Rockwell Automation SMC-Flex Page 149 User Manual Download

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Appendix

Renewal Parts

➀

One piece provided per part number.

➁

Three-phase power pole structure provided per part no.

➂

One-phase power pole provided per part no.

➃

See Appendix D for special installation instructions.

Description

SMC Rating

Part No.

➀

For units rated 200…600V AC

For units rated 690V

100…240V AC

24V AC/DC

100…240V AC

Control Modules

Standard

All

41391-454-01-S1FX

41391-454-02-S2FX

41391-454-05-S1FZ

Pump

All

41391-454-01-B1FX

41391-454-02-B2FX

41391-454-05-B1FZ

Braking

5…85 A

41391-454-01-D1AX 41391-454-02-D2AX 41391-454-05-D1AZ

108…251 A

41391-454-01-D1BX 41391-454-02-D2BX 41391-454-05-D1BZ

317…480 A

41391-454-01-D1CX 41391-454-02-D2CX 41391-454-05-D1CZ

625…780 A

41391-454-01-D1DX

N/A

41391-454-05-D1DZ

970…1250 A

41391-454-01-D1EX

N/A

41391-454-05-D1EZ

Description

SMC Rating

Series

Part No.

➀

Line Voltage

200…480V

200…600V

230…690V

Power Poles

5 A

150-FPP5B

➁

150-FPP5C

➁

N/A

25 A

150-FPP25B

➁

150-FPP25C

➁

N/A

43 A

150-FPP43B

➁

150-FPP43C

➁

N/A

60 A

150-FPP60B

➁

150-FPP60C

➁

N/A

85 A

150-FPP85B

➁

150-FPP85C

➁

N/A

108 A

150-FPP108B

➁

150-FPP108C

➁

150-FPP108Z

➁

135 A

150-FPP135B

➁

150-FPP135C

➁

150-FPP135Z

➁

201 A

150-FPP201B

➂

150-FPP201C

➂

150-FPP201Z

➂

251 A

150-FPP251B

➂

150-FPP251C

➂

150-FPP251Z

➂

317 A

150-FPP317B

➂

150-FPP317C

➂

150-FPP317Z

➂

361 A

150-FPP361B

➂

150-FPP361C

➂

150-FPP361Z

➂

480 A

150-FPP480B

➂

150-FPP480C

➂

150-FPP480Z

➂

625 A

150-FPP625B

➂

150-FPP625C

➂

150-FPP625Z

➂

780 A

150-FPP780B

➂

150-FPP780C

➂

150-FPP780Z

➂

970 A

150-FPP970B

➂

150-FPP970C

➂

150-FPP970Z

➂

1250 A

150-FPP1250B

➂

150-FPP1250C

➂

150-FPP1250Z

➂

Heatsink Fans

5…85 A

41391-801-03

108…135 A

41391-801-03

201…251 A

41391-801-01

317…480 A

41391-801-02

110/120V AC

Control Power

625…1250 A

41391-801-04

230/240V AC

Control Power

625…1250 A

41391-801-05

Base Plate

201…251 A

41391-803-01

317…480 A

41391-803-02

By-Pass

Contactor

110/120V AC

Control Power

625…780 A

100-D180ED11

➃

970…1250 A

100-D420ED11

➃

230/240V AC

Control Power

625…780 A

100-D180EA11

➃

970…1250 A

100-D420EA11

➃

Summary of Contents for SMC-Flex

Page 1: ...USER MANUAL FOR SERIES B SMC Flex BULLETIN 150...

Page 2: ...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...

Page 3: ...ive 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 Dire...

Page 4: ...Notes...

Page 5: ...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 Unbalan...

Page 6: ...ire Specifications 3 11 Fan Power 3 11 Fan Terminations 3 11 Control Terminal Designations 3 12 Standard Controller Wiring Diagrams 3 13 Soft Stop Pump Control and SMB Smart Motor Braking 3 24 Preset...

Page 7: ...ations Overview 7 1 Communication Ports 7 1 Human Interface Module 7 2 Keypad Description 7 2 Connecting the Human Interface Module to the Controller 7 4 HIM Control Enable 7 4 Control Enable 7 6 Loss...

Page 8: ...tings A 2 Short Circuit Protection A 3 Environmental A 5 Mechanical A 5 Other A 6 Approximate Dimensions and Shipping Weights A 6 Open Type Controllers A 6 Enclosed Type Line Connected Controllers A 7...

