Rockwell Automation Allen-Bradley SMC-PLUS Bulletin 150 User manual

This manual describes the installation, setup,
operation and use of the SMC PLUS Controller. Basic
installation and troubleshooting instructions apply to
all of the SMC PLUS Controllers. The wiring and
set-up procedures are for the SMC PLUS Controllers
without options only. Wiring and set-up procedures fo
the SMC PLUS Controllers with options can be found
in the following publications:
• 150-805 Soft Stop Option
• 150-806 Pump Control Option
• 150-807 Preset Slow Speed
• 150-808 SMBTM Smart Motor Braking
• 150-809 Accu-StopTM Option
• 150-810 Slow Speed with Braking

1
Chapter Catalog Number
Identification
The following is an explanation of the catalog numbering system for the Bulletin 150 SMC
PLUSSmart Motor Controller.
Figure 1.1 – Open Type Controllers Figure 1.2 – Combination Controllers
8L4BD –A24 N150 – A
Bulletin Number
150 Solid–State Controller
Controller Rating
A24 24 amperes (standard duty)
1–15 hp @ 480V
21 amperes (heavy duty)
1–15 hp @ 480V
A35 35 amperes (standard duty)
1–25 hp @ 480V
30 amperes (heavy duty)
1–20 hp @ 480V
A54 54 amperes (standard duty)
1–40 hp @ 480V
45 amperes (heavy duty)
1–30 hp @ 480V
A97 97 amperes (standard duty)
5–75 hp @ 480V
79 amperes (heavy duty)
5–60 hp @ 480V
A135 135 amperes (standard duty)
5–100 hp @ 480V
105 amperes (heavy duty)
5–75 hp @ 480V
Type of Enclosure
N Open
A NEMA 1 B NEMA 1 Vent.
Input Line Voltage
BD 200–480 volts, 3–phase, 50 and 60 Hz
CD 200–600 volts, 3–phase, 50 and 60 Hz
Options
8L4 Max. 480 volt, line mounted Protective Module
8L6 Max. 600 volt, line mounted Protective Module
8M4 Max. 480 volt, load mounted Protective Module
8M6 Max. 600 volt, load mounted Protective Module
8B4 Max. 480 volt, line and load mounted Protective Module
8B6 Max. 600 volt, line and load mounted Protective Module
Options Functions
(Only one option may be added to standard unit)
A Soft Stop D SMBSmart Motor Braking
B Pump Control E Accu–Stop
C Preset Slow Speed F Slow Speed with Braking
Horsepower
Cat. HP Cat. HP Cat. HP
No. Rating No. Rating No. Rating
39 5 47 50 57 300
40 7.5 48 60 58 350
41 10 49 75 59 400
42 15 50 100 60 450
43 20 51 125 61 500
44 25 52 150 62 600
45 30 54 200 63 700
46 40 56 250
Type of Enclosure
A NEMA1 B NEMA 1 Vent.
J NEMA12
Options (only one option may be added to standard unit)
A Soft Stop
B Pump Control
C Preset Slow Speed
D SMBSmart Motor Braking
E Accu-Stop
F Slow Speed with Braking
Voltage Rating
H 200 volts, 50/60 Hz
A 240 volts, 50/60 Hz
B 480 volts, 50/60 Hz
C 600 volts, 50/60 Hz
Bulletin Number
152H Combination Controller
with fusible disconnect
and isolation contactor
152B Combination Controller
with fusible disconnect
153H Combination Controller
with circuit breaker
and isolation contactor
153B Combination Controller
with circuit breaker
39–B152H – W A A–
Protective Module –
•For 24A, 35A, and 54A controllers:
150-N84 Protective Module (max. 480V)
150-N86 Protective Module (max. 600V)
•For 97A–135A controller:
150-N84L Protective Module with wire leads (max. 480V)
150-N86L Protective Module with wire leads (max. 600V)
150-NT1 IEC line and load terminal cover
199-LF1 Terminal Lug Kit
Controller Rating
W Standard duty
Z Heavy duty
Accessories for Field Mounting
Catalog Number
Identification

