-1
Figure 3.2 Wiring Terminal Locations (108…480 A) ...................3-2
Figure 3.3 Line Power Wiring diagram ........................................3-3
Figure 3.4 Delta Power Wiring diagram ......................................3-4
Figure 3.5 5…480 A Fan Terminations .......................................3-6
Figure 3.6 SMC-Flex Controller Control Terminals .......................3-7
Figure 3.7 Typical Wiring Diagram for Standard Controller ..........3-8
Figure 3.8 Typical Wiring Diagram for Two-Wire Control with
No Stopping Control (No DPI Control) .........................3-9
Figure 3.9 Typical Wiring Diagram for Two-Wire Control with
Stopping Control ......................................................3-10