Page 9: ...ith 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 requ...

Page 10: ...neral 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 inc...

Page 11: ...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...

Page 12: ...orque settings Figure 1 4 Dual Ramp Start Dual Ramp Start is available only with the standard controller Full Voltage Start This starting mode is used for applications requiring across the line starti...

Page 13: ...se 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...

Page 14: ...speed to full speed Kickstart is available with this option Figure 1 7 Linear Speed Acceleration Kickstart is also available with Linear Speed Acceleration The Linear Stop does not need to be set up e...

Page 15: ...e 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 Start Run 100 Initial Torque Percent V...

Page 16: ...roprocessor 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...

Page 17: ...raking current setting from 0 to 400 of the motor s full load current rating Further it provides automatic shut off at zero speed detection Figure 1 10 SMB Smart Motor Braking Option Note All braking...

Page 18: ...preset slow speed setting then brakes to stop Figure 1 11 Accu Stop Option Slow Speed with Braking Option The Slow Speed with Braking option provides a jog speed for process set up and braking to stop...

Page 19: ...The motor s full load current rating must be programmed to properly set overload protection 2 Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme The...

Page 20: ...Time seconds Approximate Trip Time seconds Approximate Trip Time seconds 1 0 10 0 100 0 1000 0 10000 0 1 10 2 3 9 8 7 6 5 4 0 1 1 0 10 0 100 0 1000 0 1 10 2 3 9 8 7 6 5 4 1 0 10 0 100 0 1000 0 10000...

Page 21: ...ip setting from 0 199 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to f...

Page 22: ...lose to faulting The alarm modification information is displayed through the LCD HIM Communication if applicable and alarm contact closing Jam detection allows the user to determine the jam level up t...

Page 23: ...n of enabling Ground Fault Trip Ground Fault Alarm or both For the 5 480 Amp devices the recommended sensor is a Cat No 825 CBCT core balance current transformer for 1 5 A core balanced ground fault p...

Page 24: ...ustable from 1 0 5 0 A or 5 0 25 A depending on the service size Important The ground fault inhibit timer starts after the maximum phase of load current transitions from 0 A to 30 of the device s mini...

Page 25: ...d high ambient temperatures The following table defines the SMC Flex PTC thermistor input and response ratings Table 1 A PTC Input Ratings The following figure illustrates the required PTC sensor char...

Page 26: ...indicate inadequate ventilation high ambient temperature overloading or excessive cycling After the temperature is reduced to allowable levels the fault can be cleared Open Gate An open gate fault ind...

Page 27: ...fault occurs when this value reaches 100 I O The SMC Flex has the ability to accept up to two 2 inputs and four 4 outputs controlled over a network The two inputs are controlled at terminal 16 Option...

Page 28: ...built in keypad and three line sixteen character backlit LCD Parameters are organized in a three level menu structure using a text format for straightforward programming Figure 1 20 Built in Keypad a...

Page 29: ...C Alarm N O N C Fault N O N C Network Control N O N C External Bypass N O Figure 1 21 Control Terminals Network inputs can be obtained through proper programming of Option Input 1 and Option Input 2 1...

Page 30: ...1 22 Product Overview Notes...

Page 31: ...uld any concealed damage be found during unpacking it is again the responsibility of the user to notify the freight agent The shipping container must be left intact and the freight agent should be req...

Page 32: ...1250 A the device should only be lifted from designated lifting points The lifting points are designed to accept a 13 threaded hoist ring capable of lifting 2500 pounds These points are identified in...

Page 33: ...TTENTION An incorrectly applied or installed controller can damage components or reduce product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or exc...

Page 34: ...06 16 254 10 85 610 24 406 16 254 10 108 762 30 610 24 305 12 135 762 30 610 24 305 12 201 965 38 762 30 356 14 251 965 38 762 30 356 14 317 1295 51 914 36 356 14 361 1295 51 914 36 356 14 480 1295 51...

Page 35: ...through the power module The controller must be mounted in a vertical plane and have a minimum of 15 cm 6 in free space above and below the controller When drilling or installing near the softstarter...

Page 36: ...not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings Unit A Width B Height C Depth D E F H Approx Ship Wt 5 85 A Controller mm 150 1 30...

