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Rockwell Automation Allen-Bradley SMC-PLUS Bulletin 150, Installation Manual

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Rockwell Automation Allen-Bradley SMC-PLUS Bulletin 150 Installation Manual Download Page 24

Chapter

Troubleshooting

4-6

4

7.

Measure resistance between pins 2 and 3.  Resistance should be less than 100
ohms.

8.

Measure resistance between pins 6 and 7.  Resistance should be less than 100
ohms.

9.

Measure resistance between pins 4 and 5.  Resistance should be less than 250
ohms.

If the power module fails for any of the above tests, replace it.
The gold interconnection pins on the power module are protected with a special
contact lubricant.  

Do not clean or wipe these pins.

  This contact lubricant is

necessary for proper operation.  Inspect  each pin prior to assembly of the control
module.  If the lubricant is missing, apply a thin film of the recommended contact
lubricant.
The Allen-Bradley approved contact lubricant is NYOGEL 759G, manufactured by
William F. Nye, Inc., Specialty Lubricants, New Bedford, MA 02742  U.S.A.

Figure 4.6 - Pin Locations for Power Module Resistance Check

2

3

7

6

1

4

8

5

Renewal Parts

Description

Controller Rating

Line Voltage Rating

Part Number

Control Module (Standard)

All

All

40888-899-01

Preset Slow Speed

All

All

40888-899-03

Soft Stop

All

All

40888-899-02

Pump Control

All

All

40888-899-14

SMB

Smart Motor Braking

24A-54A

97A-135A

All

40888-899-09
40888-899-10

Accu-Stop

24A-54A

97A-135A

All

40888-899-04
40888-899-05

Slow Speed with Braking

24A-54A

97A-135A

All

40888-899-15
40888-899-16

Power

Modules

24A

35A

54A

97A

135A

 

200-480
200-600

200-480
200-600

200-480
200-600

200-480
200-600

200-480
200-600

40382-899-02
40382-899-04

40382-899-03
40382-899-04

40382-899-03
40382-899-04

40382-806-01
40382-806-02

40382-806-03
40382-806-04

Fan

97A-135A

All

40382-807-01

Power Module

Resistance Check

(continued)

Summary of Contents for Allen-Bradley SMC-PLUS Bulletin 150

Page 1: ...ollers 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 ...

Page 2: ......

Page 3: ...e 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 Ven...

Page 4: ...otor 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 ...

Page 5: ...eductions 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 dis...

Page 6: ... 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 dimen...

Page 7: ...ntrol Wiring and Tightening Torque Wire Size Torque Metric 1 5 4 mm2 3 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 Fig...

Page 8: ...hanical 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 ...

Page 9: ...11 12 13 14 Customer Supplied Customer wires fan to control voltage supply Jumpers are arranged for 110 120 VAC fan power Set 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...

Page 10: ...res fan to control voltage supply Jumpers are arranged for 110 120 VAC fan power For two wire control remove stop start push buttons and connect two wire device between points A and B Set 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 ...

Page 11: ...0P70 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 accorda...

Page 12: ...Rev R F Customer 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 Au...

Page 13: ...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 optio...

Page 14: ...ntil 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 Con...

Page 15: ...ing 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 Disconne...

Page 16: ...r 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 O...

Page 17: ...t 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 resis...

Page 18: ... 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...

Page 19: ...es 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 u...

Page 20: ...ystem 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...

Page 21: ...tly 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 Cor...

Page 22: ...he motor Motor surges still occur with soft stop option Misapplication The soft stop option is intended for loads that stop suddenly when voltage is removed from the motor Refer to Publication 150 806 Pump Control Option Motor overheats Duty Cycle Preset Slow Speed Option Extended operation reduces motor cooling efficiency Consult motor manufacturer for limits of operation Smart Motor Brake Option...

Page 23: ... Bedford MA 02742 U S A To install control module follow the reverse order for removal Figure 4 5 Removal of Control Module 1 2 If a power module needs to be checked use the following procedure WARNING To avoid shock hazard disconnect main power before working on the controller motor or control devices such as Start Stop push buttons CAUTION Make sure that wires are properly marked and DIP switch ...

Page 24: ... is NYOGEL 759G manufactured by William F Nye Inc Specialty Lubricants New Bedford MA 02742 U S A Figure 4 6 Pin Locations for Power Module Resistance Check 2 3 7 6 1 4 8 5 Renewal Parts Description Controller Rating Line Voltage Rating Part Number Control Module Standard All All 40888 899 01 Preset Slow Speed All All 40888 899 03 Soft Stop All All 40888 899 02 Pump Control All All 40888 899 14 SM...

Page 25: ...Publication 150 811 April 1996 Supersedes Publication 150 811 October 1992 Copyright 1996 Allen Bradley Company Inc a Rockwell International company Printed in USA ...

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