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

Chapter Installation & Wiring
2
2-7
The controller can be installed on a system with power factor correction capacitors.
The capacitors must be located on the line side of the controller. This must be done
to prevent damage to the SCRs in the SMC PLUS controller.
When discharged, a capacitor has essentially zero impedance. For switching
sufficient impedance should be connected in series with the capacitor bank to limit
the inrush current. A method of limiting the surge current is to add inductance in
the capacitance conductors. This can be accomplished by putting turns or coils in
the power connections to the capacitors.
480 – 600 volts – 6 inch diameter coil, 8 loops
250 volts – 6 inch diameter coil, 6 loops
Care should be used in mounting the coils so that they are not stacked directly on
top of each other or they will have a canceling effect. Also, the coils should be
mounted on insulated supports away from metal parts so they will not act like
induction heaters.
If an isolation contactor is used, put capacitors in front of contactor.
Fast acting current-limiting fuses are coordinated with the SCRs for protection of
the SCRs in the event of short circuits in the load. Refer to Figure 2.13 below for
recommended fuses.
Figure 2.13 - Fast Acting Current-limiting Fuses
Fuse SMC PLUS Rating
F
u
se
Manufacturer 150-A24 150-A35 150-A54 150-A97 150-A135
Shawmut A70P70 A70P100 A70P200 A70P300 A70P300
Buss SPP-4F60 SPP-4F100 SPP-4F150 SPP-4F300 SPP-4F300
Brush XL70F080 XL70F125 XL70F200 XL70F300 XL70F300
NOTES: 1. Fuse numbers are fuse manufacturers’ catalog number
2. Fuse size listed is for 230, 460 or 575 volt.
CAUTION: The fast acting current-limiting fuses specified in the
above table do not provide branch circuit protection. Branch circuit
protection in accordance with applicable electrical codes is required
even though fast acting current-limiting fuses are used.
!
Thermal motor overload protection is not provided unless specified with
non-combination controller. It can be separately provided. The overload trip time
should be greater than the acceleration time to avoid nuisance tripping.
CAUTION: Overload relays should be properly coordinated with the
motor.
!
A protective module containing metal oxide varistors (MOVs) and capacitors can be
installed to protect the power components from electrical transients and/or high
electrical noise. The protective modules clip transients generated on the lines and
prevent such surges from damaging the SCRs. The capacitors in the protective
modules are used to shunt noise energy away from the controller electronics.
WARNING: When installing or inspecting the protective module,
make sure the controller has been disconnected from the power source.
The protective module must be checked periodically for damage.
Inspect for damage or discoloration. Replace if necessary.
!
Power Factor
Capacitors
Fast Acting
Current-limiting
Fuses
Motor Overload
Protection
Protective Module
(optional)

Chapter Installation and Wiring
2-8
2
Figure 2.14 - Typical Application with a Single Speed, Reversing Starter
M
L1/1
L2/3
L3/5
T1/2
T2/4
T3/6
11 12 13 14
R
10 20 30 40 50 60 70 80 90
F
11 12 13 14
SMC PLUS Control Terminals
Optional
220/240 VAC Fan Power
Jumper
To Supply
SMC PLUS
Controller
Fan Power
(97A and
135A Only)
Auxiliary
Contacts
Power Input
3-Phase
O.L. ➀
➀➀
Branch
Protection
➀
R
➀
➀
➀
F➀
R➀
Stop ➀For Off Rev
➀
R➀
F➀
➀Customer Supplied
NOTE: Minimum transition time for
reversing direction is 1/2 second. Reversing Motor Starter
Figure 2.15 - Typical Application with a Two-Speed Motor Starter
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
1 sec.
1 sec.
11 12 13 14
SMC PLUS Control Terminals
Optional
220/240 VAC Fan Power
Jumper
To Supply
SMC PLUS
Controller
Fan Power
(97A and
135A Only)
Auxiliary
Contacts
➁
Power Input
3-Phase
➀
Branch
Protection
➀
➀
Stop ➀
➀
IC ➀
Two-Speed Motor Starter ➀
Low LOL
High HOL
High ➀Low ➀HL
L
L
H
HIC
➀
➀HOL ➀LOL ➀
L
H
➀
➀
➀Customer Supplied
➁Set auxiliary contacts for normal setting.

