Rockwell Automation SMC FLEX User manual

QUICK START
SMC™FLEX
BULLETIN 150
This guide provides you with the basic information required to start up your SMC Flex controller. When reading
this document, look for this symbol “Step x” to guide you through the four basic steps required to install, start-up,
and program the SMC Flex.
The information provided in this Quick Start guide does not replace the User Manual which can be ordered or
downloaded by visiting www.ab.com. The Quick Start guide assumes the installer is a qualified person with
previous experience and basic understanding of electrical terminology, configuration procedures, required
equipment, and safety precautions.
For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with
maintenance activities, follow all local safety related work practices (for example, the NFPA 70E, Part II in the
United States). Maintenance personnel must be trained in the safety practices, procedures, and requirements that
pertain to their respective job assignments.
For detailed SMC Flex information including set-up, programming, precautions, and application considerations,
refer to the following documentation.
For product technical support:
Title Publication Number Availability
SMC Flex User Manual 150-UM008* www.ab.com/literature
SMC Flex Application Guide 150-AT002* www.ab.com/literature
Online Support www.ab.com/support
Telephone Support 440-646-5800 (option 2, option 4 or use
direct dial code 804)

2SMC™ Flex Quick Start
Step 1 - Read the General Precautions
• Only personnel familiar with the controller and associated machinery should plan or implement the
installation, start-up, and subsequent maintenance of the system. Failure to do this may result in personal injury
and/or equipment damage.
• Hazardous voltage is present in the motor circuit even when the SMC-Flex controller is off. To avoid shock
hazard, disconnect main power before working on the controller, motor, and control devices such as Start-Stop
push buttons. Procedures that require parts of the equipment to be energized during troubleshooting, testing,
etc., must be performed by properly qualified personnel, using appropriate local safety work practices and
precautionary measures.
• Failure of solid state power switching components can cause overheating due to a single-phase condition in the
motor. To prevent injury or equipment damage, the use of an isolation contactor or shunt trip type circuit
breaker on the line side of the SMC is recommended. This device should be capable of interrupting the motor’s
lock rotor current.
• Hazardous voltages that can cause shock, burn, or death are present on L1, L2, L3, T1, T2, T3, T4, T5, and T6.
Power terminal covers for units rated 108…480 A can be installed to prevent inadvertent contact with
terminals. Disconnect the main power before servicing the motor controller, motor, or associated wiring.
!
WARNING

SMC™ Flex Quick Start 3
• The controller contains ESD- (electrostatic discharge) sensitive parts and assemblies. Static control precautions
are required when installing, testing, servicing, or repairing the assembly. Component damage may result if
ESD control procedures are not followed. If you are not familiar with static control procedures, refer to
applicable ESD protection handbooks.
• Stopping modes are not intended to be used as an emergency stop. The user is responsible for determining
which stopping mode is best suited to the application. Refer to the applicable standards for emergency stop
requirements.
• 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.
• Slow Speed running is not intended for continuous operation due to reduced motor cooling.
• The fan jumpers have been factory installed for 110/120V AC input. Refer to page 9 for 220/240V AC fan
wiring (5…480 A devices only).
• Two peripheral devices can be connected to the DPI port. The maximum output current through the DPI port is
280 mA.
• When installing or inspecting protective modules, make sure that the controller has been disconnected from the
power source. The protective module should be inspected periodically for damage or discoloration. Replace if
necessary.
• An incorrectly applied or installed controller can damage components or reduce product life. Wiring or
application errors such as under sizing the motor, over sizing the controller, incorrect or inadequate AC supply,
excessive ambient temperatures, or power quality may result in malfunction of the system.
• The Motor Overload parameter must be programmed by the installer to provide proper protection. Overload
configuration must be properly coordinated with the motor.
• This product has been designed and tested as Class A equipment for EMC compatibility. Use of the product in
domestic environments may cause radio interference, in which case, the installer may need to employ
additional mitigation methods.
• Disconnect the controller from the motor before measuring insulation resistance (IR) of the motor windings.
Voltages used for insulation resistance testing can cause SCR failure. Do not make any measurements on the
controller with an Insulation Resistance (IR or Megger) tester.
NOTICE

4SMC™ Flex Quick Start
Step 2 - Installation
Mounting
Controllers rated 625…1250 A
Device must be lifted only at the designated lift points identified with labels.
Enclosure Ratings
Standard Device Rating IP00 (NEMA Open Type)
Minimum Required Enclosure IP23 (NEMA Type 1)
Recommended Enclosure IP54 (NEMA Type 12), sizing guide in User Manual
Enclosure Internal Temperature -5…50 °C (23…122 °F)
Orientation and Clearance
Mounting Orientation Vertical
Minimum horizontal clearance 0 cm (0 in.)
Minimum vertical clearance 15 cm (6 in.)
Lifting Points