Page 37: ...e not intended for manufacturing purposes Consult your local Allen Bradley distributor for complete dimension drawings Unit A Width B Height C Depth D E F G Approx Ship Wt 108 135 A Controller mm 196...

Page 38: ...Wt 201 251 A Controller mm 225 560 253 8 150 504 1 157 25 91 189 44 311 79 811 30 4 kg in 8 858 22 047 9 992 5 906 19 847 6 2 3 59 1 74 3 14 67 lb 157 25 6 2 6 4 250 253 8 9 992 40 9 1 6 C F 1 000 13...

Page 39: ...y distributor for complete dimension drawings Unit A Width B Height C Depth D E F G H I Approx Ship Wt 317 480 A Controller mm 290 600 276 5 200 539 18 182 25 104 5 55 5 103 5 45 8 kg in 11 42 23 62 1...

Page 40: ...1 6 1 20 1 20 30 5 30 5 21 69 21 69 550 9 550 9 1 64 1 64 41 6 41 6 7 89 7 89 200 4 200 4 23 39 23 39 594 1 594 1 38 45 38 45 976 6 976 6 90 90 23 23 13 63 13 63 346 2 346 2 2X 2X 25 25 6 4 6 4 78 78...

Page 41: ...1 6 90 90 23 23 21 69 21 69 550 9 550 9 23 50 23 50 596 9 596 9 3X 3X 15 15 3 8 3 8 13 86 13 86 351 9 351 9 14 54 14 54 369 4 369 4 19 54 19 54 496 3 496 3 29 02 29 02 737 737 4 57 4 57 116 2 116 2 8...

Page 42: ...ling effect Also mount the coils on insulated supports away from metal parts so they will not act as induction heaters If an isolation contactor is used put capacitors in front of contactor Note For f...

Page 43: ...ideration two speed motors and multi motor protection Two speed Motors The SMC Flex controller has overload protection available for single speed motors When the SMC Flex controller is applied to a tw...

Page 44: ...dditional Requirements If linear acceleration is used a separate conduit or wire way should be used for the tachometer leads Wire earth ground to control terminal 14 Use shielded wire for PTC Tachomet...

Page 45: ...3 5 Load connections to Line motors are made to T1 2 T2 4 and T3 6 while load connections to Wye Delta motors are made to T1 2 T2 4 T3 6 T4 8 T5 10 and T6 12 Figure 3 1 Wiring Terminal Locations 5 85...

Page 46: ...ure 3 2 Wiring Terminal Locations 108 480 A 4 1 5 3 2 3 3 Table 3 A Wiring Terminal Locations 1 Incoming Line Termination 2 Line Motor Connections 3 Delta Motor Connections 4 Control Terminations 5 Fa...

Page 47: ...ulled in all at once The SMC Flex product also has a Current Transformer CT built in on each phase of the motor to provide current readings Power Wiring Refer to the product nameplate or User Manual f...

Page 48: ...an isolation contactor be added to the circuit to provide galvanic isolation of the motor and final electro mechanical removal of power Figure 3 5 ATTENTION Failure of solid state power switching com...

Page 49: ...figured as a line connection Table 3 D lists the recommended lugs when using the SMC Flex with a delta connection Note that devices rated 625 1250 A require the use of a power distribution block when...

Page 50: ...3 N m 100 lb in 108 135 A 199 LF1 18 20 mm 16 120 mm2 6 250 MCM 1 1 31 N m 275 lb in 23 N m 200 lb in 201 251 A 199 LF1 18 20 mm 16 120 mm2 6 250 MCM 2 2 31 N m 275 lb in 23 N m 200 lb in 317 480 A 19...

Page 51: ...s are shown in Table 3 E The fans require additional power as defined in Table 3 G Table 3 E Control Module Requirements Controllers rated 625 1250 A For controllers rated 625 1250 A common control is...

Page 52: ...ngs for 625 1250 A Devices SEE NAMEPLATE FOR STATUS LED 240 208 220 PICK UP NOMINAL VOLTAGE NOMINAL VOLTAGE 85 115 DROP OUT PICK UP 0 95 10 0 1 SEC TIME DELAY PICK UP 10 0 1 SEC TIME DELAY DROP OUT GE...