3
Chapter
Set-up Procedures: SMP PLUS
Controller without Options
During the “Starting” and “Running” modes, the controller’s microcomputer
monitors the following conditions. If any of the conditions exist, the controller
shuts down and lights the FAULT LED and the appropriate LED. The controller
provides the following protection:
•Start Fault •Temperature Fault
•Stalled Motor •Line Fault
Any fault condition will cause the auxiliary contacts to change over and hold in
circuit to release.
NOTE: The Fault LEDs remain ON as long as control power is applied to the
logic. If control power is removed, the controller resets and the LEDs turn
off.
The controller also has advisory LEDs. They indicate:
•Energy Saver Active •Running Mode
•Stopping Mode •Control Voltage Present
•Starting Mode
The Start Fault indicates an abnormal condition has been sensed. This is any fault
which causes faulty SCR firing (for example, open SCR gate). If the fault occurs in
this category, the controller will attempt to restart three times. After the third
unsuccessful start, the controller will go into a fault condition. The FAULT and
START LEDs light.
The controller is designed to sense motor stall in both the “Starting” and “Running”
modes. If during the “Starting” cycle, the controller senses that the motor is stalled
and the motor remains stalled, the controller shuts down in a predetermined time
based on the selected ramp time. In the “Running” mode, the controller will trip in
5 seconds in the event of a locked rotor condition. The FAULT and STALL LEDs
light. Starting stall trip times are illustrated in the table in Figure 3.1.
The stall option does not replace the need for properly coordinated overload relay
protection.
Figure 3.1 - Starting Stall Trip Characteristics
Soft Start — 2 5 10 20 25 30 — —
Start
Times
Current Limit — — — — — — — 15 30
Ti
mes
(sec.) Full Voltage 1/4 — — — — — — — —
(sec.)
Stall Trip Times (sec.) from Start 5 7 10 10 20 25 30 20 35
The microcomputer monitors the temperature of the SCRs by means of internal
thermistors. When the power poles’ maximum rated temperature is reached, the
microcomputer turns off the SCRs. The controller trips and the FAULT and TEMP
LEDs light.
An overtemperature condition could indicate inadequate ventilation, high ambient
temperature, overloading or excessive cycling.
If an overtemperature condition exists at start-up, the SCR gate signals will be
inhibited to guard against start-up, the controller will trip and the appropriate LEDs
light. After the SCR temperature is reduced to allowable levels, the fault can be
reset by removing and reapplying the control power.
Protective Features
Start Fault
Stalled Motor
Temperature
Fault

Chapter Set-up Procedures: SMP PLUS
Controller without Options
3-2
3
The line fault indicates an abnormal condition has been sensed in the line.
Conditions which will cause line fault indications are phase loss, open motor lead
and shorted SCR.
If detected in either the “Starting” or “Running” modes, the controller trips and the
FAULT and LINE LEDs light.
The controller has been factory-set for the following as shown in Figure 3.3:
•10 second soft start
•Energy Saver “OFF”
•Auxiliary Contacts “OFF” (Normal)
•Stall feature “OFF”
•Initial Torque 70%
•Kickstart “OFF”
When wired as indicated in the typical connection diagram, the controller operates
as follows:
Pressing the Start push button signals the controller to initiate the “Start” sequence,
provided the overload contacts are closed. The STARTING LED turns on, the
internal hold-in circuit latches across terminals 30 and 40, and the Form C auxiliary
contacts simultaneously change state (if so selected on the DIP switches). The
controller then applies voltage to the motor to an initial value. This voltage rise
continues (in the soft start mode) until the motor reaches full voltage or the motor is
up-to-speed. At that point, the RUNNING LED turns on and the STARTING LED
turns off. If “up-to-speed” auxiliary contacts are selected instead of normal
auxiliaries, these auxiliary contacts would change state at this time.
Figure 3.2 - Typical Connection Diagram for Standard Unit
10 20 30 40 50 60 70 80 90
SMC PLUS Control Terminals Auxiliary Contacts
Control Power
Stop ➀ ➁ Start ➀ ➁ O.L. ➀
➀Customer Supplied
➁For two wire control, remove stop/start
push buttons and connect two wire device
between terminals 10 and 40.
WARNING: Disconnect main power before servicing motor controller
or associated wiring. Hazardous voltages are present in the motor
circuit even when the solid-state controller is off.
!
Pressing the Stop push button signals the controller to initiate a shutdown. The
controller stops firing the SCRs allowing the load to stop. When the logic
completes its shutdown sequence, it releases the latch circuit across terminals 30
and 40, and the Form C auxiliary contacts change over. The RUNNING LED turns
off.
When an overload trip occurs the normally closed contact (wired into terminals 50
and 60) opens, causing the controller logic to shut off immediately.
Line Fault
Factory Settings
Start Sequence
Normal Stop
Sequence
Overload Trips