SMC™ Flex Quick Start 5
Dimensions
For detailed dimensions, please refer to the SMC Flex User Manual.
Dimensions are in millimeters (inches).
Controller Rating [A] Height (B) Width (A) Depth (C) Approximate Shipping
Weight
5…85 321.0 (12.60) 150.0 (5.90) 203.0 (8.00) 5.7 kg (12.5 lb)
108…135 443.7 (17.47) 196.4 (7.74) 212.2 (8.35) 15.0 kg (33.0 lb)
201…251 560.0 (22.05) 225.0 (8.86) 253.8 (9.99) 30.4 kg (67.0 lb)
317…480 600.0 (23.62) 290.0 (11.42) 276.5 (10.89) 45.8 kg (101 lb)
625…780 1041.1 (41.00) 596.9 (23.50) 346.2 (13.63) 179 kg (395 lb)
970…1250 1041.1 (41.00) 596.9 (23.50) 346.2 (13.63) 224 kg (495 lb)
23 24 25 26 27 28 29 30 31 32 33 34
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Lang
TM
Esc Sel
C
A
B

6SMC™ Flex Quick Start
Power Wiring
Refer to the product nameplate or the SMC Flex User Manual for device specific information.
Control Terminals
SMC Rating
[A]
Lug Kit
Cat. No.
Wire Strip
Length
Conductor
Range
Max. No. Lugs/Pole Tightening Torque
Line Side Load Side Wire - Lug Lug - Busbar
5…85 — 18…20 mm 2.5…85 mm2
(#14…3/0 AWG) ——
11.3 N•m
(100 lb•in) —
108…135 199-LF1 18…20 mm 16…120 mm2
(#6…250 MCM) 11
31 N•m
(275 lb•in)
23 N•m
(200 lb•in)
201…251 199-LF1 18…20 mm 16…120 mm2
(#6…250 MCM) 22
31 N•m
(275 lb•in)
23 N•m
(200 lb•in)
317…480 199-LG1 18…25 mm 25…240 mm2
(#4…500 MCM) 22
42 N•m
(375 lb•in)
28 N•m
(250 lb•in)
625…780 100-DL630 32 mm/64 mm 70…240 mm2
(2/0…500 MCM) 22
45 N•m
(400 lb•in)
68 N•m
(600 lb•in)
970 100-DL860 26 mm/48 mm 120…240 mm2
(4/0…500 MCM) 11
45 N•m
(400 lb•in)
68 N•m
(600 lb•in)
1250
100-DL630 32 mm/64 mm 70…240 mm2
(2/0…500 MCM) 11
45 N•m
(400 lb•in)
68 N•m
(600 lb•in)
100-DL860 26 mm/48 mm 120…240 mm2
(4/0…500 MCM) 11
Terminal Description Terminal Description Footnotes
11➂➃ Control Power Input (+) 23➀PTC Input
➀Do not connect any additional loads to these
terminals. These “parasitic” loads may cause
incorrect operation.
➁When set for External Bypass mode, the SMC
Flex can be used to control a properly sized
external contactor and overload once the motor
reaches full speed. The SMC-Flex overload
functionality is disabled in this mode.
➂RC Snubbers are required on inductive type
loads connected to auxiliary contacts.
➃Control power on units rated 625…1250 A is
pre-wired internally, from terminal block CP1.
12➂➃ Control Power Common 24➀PTC Input
13➀Controller Enable Input 25 Tachometer Input
14 Ground 26 Tachometer Input
15➀➂ Option Input #2 27➀Ground Fault Transformer Input
16➀➂ Option Input #1 28➀Ground Fault Transformer Input
17➀➂ Start Input 29➁➂ Aux Contact #2
18➀➂ Stop Input 30➁➂ Aux Contact #2
19➁➂ Aux Contact #1 31➁➂ Aux Contact #3
20➁➂ Aux Contact #1 32➁➂ Aux Contact #3
21 Not Used 33➁➂ Aux Contact #4
22 Not Used 34➁➂ Aux Contact #4
23 24 25 26 27 28 29 30 31 32 33 34
11 12 13 14 15 16 17 18 19 20 21 22