Chapter Catalog Number Identification
1-2
1
Specifications
•Input Voltage – Power Module:
– 200 – 480 VAC, 3–phase, +10%, –15%
– 200 – 600 VAC, 3–phase, +10%, –15%
•Control Voltage – Control Module:
100 – 240 VAC, 1 phase, +10%, –15%
•Input Frequency – Control and Power:
50 and 60 Hz
•Repetitive Peak Inverse Voltage Rating:
– 1400V (Line voltage 200–480V)
– 1600V (Line voltage 200–600V)
•Operating Temperature:
0°C to +50°C
•Storage Temperature:
–40°C to +85°C
•Relative Humidity:
5 – 95% (non–condensing)
•Shock:
30 G shock peak acceleration for 11 ms
•Vibration:
2.5 G vibration for 60 minutes
•Altitude:
2000 meters without derating
•Noise and RF Immunity:
Surge transient 3KV peak, 1500 V
showering arc
•Auxiliary Contact Rating:
– N.O.– 470 VA sealed, 4700 VA inrush,
240V max., 24V min.
– N.C.– 275 VA sealed, 2750 VA inrush,
240V max., 24V min.
•Diagnostics:
– Start Fault
– Stalled Motor
– Temperature Fault
– Line Fault
•DV/DT Protection:
RC Snubber Network
•Transient Protection (optional):
Metal Oxide Varistors, 220 joules
Standard Adjustments
•Soft Start:
– 2 to 30 seconds
•Initial Torque:
– 5 to 90% locked rotor torque
•Kickstart:
– 500% current for 0.4 to 2 seconds
•Current Limit:
– 50 to 500% full load amperes
Options
•Soft Stop:
– 2 to 60 seconds
•Preset Slow Speed:
– Forward: 7% (LOW) or 15% (HIGH) speed
– Reverse: 10% (LOW) or 20% (HIGH) speed
– Slow Speed Current adjustment (50 to 450%
of full load current)
•Pump Control:
– Starting: 2 to 30 seconds
– Stopping: 2 to 120 seconds
•SMB Smart Motor Brake:
– Braking Current 150 to 400% full load
amperes
•Accu-Stop
– Slow Speed:7% (LOW) and 15% (HIGH)
– Slow Speed Current adjustment
(50 to 450% of full load current)
– Braking Current (150 to 400% full load current)
•Slow Speed with Braking
– Slow Speed: 7% (LOW) and 15% (HIGH)
– Slow Speed Current adjustment
(50 to 450% of full load current)
– Braking Current (150 to 400% full load
current)
–Slow Speed Acceleration Current Adjustment
(50 to 400% of full load current)

2
Chapter Installation and
Wiring
Before installing the controller, make a complete visual check of the controller for
damage in shipment or handling. Claims for damaged or missing parts must be
made to the carrier as soon as possible after receipt of shipment.
The open-style controller can be installed in an enclosure. The internal
temperature of the enclosure must be kept within the range of 0°C to 50°C.
For NEMA Type 1 enclosures, the following guidelines are recommended in order
to limit the maximum controller ambient temperature.
There should be a clearance of at least six inches above and below the controller.
This area allows air to flow through the heatsink. Ventilation openings are required
above and below this air space.
An outlet should be placed at least six inches above the controller. The inlet should
be placed near the bottom of the enclosure. It should be capable of accepting a fan
rated 110 CFM or greater. A filter is required to prevent contaminants from
entering the enclosure.
The minimum vent area should be ten square inches. For the 97 and 135 amp
controller, the minimum vent area should be 36 square inches. Deductions must be
made for the grill work or ventilation pattern.
CAUTION: When thermal overload relays are installed in the same
enclosure, a barrier should be provided around the relay. However, this
should not inhibit air flow on forced air cooled units (97 and 135A).
!
The following table shows the maximum heat dissipation at rated current for the
controllers. For currents lower than rated value, heat dissipation will be lower.
Figure 2.1 - Maximum Heat Dissipation
SMC PLUS Controller Current
Size 24A 35A 54A 97A 135A
Maximum Watts 110 150 200 285 410
For NEMA Type 12 or non-ventilated enclosures, it is recommended that a by-pass
contactor be used. This will allow the controller to start the motor. Once up to full
voltage, the controller would be by-passed. Note that the energy saver and
protective features of the controller would no longer be available. See Page 2-5,
Figure 2.10 for this configuration.
The controller is convection cooled except for the 97A and 135A fan cooled unit. It
is important to locate the controller in a position which allows free air flow
vertically through the power module. The controller must be mounted with
heatsink fins in a vertical plane and have a minimum of 6 inches free
space above and below the controller. See Figure 2.2.
Inspection
Enclosures
Ventilated Enclosures
Non-ventilated
Enclosures
Mounting