Page 53: ...A1 C O N T A C T O R A UV RELAY S M C F L E X C O N T R O L M O D U L E 14 13 22 21 A2 C A1 C O N T A C T O R B 14 13 22 21 A2 C A1 C O N T A C T O R C 1112131415 16171819 202122 2324 252627282930 31...

Page 54: ...A C T O R A S M C F L E X C O N T R O L M O D U L E C O N T A C T O R B C O N T A C T O R C F A N A F A N B F A N C C O N T A C T O R F A N IN P U T 1 2 0 V A C 1112131415 16171819 202122 2324 2526272...

Page 55: ...tions Figure 3 9 Power Terminations Table 3 G Heatsink Fan Control Power Internally wired Wire Size Torque Wire Strip Length 0 75 2 5 mm2 18 14 AWG 0 6 N m 5 lb in 5 6 8 6 mm 0 22 0 34 in ATTENTION Th...

Page 56: ...d functionality diagnostics and metering are disabled when the external bypass is activated Proper sizing of the contactor and overload is required Control power on units rated 625 1250 A is pre wired...

Page 57: ...nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 11 12 13 14 15 16 17 18 19 20...

Page 58: ...1 4 Notes 1 Programmable controller interfacing in this diagram refers to hard wiring between the PLC s output contacts and the SMC Flex controller s control terminals 2 The OFF state leakage current...

Page 59: ...11 12 are factory pre wired from terminal block CP1 terminals 1 4 Note The Dual Ramp feature is available only with the standard control version 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29...

Page 60: ...properly configured see Chapter 8 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 12 are factory pre...

Page 61: ...voltage For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Aux 4 should be set for normal operation 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27...

Page 62: ...5 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Aux 4 should be set for normal operation 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 22 34 SM...

Page 63: ...rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Aux 2 should be set to fault operation 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 22...

Page 64: ...ing manuever allowed in wiring diagram Maintained pushbutton Notes 1 Minimum transition time for reversing direction is 1 2 second 2 Phase Reversal protection must be disabled in reversing application...

Page 65: ...A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Overload must be disabled in SMC Flex 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 22 34 SMC Flex Co...

Page 66: ...625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 22 34 L1 1 L3 5 L2 3 T3 6 T2 4 T1 2 M 3 Phase...

Page 67: ...ate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 11 12 13 14 15 16 17 18 19 20 21 23 2...

Page 68: ...p Stop or Brake Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 termi...

Page 69: ...age For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Soft Stop Pump Stop or Brake Aux 4 should be set to normal operation Note Refer to Chapter 3...

Page 70: ...ts rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Soft Stop Pump Stop or Brake Aux 4 should be set to normal operation Note Refer to Chapter 3 for typical...

Page 71: ...Only Customer supplied 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 22 34 L1 1 L3 5 L2 3 T3 6 T2 4 T1 2 M 3 Phase Input Power Branch Protection SMC Flex Controller H A Control Pow...

Page 72: ...te to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Slow Speed Note Refer to Chapter 3 for...

Page 73: ...ated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 terminals 1 4 Aux 4 should be set to normal operation 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 22...

Page 74: ...stomer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 12 are factory pre wired from terminal block CP1 termi...

Page 75: ...Figure 3 29 Soft Stop Sequence of Operation Start Run 100 Motor Speed Time seconds Soft Stop Coast to rest Soft Stop Push Buttons Start Stop Soft Stop Auxiliary Contacts Normal Closed Open Open Closed...

Page 76: ...Sequence of Operation Start Run 100 Motor Speed Time seconds Up to speed Auxiliary Contacts Push Buttons Normal Slow Speed Stop Start Closed Closed Open Closed Open Closed Open Open Closed Open 7 or 1...

Page 77: ...n Closed Open Closed Open Closed Open Closed Open Start Auxillary Contacts Time in Seconds If the Pump Stop is Selected If the Coast to Rest is Selected Pump Stop Run Pump Start 1 ATTENTION The user i...

Page 78: ...losed Open Closed Open Start Auxillary Contacts Time in Seconds Run Coast to Rest Smart Motor Braking Start Start Automatic Zero Speed Shut Off If Brake Selected If Coast to Rest Selected Stop Option...

Page 79: ...ow Speed Slow Speed Braking Accu Stop Push Buttons Auxiliary Contacts Up to speed Normal Stop Start Closed Open Open Closed Open Closed If Coast to rest Selected Slow Speed Braking Slow Speed Coast to...

