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

Bulletin 150 SMC-Flex™
ii
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

Bulletin 150 SMC-Flex™
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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

Bulletin 150 SMC-Flex™
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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™
vi
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

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viivii
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) ................................................................ 3-14
Figure 3.14 Typical Wiring Diagram for Shunt Trip
Applications ............................................................ 3-15
Figure 3.15 Typical Wiring Diagram for Single-Speed Reversing
Applications ............................................................ 3-16
Figure 3.16 Typical Wiring Diagram for Two-speed
Applications ............................................................ 3-17
Figure 3.17 Typical Wiring Diagram for SMC-Off-Bypass
Control .................................................................... 3-18
Figure 3.18 Typical Wiring Diagram for Hand-Off-Auto (DPI)
Control .................................................................... 3-19
Figure 3.19 Typical Wiring Diagram for Hand-Off-Auto (DPI)
Control .................................................................... 3-20
Figure 3.20 Typical Wiring Diagram ........................................... 3-21
Figure 3.21 Typical Retrofit Wiring Diagram ............................... 3-22
Figure 3.22 Typical Wiring Diagram for Applications Requiring an
Isolation Contactor .................................................. 3-23
Figure 3.23 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control
(Soft Stop, Braking, and Pump Control Only)............ 3-24
Figure 3.24 Typical Wiring Diagram for the Preset Slow
Speed ..................................................................... 3-25
Figure 3.25 Typical Slow Speed Wiring Diagram for Hand-Off-Auto
(DPI) Control ............................................................ 3-26
Figure 3.26 Typical Wiring Diagram for the Slow Speed with
Braking ................................................................... 3-27
Figure 3.27 Soft Stop Sequence of Operation ............................. 3-28
Figure 3.28 Preset Slow Speed Sequence of Operation .............. 3-29
Figure 3.29 Pump Control Sequence of Operation ...................... 3-30
Figure 3.30 SMB Smart Motor Braking Sequence of
Operation ................................................................ 3-31
Figure 3.31 Accu-Stop Sequence of Operation ........................... 3-32
Figure 3.32 Slow Speed with Braking Sequence of Operation .... 3-33
Chapter 4
Programming
Figure 4.1 Menu Structure Hierarchy ......................................... 4-2
Figure 4.2 Parameter Menu Structure ........................................ 4-3
Figure 4.3 Memory Block Diagram ............................................. 4-6

Bulletin 150 SMC-Flex™
viii
Chapter 8
Communications
Figure 8.1 SMC-Flex Controller with Human Interface Module ....8-4
Chapter 9
Diagnostics
Figure 9.1 Fault Display ..............................................................9-1
Chapter 10
Troubleshooting
Figure 10.1 Troubleshooting Flowchart .......................................10-2
Appendix A Figure A.1 Wiring Diagram ..........................................................A-2

Chapter 1
Product Overview
Other Related Documents • Quick Start — Publication 150-QS001_①-EN-P
• Renewal Part Instructions — 41053-277-01 (5…85 A)
41053-228-01 (108…480 A)
• Selection Guide — Publication 150-SG008_①-EN-P
• Application Guide — Publication 150-AT002_①-EN-P
Description The SMC-Flex™ controller offers a full range of starting modes as
standard:
• Soft Start with Selectable Kickstart
• Current Limit with Selectable Kickstart
• Dual Ramp Start with Selectable Kickstart
• Full Voltage Start
• Preset Slow Speed
• Linear Speed Acceleration with Selectable Kickstart (requires
Tach feedback)
• Soft Stop
Other features that offer further user benefit include:
• Expanded protective features
• Metering
• Communication capability
Innovative starting and stopping options provide enhanced
performance:
• Pump Control
• Braking Control
• Smart Motor Braking (SMB™)
• Accu-Stop™
• Slow Speed with Braking
These modes, features, and options are further described in this
chapter.
➀Latest revision

1-2 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. If the control power
input option is 100…240V AC, the controller’s microprocessor will
self-adjust to the input control voltage.
Note that the motor FLA must fall within the range of the SMC-Flex
as specified in the selection guide for proper operation.
Modes of Operation (Standard) Soft Start ①
This mode has the most general application. The motor is given an
initial torque setting, which is user-adjustable from 0…90% of locked
rotor torque. From the initial torque level, the output voltage to the
motor is steplessly increased during the acceleration ramp time. The
acceleration ramp time is user-adjustable from 0…30 seconds. If the
SMC-Flex controller senses that the motor has reached the up-to-
speed condition during the voltage ramp operation, the internal
bypass contactor will be pulled in.
Figure 1.1 Soft Start
➀Kickstart is also available with Soft Start.
S
tar
t
R
un
1
00%
Initi
a
l
Tor
q
u
e
P
e
r
ce
nt
Volta
ge
Time
(
seconds
)