Chapter Installation and Wiring
2-2
2
Figure 2.2 - Dimension Drawings
24, 35, and 54 Amp Controller 97 and 135 Amp Controller
AA
C
DE
HJ
BFG
E
G
FB
CD
.281DIA.
(04.14)
4 Mtg. Holes
.219DIA.
(05.56)
4 Mtg. Holes
.281DIA.
(04.14)
4 Mtg. Holes
Unit A
Width B Height C Depth D E F G H J Approx. Ship. Wt.
24A Millimeter 154 180 159 50 140 160 140 10 20 4.5 kg
24A
Controller Inch 6-1/16 7-3/32 6-17/64 1-31/32 5-33/64 6-5/16 5-33/64 13/32 51/64 10 lbs
35A Millimeter 214 240 169 60 200 200 180 20 30 6.8 kg
35A
Controller Inch 8-7/16 9-29/64 6-21/32 2-23/64 7-7/8 7-7/8 7-3/32 51/64 1-3/16 15 lbs
54A Millimeter 244 290 199 90 230 240 200 25 45 11.3 kg
54A
Controller Inch 9-39/64 11-27/64 7-27/32 3-35/64 9-1/64 9-29/64 7-7/8 63/64 1-25/32 25 lbs
97A
and Millimeter 248 336 230 128 220 250 40 10.4 kg (97A)
11.8 kg (135A)
and
35A
Controllers Inch 9-49/64 13-15/64 9-1/16 5-3/64 8-21/32 9-27/32 1-39/64 23 lbs (97A)
26 lbs (135A)
All dimensions are approximate and are not to be used for construction purposes. Refer to nearest Sales Office or the Sales Department at
Milwaukee, Wisconsin, for complete dimension drawings.
Figure 2.3 - Wiring Terminal Locations
The controller wiring terminal locations
are shown in Figure 2.3. Make wiring
connections as indicated in the typical
connection diagrams shown in Figures
2.7, 2.8, 2.9, 2.10, and 2.11. Connect
the line to terminals L1/1, L2/3, and
L3/5. Connect the load to terminals
T1/2, T2/4, and T3/6. A provision is
available for grounding the isolated
heatsink per applicable codes.
Wiring
Input
Connections
Control
Circuit
Connections
Output
Connections

Chapter Installation & Wiring
2
2-3
Figure 2.4 - Power Wiring and Power Lug Connections
Controller
Wire Size
C
on
t
ro
ll
er Metric AWG
24 A-54 A 2.5 - 25 mm2#14 – #4
97 A-135 A 16 - 120 mm26 – 4/0
Tightening Torque
Wiring Size
2.5-6 mm210 mm216-25 mm216-120 mm2
Wi
r
i
ng
Si
ze 14–10 AWG 8 AWG 6–4 AWG 6 – 4/0
Torque
2.80 N-m 3.4 N-m 3.95 N-m 31 N-m
T
orque 25 LB-IN 30 LB-IN 35 LB-IN 275 LB-IN
Control voltage: 100–240 VAC, (+10/–15%), 1 phase, 50/60 Hz. Connect control
power to the controller at terminals 10 and 60. The control power requirement is 30
VA. In addition, 45 VA capacity is required to operate the heatsink fan on the 97
and 135 Amp controller. Additional control circuit transformer VA capacity may be
required depending on the specific application.
Use the following figure as a guide for control wiring:
Figure 2.5 - Control Wiring and Tightening Torque
Wire Size Torque
Metric 1.5 - 4 mm23.95 N-m
AWG #14 – #12 35 LB-IN
The wiring of the control circuit depends on the specific application. Typical
connections for a number of typical applications are shown in Figures 2.7 through
2.12.
The 97 and 135 Amp controllers have a heatsink fan which requires an additional
45VA capacity. To gain access to the fan connection, see Figure 2.6.
CAUTION: The fan jumpers have been factory installed for 110/120
VAC input. Refer to Figure 2.6 for optional 220/240 VAC fan wiring.
After control wiring is complete, replace control terminal strip cover.
!
NOTE: Jumpers have been factory installed for 110/120 VAC input.
Figure 2.6 - Location of Fan Wiring and Jumpers for 97A and 135A Controller
Factory Set
110/120 VAC Fan Power Optional
220/240 VAC Fan Power
11
12
13
14 To Supply
11
12
13
14
Jumpers To Supply
Jumpers
NOTE: Customer is to wire fan to control voltage supply.
Jumpers are factory arranged for 110/120 VAC fan power.
Control Power
Fan Power