Page 80: ...ed on the lines and prevent such surges from damaging the SCRs 100 Up to Speed Normal Slow Speed Stop Motor Speed Push Buttons Closed Open Closed Open Closed Open Closed Open Closed Open Start Auxilla...

Page 81: ...chanical brakes Lightning can also cause spikes 2 The second situation arises when the SMC Flex controller is installed on a system that has fast rising wavefronts present although not necessarily hig...

Page 82: ...tures should be turned off Separate overloads are still required to meet the National Electric Code NEC requirements Note The SMC Flex controller s built in overload protection cannot be used in multi...

Page 83: ...able in the bypass mode Figure 3 37 Typical Application Diagram of a Bypass Contactor for an AC Drive M 3 Phase Input Power VFD Branch Protection VFD L1 1 L3 5 L2 3 T1 2 T3 6 T2 4 SMC Flex Controller...

Page 84: ...ical Application Diagram of SMC Flex Controller with a Bulletin 1410 Motor Winding Heater M 3 Phase Input Power L1 1 L3 5 L2 3 T1 2 T3 6 T2 4 SMC Flex Controller IC O L HC Bulletin 1410 MWH Customer s...

Page 85: ...rogramming Menu Parameters are organized in a three level menu structure for straightforward programming Figure 4 1 details the programming menu structure and the three level hierarchy In order to cha...

Page 86: ...r Memory Storage Preferences Diagnostics Select 0 Monitoring Set Up Motor Protection Communications Utility Linear LIst 0 SMC FLEX 0 Reset to Defaults 0 Change Password User Dspl Line User Dspl Time U...

Page 87: ...Input Underload A Lvl Ground Fault Data In D1 Motor Speed Stop Mode Underload A Dly Data In D2 Stop Time Parameter Mgt Gnd Flt Enable Data Out A1 Braking Current Gnd Flt Lvl Data Out A2 Overload Class...

Page 88: ...er Mgmt 20 Cur Limit Start 68 Jam F Dly 116 Backspin Timer 21 Reserved 69 Jam A Lvl 117 VShut Off Level 22 Kickstart Time 70 Jam A Dly 118 OL Reset Level 23 Kickstart Level 71 Stall Delay 119 Ambient...

Page 89: ...ntil the Preferences option is highlighted 3 Press the Enter key to access the Preferences menu 4 Scroll with the Up Down keys until the Change Password option is highlighted 5 Press the Enter key 6 P...

Page 90: ...power is lost prior to the enter key being pressed these values will be lost When the device first powers up the values from the EEPROM area of memory are copied into RAM Read only Memory ROM The SMC...

Page 91: ...lay to the Main menu 2 Scroll with the Up Down keys until the Parameter option is highlighted 3 Press the Enter key to access the Parameter menu 4 Scroll with the Up Down keys until the option you wan...

Page 92: ...level programmed 0 30 s Initial Torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter 0 90 locked rotor torque Kickstart Tim...

Page 93: ...input to terminal 15 When this input signal is low ramp time initial torque are selected When this input is high ramp time 2 initial torque 2 are selected Once the Option 2 Input has been set to Dual...

Page 94: ...ired as specified in Linear Speed Acceleration on page 1 6 Parameter Option Starting Mode This must be programmed for Full Voltage Full Voltage Parameter Option Starting Mode This must be programmed f...

Page 95: ...the time period for the soft stopping function 0 120 s Preset Slow Speed SMC Option This parameter identifies the type of control present and is not user programmable Standard Slow Speed Select Allows...

Page 96: ...current applied to the motor 0 400 of full load current Accu Stop SMC Option This parameter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allow...

Page 97: ...llows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation...

Page 98: ...n of terminal 18 Stop Input Coast Stop Option Option 1 Input Allows the user to select the operation of terminal 16 Option Input 1 Disable Coast Stop Option Fault Fault NC Network Option 2 Input Allow...

Page 99: ...ine voltage and the delay period Undervoltage Fault Level Undervoltage Fault Delay Undervoltage Alarm Level Undervoltage Alarm Delay Overvoltage Determines the trip level as a percentage of line volta...

Page 100: ...age level programmed for 115 the trip value is 276V Jam With Motor FLC programmed for 150 A and the Jam level programmed for 400 the trip value is 600 A Underload With Motor FLC programmed for 90 A an...