Product Overview 1-3
Selectable Kickstart
This feature provides a boost at startup to break away loads that
require a pulse of high torque to get started. This is intended to
provide a pulse of current that is selectable from 0…90% of locked
rotor torque. Selectable kickstart is user-adjustable from
0.0…2.0 seconds.
Figure 1.2 Selectable Kickstart
Current Limit Start ➀
This starting mode provides a true current limit start; it is used when
limiting maximum starting current is necessary. The Current Limit
level is user-adjustable from 50…600% of the motor full load ampere
rating; and the current limit time is user-adjustable from 0…30
seconds. If the SMC-Flex controller senses that the motor has reached
the up-to-speed condition during the current limit starting mode, the
internal bypass contactor will be pulled in.
Figure 1.3 Current Limit Start
➀Kickstart is also available with Current Limit Start.
S
tar
t
R
un
1
00%
Initi
a
l
Tor
q
u
e
P
e
r
ce
nt
Volta
ge
Time
(
seconds
)
S
electable Kickstar
t
Soft Sto
p
C
oast-to-res
t
Soft Sto
p
S
tar
t
600%
50%
P
e
r
ce
nt F
u
ll
Load
C
urren
t
Time
(
seconds
)

1-4 Product Overview
Dual Ramp Start ➀
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
➀Dual Ramp Start is available only with the standard controller.
Full Voltage Start
This starting mode is used for applications requiring across-the-line
starting. The output voltage to the motor will reach full voltage within
1/4 second.
Figure 1.5 Full Voltage Start
S
tart #
1
R
u
n #
1
1
00%
Initial Tor
q
ue
#1
P
e
r
ce
nt
Volta
ge
Time
(
seconds
)
Initial Tor
q
ue
#2
S
tart #
2
R
u
n #
2
Ram
p
#
2
Ram
p
#
1
1
00%
P
e
r
ce
nt
Volta
ge
Time
(
seconds
)

Product Overview 1-5
Preset Slow Speed
This option can be used in applications that require a slow speed jog
for general purpose positioning. Preset Slow Speed provides either
7% of base speed (low) or 15% of base speed (high) settings in the
forward direction. Reverse can also be programmed and offers 10%
of base speed (low) and 20% of base speed (high) settings.
Figure 1.6 Preset Slow Speed
S
tar
t
R
un
1
00%
M
o
t
o
r
S
p
ee
d
Time
(
seconds
)
15% - Hi
gh
7
%
- Lo
w
1
0%
- Lo
w
20% - Hi
gh
Forw
a
r
d
R
e
v
e
r
se
ATTENTION
!
Slow speed running is not intended for continuous
operation due to reduced motor cooling.

1-6 Product Overview
Linear Speed Acceleration ➀
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. Kickstart is available with this option.
Figure 1.7 Linear Speed Acceleration
➀Kickstart is also available with Linear Speed Acceleration.
The Linear Stop does not need to be set up even if the linear start has
been programmed. The Linear Stop can not brake the motor/load and
reduce the stopping time.
S
tar
t
1
00%
P
e
r
ce
nt
S
p
ee
d
Time
(
seconds
)
R
un
S
to
p
ATTENTION
!
Linear Stop is not intended to be used as an
emergency stop. Refer to the applicable standards
for emergency stop requirements.

Product Overview 1-7
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.
Figure 1.8 Soft Stop
S
tar
t
R
un
1
00%
Initi
a
l
Tor
q
u
e
P
e
r
ce
nt
Volta
ge
Time
(
seconds
)
S
electable Kickstar
t
Soft Sto
p
C
oast-to-res
t
Soft Sto
p
ATTENTION
!
Soft Stop is not intended to be used as an emergency
stop. Refer to the applicable standards for
emergency stop requirements.

1-8 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. Consult your local
Allen-Bradley distributor.
Modes of Operation
(Pump Control)
Pump Control Option ➀
This option reduces surges during the starting and stopping of a
centrifugal pump by smoothly accelerating and decelerating the
motor. The microprocessor analyzes the motor variables and
generates commands that control the motor and reduce the possibility
of surges occurring in the system.
The starting time is programmable from 0…30 seconds, and the
stopping time is programmable from 0…120 seconds.
Figure 1.9 Pump Control Option
➀Kickstart is also available with Pump Control.
Pum
p
Star
t
R
un
1
00%
M
o
t
o
r
S
p
ee
d
Time
(
seconds
)
Pum
p
Sto
p
ATTENTION
!
Pump stopping is not intended to be used as an
emergency stop. Refer to the applicable standard for
emergency stop requirements.
ATTENTION
!
Pump stopping may cause motor heating depending
on the mechanical dynamics of the pumping system.
Therefore, select the lowest stopping time setting
that will satisfactorily stop the pump.