SMC™ Flex Quick Start 7
Control Wiring
Refer to the product nameplate for additional details. Depending on the specific application, additional control
circuit transformer VA capacity may be required.
Controllers rated 5…480 A
Control power is connected to the product through terminals 11 and 12.
Controllers rated 625…1250 A
Control power is connected to the product through terminal block CP1, at terminals 1 and 4.
Conductor Range 0.75…2.5 mm2(18…14 AWG)
Torque 0.6 N•m (5 lb•in)
Maximum Number of Wires per Terminal 2
AC Control Voltage Input 100…240V AC or 24V AC (+10/-15%)
Supply Type 1-phase, 50/60 Hz
24V AC Power Requirement 130VA
100…240V AC Power Requirement 75VA
DC Control Voltage Input 24V DC (+10/-15%)
Inrush Current 5 A
Inrush Time 250 ms
Transient Watts 60 W
Transient Time 500 ms
Staedy State Watts 24 W
Recommended Supply 1606-XLP50E
Fan Power Input (AC only) separately wired
F5…F135 20VA
F201…F251 40VA
F317…F480 60VA
Conductor Range 0.75…2.5 mm2(18…14 AWG)
Torque 0.6 N•m (5 lb•in)
Maximum Number of Wires per Terminal 2
Control Voltage Input 110/120V AC or 230/240V AC, (+10/-15%)
Supply Type 1-phase, 50/60 Hz
Control Power Input 800VA (includes controller, bypass, and fans)

8SMC™ Flex Quick Start
Typical Wiring Diagrams
Typical Power Wiring Examples
L1 L2 L3
T1 T2 T3
Motor
T6 T4 T5
K1
L1 L2 L3
T1 T2 T3
Motor
K1
Diagrams per NEMA Symbology
Delta Connection with
Isolation Contactor
(Optional Mode)
Line Connection with
Isolation Contactor
(Default Mode)
2
1
4
3
6
5
L1 L2 L3
M
3
2
U
K1
2
1
1
4
V
4
3
3
6
W
6
5
5
M
3
L1
2
K1
1
2
1
L2
4
3
4
3
L3
6
2
1
4
3
6
5
5
6
5
U1V1W1
W2
U2
V2
Diagrams per IEC Symbology
L1 L2 L3
T1 T2 T3
Motor
T6 T4 T5
Delta Connection with
Shorted SCR Protection
(Optional Mode)
K1
Delta Connection with
Isolation Contactor
(Optional Mode)
Line Connection with
Isolation Contactor
(Default Mode)
Delta Connection with
Shorted SCR Protection
(Optional Mode)
M
3
L1
2
1
L2
4
3
L3
2
1
4
3
6
5
6
5
U1V1W1W2U2V2
2
K1
1
4
3
6
5

SMC™ Flex Quick Start 9
Typical Control Wiring Examples
11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26
SMC Flex Control Terminals
Aux#1
Aux#4
27 28 29 30 31 32 33 34
Aux#3Aux#2
Hold In
11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26
SMC Flex Control Terminals
Aux#1
Aux#4
27 28 29 30 31 32 33 34
Aux#3Aux#2
Hold In
2 Wire
Device
Up-to-Speed
Indication
Fault
Indication
L1 (L+)
N (L-)
Programming Notes:
Aux#4 – Set for Fault
Parameter#132 – Set for Diable
Programming Notes:
Aux#1 – Set for Normal
Aux#4 – Set for Up to Speed
FAN
Start
L1 (L+)
N (L-)
FAN
K1 A1
A2
Stop
Connection Required
for DPI Control
Fig 1.x
3 Wire Control (With or Without DPI control), Isolation Contactor (K1),
and Up-to-Speed Indication
Fig 1.x
2 Wire Control (No DPI control or Option Stopping) with Fault Indication
Fan Power Terminations Example
(Separately Wired for F5...F480 Devices)
1
2
3
4
Factory Default Position
110/120 VAC
Optional Configuration
220/240 VAC
Jumpers
Supply
1
2
3
4
Supply Jumper

10 SMC™ Flex Quick Start
Typical Control Wiring Examples, Continued
11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26
SMC Flex Control Terminals
Aux#1
Aux#4
27 28 29 30 31 32 33 34
Aux#3Aux#2
Hold In
11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26
SMC Flex Control Terminals
Aux#1
Aux#4
27 28 29 30 31 32 33 34
Aux#3Aux#2
Hold In
Alarm
Indication
Programming Notes:
Aux#1 – Set for Normal
Aux#4 – Set fot Alarm
Start
L1 (L+)
N (L-)
FAN
K1 A1
A2
Stop
Fig 1.x
3 Wire Control with Option Stopping, DPI control, Isolation Contactor (K1),
and Alarm Indication
Option Stop
Programming Notes:
Aux#1 – Set for Normal
Parameter
#87 - Logic Mask must be set for DPI Control.
- Value of 4 enables HIM control only
- Value of 32 enables Communication Port control only
- Value of 44 enables ALLDPI ports for control
L1 (L+)
N (L-)
FAN
K1 A1
A2
Fig 1.x
Start and Stop Control via DPI Communication ONLY with Isolation
Contactor (K1)