Page 101: ...ing functions Description Action Display 1 Press any of the following keys to access the Main Menu 2 Scroll with the Up Down keys until the Parameter option is shown 3 Press the Enter key to select th...

Page 102: ...keys to access the desired information Press the Enter key to view that parameter F G P 4 Current Phase A Amps P F G P 5 Current Phase B Amps P F G P 6 Current Phase C Amps P F G P 7 Watt Meter KW P...

Page 103: ...commands to the SMC Flex controller Refer to HIM Control Enable on page 7 4 for instructions 2 The control terminals must be wired according to Figure 3 14 on page 3 16 or Figure 3 25 on page 3 27 Op...

Page 104: ...The red stop button when pressed will provide a coast stop and or reset a fault With a stopped status the jog button when pressed will initiate slow speed motor operation From an at speed condition t...

Page 105: ...ng used A list of available interfaces is located below Denotes revision level of user manual Example Publication 20COMM UM002C EN P is at revision C Communication Ports The SMC Flex supports three DP...

Page 106: ...etin 20 HIM LCD interface modules may be used to program and control the SMC Flex controller The human interface modules have two sections a display panel and a control panel The display panel duplica...

Page 107: ...op button when pressed will halt motor operation and or reset a fault Jog The jog button is active only when a control option is present Pressing the jog button will initiate the option maneuver for e...

Page 108: ...r with Human Interface Module Table 7 C Description of Ports HIM Control Enable To enable motor control from a connected human interface module follow the procedure below with the connected human inte...

Page 109: ...e HIM On Initializing screen the bottom right cor ner of LCD shows Port X Note this port number 3 Go to Logic Mask found as follows Main Menu Parameter Communications Comm Mask Logic Mask 4 Set b0X eq...

Page 110: ...oss of communication fault will follow the functionality as defined in the DPI specification There will be separate faults for each device Since three DPI ports are supported there will be three fault...

Page 111: ...being used For more information refer to the User Manual for the communication card Variable Input Output Configuration The SMC Flex supports 16 bit DataLinks Therefore the device can be configured to...

Page 112: ...ver 0 Not Performing a Start Maneuver X Stopping Decel 1 Performing a Stop Maneuver 0 Not Performing a Stop Maneuver X Alarm 1 Alarm Present 0 No Alarm Present X Fault 1 Fault Condition Exists 0 No Fa...

Page 113: ...is 85 Since this value has two decimal places the value should be divided by 100 The correctly read value is 0 85 Write Example Parameter 46 Motor FLC The value which is to be written to the SMC is 75...

Page 114: ...explicit message Rules for Using DataLinks Each set of DataLink parameters in an SMC Flex can be used by only one adapter If more than one adapter is connected multiple adapters must not try to use t...

Page 115: ...ped with a built in three line 16 character LCD The LCD displays the unit has faulted on the first line the fault number on the second line and the fault code on the third line Figure 8 1 Fault Displa...

Page 116: ...tact can be connected to Option Input 2 terminal 15 Option Input 2 must be programmed for Clear Fault Cycle control power to the SMC Flex controller Important An overload fault cannot be reset until t...

Page 117: ...1 Stall 25 Line Loss B 2 Phase Reversal 26 Line Loss C 3 Coms Loss P2 27 Shorted SCR A 4 Coms Loss P3 28 Shorted SCR B 5 Coms Loss P5 29 Shorted SCR C 6 Network P2 30 Open Gate A 7 Network P3 31 Open...

Page 118: ...rvoltage protection are user defined as a percentage of the programmed line voltage The SMC Flex controller continuously monitors the three supply phases The calculated average is then compared to the...

Page 119: ...or noise during the stopping cycle This may be minimized by lowering the braking current adjustment If this is a concern in your application please consult the factory before implementing these optio...

Page 120: ...for open line i e blown fuse Check for open load lead Consult the factory Shorted SCR 4 5 6 Shorted Power Module Check for shorted SCR replace power module if necessary Open Gate with phase indication...

Page 121: ...ck pump system Jam 24 Motor current has exceeded the user programmed jam level Correct source of jam Check programmed time value Stall 25 Motor has not reached full speed by the end of the programmed...

Page 122: ...e connected to system earth ground Ensure an RC snubber is connected to all inductive loads in the control circuit refer to input wiring Replace the control module Table 9 A SMC Fault Display Explanat...