Chapter Set-up Procedures: SMP PLUS
Controller without Options
3
3-3
During the “Starting” and “Running” modes, the controller’s microcomputer
monitors the following conditions. If any of the conditions exist, the controller
shuts down, changes state of the auxiliary contacts, and turns on the FAULT LED
and the appropriate LED.
•Start Fault •Temperature Fault
•Line Fault •Stalled Motor
Once tripped, the controller cannot be restarted until control voltage is cycled. To
reset the controller, remove control power and reapply. (Refer to Page 3-1,
Protective Features, for additional details.)
After the controller has been installed, further set-up may be necessary. This set-up
is accomplished through DIP and rotary digital switches located on the front of the
controller. See Figure 3.3 below.
Figure 3.3 - Switch Access Door and Factory Switch Settings (Without
Options)
Not Used
Not Used
Auxiliary Contact Select Up to
Speed/Normal
Current Limit /Soft Start Select
Energy Saver Select (On/Off)
Starting Time*
Starting Time*
Starting Time*
Stall Trip Select (On/Off)
*NOTE: The time it takes for the motor to come up to speed may be less than the
start time setting and will vary depending on the frictional and inertial
characteristics of the system.
If the factory settings are not suitable for the specific application, Figures 3.5, 3.7,
and 3.8 which follow, describe how to set the standard unit for Soft Start with
Kickstart, Current Limit and Full Voltage Starting. Refer to the publications listed
in Figure 3.3.1 for instructions on how to set controller with options.
WARNING: Disconnect power before opening access door.
!
Use a small screwdriver to pry open the access door. Set the switches to meet
application requirements.
This starting method has the most general application. The motor voltage is raised
to an initial torque value. This is adjustable between 5 and 90% of locked rotor
torque. The motor voltage is gradually increased during the ramp period, which can
be adjusted from 2 to 30 seconds. These customer settings should be set for the
best starting performance over the required load range.
A kickstart or boost can be provided. This is intended to provide a current pulse of
500% of full load current and is adjustable from 0.4 to 2 seconds. This will allow
the motor to develop additional torque at start.
Fault Trips
Customer Settings
Figure 3.3.1 Publications
150-805
150-806
150-807
150-808
150-809
150-810
Soft Stop
Pump Control
Preset Slow Speed
Smart Motor Brkg.
Accu-Stop
Slow Speed w/Brkg.
Soft Start
Soft Start with
Kickstart

Chapter Set-up Procedures: SMP PLUS
Controller without Options
3-4
3
Customer Settings (continued)
Figure 3.4 - Soft Start with Kickstart
Start Time (seconds)
Kickstart (when selected)
Percent
Voltage
Initial
Torque
Run
100
1. Starting Time – Set switches 7–9 according to the period desired. For
example, if you want a ramp of 20 seconds, switch 7 would be ON and
switches 8 and 9 would be OFF
2. Kickstart Time – Set Kickstart Time rotary digital switch to the desired value
3. Initial Torque – Set Initial Torque rotary digital switch to the desired value
4. Current Limit/Soft Start – For soft start operation, switch 6 must be OFF
5.Energy Saver Select – Set switch 5 ON if you want the energy saver feature
(or OFF if you do not want this feature active)
6. Auxiliary Contact Select – Set switch 4 OFF if you want “normal” auxiliary
contacts; ON if you want “up-to-speed” auxiliary contacts
7. Stall Select – Set switch 3 ON if you want the stall feature (or OFF if you do
not want this feature active)
NOTE: For resistive load operation, switch 3 and switch 5 must be OFF
Figure 3.5 - Set-up Procedure for Soft Start (without Options)
Switch TIME (seconds)
Number 2 5 10 20 25 30
9ON Off ON Off ON Off
8Off ON ON Off Off ON
7Off Off Off ON ON ON
6Off
5ENERGY SAVER SELECT
4AUXILIARY CONTACT SELECT
3STALL SELECT
2NOT USED
1NOT USED
Initial Torque
Position 0 1 2 3 4 5 6 7 8 9
% of Licked Rotor Torque 5 10 20 30 40 50 60 70 80 90
Kickstart Time
Position 0 1 2 3 4 5 6 7 8 9
Time (Sec.) Off 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Soft Start Selection
without Options
EXAMPLE: DIP switch on
left is set for 20 second ramp