Chapter Installation and Wiring
2-4
2
Figure 2.7 shows a typical connection for standard control module. See page 3-2
for a description of the start sequence.
Figure 2.7 - Typical Connection Diagram for Standard Unit
10 20 30 40 50 60 70 80 90
Stop Start
M
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
SMC PLUS
Controller
Overload
Relay ➀
Fast-Acting
SCR fuses
(optional) ➀
SMC PLUS Control Terminals
11 12 13 14 Fan Power
(97A and
135A Only) ➁
O.L.
Auxiliary
Contacts
11 12 13 14
Optional
220/240 VAC Fan Power
Jumper
Branch
Protection
➀
Jumper
To Supply
Power Input
3-Phase
➀
➀
➀➀
➀
➀➀
➀Customer Supplied
➁Customer wires fan to control voltage supply.
Jumpers are arranged for 110/120 VAC fan power.
NOTE: For two wire control, remove stop/start
push buttons and connect two wire device
between terminals 10 and 40.
Figure 2.8 shows a typical connection of standard unit for use with an isolation
contactor. Starting and stopping of the motor is controlled by the controller. The
controller also controls the electromechanical contactor. The contactor provides
isolation between the motor and the power lines when the controller is “OFF.”
WARNING: When not using an isolation contactor, hazardous voltages are present at the load terminals
of the controller when the controller is turned off. Warning labels must be attached to the motor
terminal box, the controller enclosure, and the control station. Additional circuitry must be included to
provide automatic isolation.
!
Figure 2.8 - Typical Connection Diagram of Standard Unit with Isolation Contactor
10 20 30 40 50 60 70 80 90
M
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
11 12 13 14
11 12 13 14
C.I.
Stop Start
SMC PLUS
Controller
Fast-Acting
SCR fuses
(optional) ➀
SMC PLUS Control Terminals
Fan Power
(97A and
135A Only) ➁
O.L.
Auxiliary
Contacts
➂
Optional
220/240 VAC Fan Power
Jumper
Branch
Protection
➀
Jumper
To Supply
Power Input
3-Phase ➀
➀
➀➀
➀
➀➀
➀Customer Supplied
➁Customer wires fan to control voltage supply.
Jumpers are arranged for 110/120 VAC fan power.
➂Set auxiliary contact for normal setting.
NOTE: For two wire control, remove stop/start
push buttons and connect two wire device
between terminals 10 and 40.
Typical Connection
Typical Connection
with Isolation
Contactor