Page 123: ...k power system Replace control module Situation Possible Cause Possible Solutions Motor current and voltage fluctuates with steady load Motor Erratic Load Verify type of motor as a standard squirrel c...

Page 124: ...period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately suited Refer to Publication 150 911 Motor o...

Page 125: ...e between the line and load terminals of each phase on the controller L1 T1 L2 T2 L3 T3 The resistance should be greater than 10 000 ohms ATTENTION To avoid shock hazard disconnect main power before w...

Page 126: ...9 8 Troubleshooting...

Page 127: ...verload underload undervoltage overvoltage unbalance jam stall and ground fault Status Indication Stopped starting stopping at speed alarm and fault Auxiliary Contacts Four fully programmable contacts...

Page 128: ...1250 A MG 1 AC 53B 3 0 50 3550 Protection Against Electrical Shock 5 85 A N A IP20 108 480 A IP2X with terminal covers 625 1250 A IP00 open Device DV DT Protection 480V 600V RC Snubber Network 690V N...

Page 129: ...A 150 5 kA 150 70 kA 90 74 10 kA 300 10 kA 300 70 kA 150 104 10 kA 400 10 kA 400 70 kA 200 147 10 kA 400 10 kA 400 70 kA 200 187 10 kA 600 10 kA 500 70 kA 300 234 10 kA 700 10 kA 700 70 kA 400 348 18...

Page 130: ...43 81 60 97 85 129 108 91 135 104 201 180 251 198 317 225 361 245 480 290 625 446 780 590 970 812 1250 1222 Auxiliary Contacts 19 20 Aux 1 29 30 Aux 2 31 32 Aux 3 33 34 Aux 4 Type of Control Circuit E...

Page 131: ...onal 5 85 A 15 G 108 480 A 5 5 G 625 1250 A 4 G Non Operat ional 5 85 A 30 G 108 480 A 25 G 625 1250 A 12 G Construction Power Poles 5 85 A Heatsink thyristor modular design 108 1250 A Heatsink hockey...

Page 132: ...7 108 47 187 135 34 135 59 234 201 67 201 116 348 251 84 251 145 435 317 106 317 183 549 361 120 361 208 625 480 160 480 277 831 625 208 625 283 850 780 260 780 300 900 970 323 970 400 1200 1250 416 1...

Page 133: ...the modified standards program Consult your local Rockwell Automation sales office or Allen Bradley distributor Controller Rating A IP65 Type 4 12 Disconnect Rating A B Height A Width C Depth Non Comb...

Page 134: ...6 14 135 200 A J 965 38 762 30 356 14 201 400 A J 965 38 762 30 356 14 251 400 A J 965 38 762 30 356 14 317 600 A J 1524 60 965 38 356 14 361 600 A J 1524 60 965 38 356 14 480 600 A J 1524 60 965 38 3...

Page 135: ...motor current measurement This measurement is always line current regardless of the motor connection Wye or Delta Metering Watt Meter 7 KW MW Provides the power usage of the connected motor This valu...

Page 136: ...ion Also refer to Parameter 129 Basic Set Up Initial Torque 19 LRT 0 90 70 When using the soft start mode this parameter allows the user to adjust the initial torque level applied to the motor at the...

Page 137: ...rque pulse for the programmed time period at the beginning of the starting maneuver for ramp profile 2 Dual Ramp Kickstart Level2 31 LRT 0 90 0 This parameter provides the user with the ability to set...

Page 138: ...d should always allow for some small coast time Setting this value to long will cause braking current to be applied to a stopped motor and likely result in overload trips Linear List Load Type SMB 37...

Page 139: ...ccu Stop Stopping Current 43 FLC 0 400 0 Provides adjustment capability for the braking intensity from slow speed operation to the stopped condition for the Accu Stop control option Basic Set Up Overl...

Page 140: ...ly 52 Secs 0 99 0 Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the motor current condition must persist within for the controller...

Page 141: ...persist within for the controller to Alarm Unbalance Unbalance F Lvl 63 V 0 25 0 Allows the user to set a percentage of line to line Voltages that will cause a fault when the voltage falls above this...

Page 142: ...e user the ability to disable inhibit ground fault protection for a selected time when starting Ground Fault Gnd Flt A Enable 76 Disable Enable Disable Enables a ground fault protection Alarm when use...