Chapter Set-up Procedures: SMP PLUS
Controller without Options
3
3-5
This starting mode is used when it is necessary to limit the maximum starting
current. This can be adjusted for 50 to 500% of full load amperes as shown in
Figure 3.6.
Figure 3.6 - Current Limit
500
Time (seconds)
Percent
Full
Load
Amps Start
50
Refer to Figure 3.7.
1. Starting Time – Set switches 7–9 according to the time desired. For example,
if you want current limit active for 30 seconds, switches 6 and 9 would be ON
and switches 7 and 8 would be OFF
2. Kickstart Time – Set Kickstart Time rotary digital switch to OFF
3. Current Limit/Soft Start – Switch 6 must be ON in the current limit mode.
Set Current Limit rotary digital switch accordingly. For example, if you want
to restrict the starting current to 300% of full load amperes, set rotary switch to
position 5
4. Energy Saver Select – Set switch 5 ON if you want the energy saver feature
(or OFF if you do not want this feature active)
5. Auxiliary Contact Select – Set switch 4 OFF if you want “normal” auxiliary
contacts, ON if you want “up-to-speed” auxiliary contacts
6.Stall Select – Set switch 3 ON if you want the stall feature (or OFF if you do
not want this feature active)
NOTE: For resistive load operation, switch 3 and 5 must be OFF
Figure 3.7 - Set-up Procedure for Current Limit (without Options)
Switch TIME (seconds)
Number 15 30
9Off ON
8Off
7Off
6ON
5ENERGY SAVER SELECT
4AUXILIARY CONTACT SELECT
3STALL SELECT
2NOT USED
1NOT USED
Current Limit
Position 0 1 2 3 4 5 6 7 8 9
% of Full Load Current 50 100 150 200 250 300 350 400 450 500
Kickstart Time
Position 0 1 2 3 4 5 6 7 8 9
Time (Sec.) Off 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Soft Start Selection
without Options
Current Limit Start
Selection without
Options
EXAMPLE: DIP switch is set
for 30 second current limit time

Chapter Set-up Procedures: SMP PLUS
Controller without Options
3-6
3
Customer Settings (continued)
This mode is used for applications requiring across the line starting. The ramp time
is set for less than 1/4 second as shown in Figure 3.8.
Figure 3.8 - Full Voltage
100
Time (seconds)
Percent
Voltage
Full Voltage Start Selection without Options
Refer to Figure 3.9.
1. Starting Time – For full voltage starting, switches 7–9 must be OFF. This
results in a ramp period of less than 1/4 second
2. Kickstart Time – Set Kickstart Time rotary digital switch to OFF
3. Initial Torque – Set Initial Torque rotary digital switch to 9
4.Current Limit/Soft Start – For full voltage starting, switch 6 must be OFF
5.Energy Saver Select – Switch 5 must be OFF. Energy Saver is not available
6.Auxiliary Contact Select – Set switch 4 OFF if you want “normal” auxiliary
contacts, ON if you want “up-to-speed” auxiliary contacts.
7. Stall Select – Set switch 3 ON if you want the stall feature (or OFF if you do
not want this feature active)
NOTE: For resistive load operation, switch 3 must be OFF
Figure 3.9 - Set-up Procedure for Full Voltage (without Options)
Switch TIME (seconds)
Number 1/4
9Off
8Off
7Off
6Off
5ENERGY SAVER SELECT
4AUXILIARY CONTACT SELECT
3STALL SELECT
2NOT USED
1NOT USED
Initial Torque
Position 0 1 2 3 4 5 6 7 8 9
% of Locked Rotor Torque 5 10 20 30 40 50 60 70 80 90
Kickstart Time
Position 0 1 2 3 4 5 6 7 8 9
Time (Sec.) Off 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Full Voltage
Starting
Full Voltage Start
Selection without
Options