Chapter Installation & Wiring
2
2-5
Figure 2.9 shows a typical connection diagram for use in a retrofit application. In
this scheme, the controller provides control of the load when the electromechanical
starter is energized. This method of controlling the load can be used in applications
where the existing control scheme is to remain intact.
Starting and stopping of the motor is controlled by the controller. The controller
also controls the electromechanical contactor. The contactor provides isolation
between the motor and the power lines when the controller is “OFF.”
If a fault occurs, the N.O. auxiliary contact opens and drops out the “M” contactor,
thus providing isolation from line potential. In this scheme the auxiliary contact
selection DIP switch must be set for normal auxiliary contact operations.
Figure 2.9 - Typical Connection Diagram for Retrofit Applications of
Standard Unit
➀
Stop Start
SMC PLUS
Controller
Fast-Acting
SCR fuses
(optional) ➀
SMC PLUS Control Terminals
Fan Power
(97A and
135A Only) ➁
O.L.
Auxiliary
Contacts
➂
Optional
220/240 VAC Fan Power
Jumper
Branch
Protection
➀
Jumper
To Supply
Power Input
3-Phase
➀
➀➀
➀
➀
➀
10 20 30 40 50 60 70 80 90
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
11 12 13 14
M
Existing Motor
Starter ➀
M
M
M
11 12 13 14 ➀
➀Customer Supplied
➁Customer wires fan to control voltage supply.
Jumpers are arranged for 110/120 VAC fan power.
➂Set auxiliary contact for normal setting.
NOTE: For two wire control, remove stop/start
push buttons and connect two wire device
between terminals 10 and 40.
By using the controller as shown in Figure 2.10 below, a soft start characteristic can
be provided. Once the motor has reached full speed, the auxiliary contact on the
SMC energizes the bypass contactor.
NOTE: The controller is by-passed in this circuit. Controller features are not
available once the by-pass contactor is energized. Also, auxiliary contacts
must be set for up to speed operation.
Figure 2.10 - Typical Application Diagram of a By-Pass Contactor with Standard Unit
M
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
11 12 13 14
10 20 30 40 50 60 70 80 90
BC
11 12 13 14
Stop ➀
Start ➀
SMC PLUS
Controller
Fast-Acting
SCR fuses
(optional) ➀
SMC PLUS Control Terminals
Fan Power
(97A and
135A Only) ➁
Auxiliary
Contacts
➂
Optional
220/240 VAC Fan Power
Branch
Protection
➀
Jumper
To Supply
Power Input
3-Phase
➀
➀
➀
BC
BC➀
O.L.
➀
Bypass
Contactor
➀Customer Supplied
➁Customer wires fan to control voltage supply.
Jumpers are arranged for 110/120 VAC fan power.
➂Set auxiliary contacts for up-to-speed setting.
NOTE: For two wire control, remove stop/start
push buttons and connect two wire device
between terminals 10 and 40.
BC
L.B.
Typical Connection
for Retrofit
Application
By-Pass Mode

Chapter Installation and Wiring
2-6
2
Figure 2.11 shows a typical connection diagram for use with a shunt trip circuit
breaker. In this scheme, the electromechanical contactor is eliminated. The shunt
trip circuit breaker provides automatic isolation from the main power lines during
abnormal conditions and can also be used to provide a manual isolation from the
main power lines.
Figure 2.11 - Typical Connection Diagram with Shunt Trip Circuit Breaker
10 20 30 40 50 60 70 80 90
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
11 12 13 14
M
CR
TR
TR ➀ST
AB
N.O.T.C
.N.O.T.C.
11 12 13 14
SMC PLUS Control Terminals
Optional
220/240 VAC Fan Power
Jumper
To Supply
Stop ➀Start ➀
SMC PLUS
Controller
Overload
Relay
O.L. ➀Fast-Acting SCR
fuses (optional) ➀
Fan Power
(97A and
135A Only) ➁O.L.
Auxiliary
Contacts
➃
Jumpers
Branch
Protection
➀
Power Input
3-Phase
➀
➀
➀
➀
➀
➀
CR ➀➀
Shunt Trip
Circuit
Breaker ➀
CR ➀
TR ➀
Shunt
Trip Coil ➀
➀Customer Supplied
➁Customer wires fan to control voltage supply.
Jumpers are arranged for 110/120 VAC fan
power.
➂For two wire control, remove stop/start push
buttons and connect two wire device between
points A and B.
➃Set auxiliary contact for normal setting.
When using solid-state devices to operate the SMC PLUS controller the voltage
and frequency range will be 100–240V, 50/60 Hz. The OFF state leakage current
from the solid-state device must be less than 6 mA. The nominal input current is
25mA at 120 VAC and 50 mA at 240 VAC.
Figure 2.12 - Typical Connection with 2-Wire Control Scheme
10 20 30 40 50 60 70 80 90
11 12 13 14
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
M
11 12 13 14
SMC PLUS Control Terminals
Optional
220/240 VAC Fan Power
Jumper
To Supply
SMC PLUS
Controller
Overload
Relay
O.L. ➀Fast-Acting SCR
fuses
(optional) ➀
Fan Power
(97A and
135A Only) ➁
Auxiliary
Contacts
Jumpers
Branch
Protection
➀
Power Input
3-Phase
➀
O.L. ➀
➀
➀
➀
Two-wire device ➀
➀Customer Supplied
➁Customer wires fan to control voltage
supply. Jumpers are arranged for
110/120 VAC fan power.
Typical Connection
with Shunt Trip
Circuit Breaker
Programmable
Controller and
Sensor Interface