Page 143: ...This parameter allows the user to override a current loss fault This is indicative of the typical failure mode of a damaged CT Comm Masks Logic Mask 87 8 bit binary 0 Allows the user to enable or disa...

Page 144: ...m Alarm NC Network Network NC External Bypass Normal Allows the user the ability to configure each Auxiliary relay contact for a specific operation Note Normal SMC in RUN Basic Set Up Aux3 Config 108...

Page 145: ...List UTS Level 114 up to speed 0 100 75 The SMC has the ability to automatically determine if the motor is up to speed If there is a problem with detecting the up to speed condition this parameter can...

Page 146: ...out specifically talking with Technical Support Linear List Notch Maximum pump control 121 50 70 70 This parameter allows for the pump stopping control algorithm to be manually modified It is recommen...

Page 147: ...ameter parameter 26 must be set to 0 Linear List Stop Time E 131 Sec 0 999 0 Allows the stop time be extended beyond the limit of 120 seconds Parameter 33 must be set to 0 for this parameter to be act...

Page 148: ...B 14 Parameter Information Notes...

Page 149: ...FPP5C N A 25 A B 150 FPP25B 150 FPP25C N A 43 A B 150 FPP43B 150 FPP43C N A 60 A B 150 FPP60B 150 FPP60C N A 85 A B 150 FPP85B 150 FPP85C N A 108 A B 150 FPP108B 150 FPP108C 150 FPP108Z 135 A B 150 F...

Page 150: ...C 2 Renewal Parts Notes...

Page 151: ...acement Installation Instructions for 625 1250 A units Prior to beginning the following steps the front cover must be removed ATTENTION Remove all power to the unit before proceeding with replacement...

Page 152: ...D 2 Contactor Replacement Installation Instructions for 625 1250 A units 1 2 Step B Step C 1 2 3 1...

Page 153: ...Contactor Replacement Installation Instructions for 625 1250 A units D 3 1 3 4 2 E I E E I E Step D Click...

Page 154: ...s for 625 1250 A units 1 2 5 6 4 3 2 1 100 lb in 11 3 N m 100 lb in 11 3 N m 140 lb in 15 8 N m 100 lb in 11 3 N m 625 780 A 140 lb in 15 8 N m 970 1250 A 5 4 3 20 lb in 2 3 Nm 30 lb in 3 4 N m 625 78...

Page 155: ...IEC Terminal Covers 108 135 A 150 TC1 201 251 A 150 TC2 317 480 A 150 TC3 HIM Hand Held 20 HIM A2 20 HIM A3 20 HIM A4 20 HIM A5 Door Mounted includes cable 20 HIM C3 20 HIM C3S 20 HIM C5 20 HIM C5S Ex...

Page 156: ...E 2 Accessories Notes...

Page 157: ...240V Braking 5 85 A 200 600V 100 240V 41391 454 01 D1AX 150 FD1AX 24V AC DC 41391 454 02 D2AX 150 FD2AX 690V 110 120V 41391 454 05 D1AZ 150 FD1AZ 230 240V 108 251 A 200 600V 100 240V 41391 454 01 D1BX...

Page 158: ...1FX 150 FPP135B 200 600V AC 5 150 F5NCD B 150 FS1FX 150 FPP5C 25 150 F25NCD B 150 FS1FX 150 FPP25C 43 150 F43NCD B 150 FS1FX 150 FPP43C 60 150 F60NCD B 150 FS1FX 150 FPP60C 85 150 F85NCD B 150 FS1FX 1...

Page 159: ...CDB B 150 FB1FX 150 FPP5C 25 150 F25NCDB B 150 FB1FX 150 FPP25C 43 150 F43NCDB B 150 FB1FX 150 FPP43C 60 150 F60NCDB B 150 FB1FX 150 FPP60C 85 150 F85NCDB B 150 FB1FX 150 FPP85C 108 150 F108NCDB B 150...

Page 160: ...135C 24V AC DC 200 480V AC 5 150 F5NBRD B 150 FD2AX 150 FPP5B 25 150 F25NBRD B 150 FD2AX 150 FPP25B 43 150 F43NBRD B 150 FD2AX 150 FPP43B 60 150 F60NBRD B 150 FD2AX 150 FPP60B 85 150 F85NBRD B 150 FD2...

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