4
Chapter Troubleshooting
For Bulletin 150 SMC Smart Motor Controller technical support on
start-up or existing installations, contact your Allen-Bradley representative.
In the United States you can also call 1-800-765-SMCS (765-7627) for
assistance during the hours of 8:00 am to 12:00 noon and 1:00 pm to 4:30
pm (Central Time Zone) from Monday through Friday.
For safety of maintenance personnel as well as others who might be exposed to
electrical hazards associated with maintenance activities, the safety related work
practices of NFPA 70E, Part II, should always be followed when working on
electrical equipment. Maintenance personnel must be trained in the safety practices,
procedures, and requirements that pertain to their respective job assignments.
WARNING: To avoid shock hazard, disconnect main power before
working on the controller, motor, or control devices such as Start/Stop
push buttons. Procedures which require parts of the equipment to be
energized during troubleshooting, testing, etc., must be performed by
properly qualified personnel, using appropriate work practices and
precautionary measures as specified in NFPA 70E, Part II.
!
CAUTION: Disconnect the controller from the motor before
measuring insulation resistance (IR) of the motor windings. Voltages
used for insulation resistance testing can cause failure of SCRs. Do not
make any measurements on the controller with an IR tester (megger).
!
NOTE: The time it takes for the motor to come up to speed may be less than the
Start Time setting and will vary depending on the frictional load and
inertial characteristics of the system.
NOTE: Depending on the application, the SMB Smart Motor Braking, Accu-Stop,
and Slow Speed with Braking options may cause some vibration or noise
during the stopping cycle and this may be minimized by lowering the
braking current. If this is a concern in your application, consult the factory
prior to applying these options.
Troubleshooting

Chapter Troubleshooting
4-2
4
Figure 4.1 - Motor will not start (no output voltage to motor)
Symptom Possible Causes Remedy
“CONTROL
VOLTAGE” LED On •Pilot devices
•Control voltage
•Failed control module
•Check wiring
•Check control voltage
•Replace control module
“CONTROL
VOLTAGE” LED Off •Control voltage not present
•Overload trip
•Failed control module
•Check for correct control voltage
•Check overload relay and heater element selection
•Replace control module
“START” LED On •Open gate circuitry •Perform resistance check; replace power module if necessary
“STALL” LED On •Motor rotor locked
•Stall select switch set incorrectly
•Failed control module
•Correct source of stall
•Check DIP switch #3 for correct setting
•Set stall feature off (DIP switch #3 to OFF) then attempt to start
motor
•Replace control module
LED “TEMP” On •Controller ventilation blocked
•Motor overloaded
•Controller duty cycle exceeded
•Fan failure (if used)
•Ambient temperature limit exceeded
•Failed Thermister
•Failed control module
•Check for proper ventilation
•Correct motor overload condition
•Check application duty cycle
•Check for correct fan operation, replace if necessary
•Wait for controller to cool or provide external cooling
•Replace Power Pole
•Replace control module
LED “LINE” On •Open line condition
•Phase Unbalance
•Motor not connected properly
•Shorted SCR
•Open gate resistors
•Motor instability
•Failed control module
•Check for open line (e.g., blown line fuse)
•Check power system
•Check for open load lead
•Check for shorted SCR, replace if necessary
•Perform resistance check; replace power module if necessary
•Check motor
•Replace control module
Figure 4.2 - Motor rotates but does not accelerate to full speed
Symptom Possible Causes Remedy
“CONTROL
VOLTAGE”
LED On •Mechanical problems •Check for binding or external loading and correct
•Repair or replace motor
LED
On
•Failed control module •Replace control module
“CONTROL
VOLTAGE”
LED Off •Control voltage not present
•Overload trip
•Failed control module
•Check for correct control voltage
•Check overload relay and heater element selection
•Replace control module
“START” LED On •Open gate circuitry •Perform resistance check; replace power module if necessary
“STALL” LED On •Motor rotor locked
•Stall select switch set incorrectly •Correct source of stall •Check DIP switch #3 for correct setting
•Set stall feature off (DIP switch #3 to OFF) then attempt to start
motor
•Failed control module •Replace control module
“TEMP”
LED On •Controller ventilation blocked
•Motor overloaded
•Controller duty cycle exceeded
•Fan failure (if used)
•Ambient temperature limit exceeded
•Failed Thermister
•Failed control module
•Check for proper ventilation
•Correct motor overload condition
•Check application duty cycle
•Check for correct fan operation, replace if necessary
•Wait for controller to cool or provide external cooling
•Replace Power Pole
•Replace control module
“LINE”
LED On •Open line condition
•Motor not connected properly
•Shorted SCR
•Failed control module
•Check for open line (e.g., blown line fuse)
•Check for open load lead
•Check for shorted SCR, replace if necessary
•Replace control module