Rockwell Automation SMC Dialog Plus User manual

User Manual

SMC Dialog Plus™

Controller

Bulletin 150

Please Read! This manual is intended to guide qualified personnel in the

installation and operation of this product.

Because of the variety of uses for this equipment and because of the

differences between this solid-state equipment and electromechanical

equipment, the user of and those responsible for applying this

equipment must satisfy themselves as to the acceptability of each

application and use of the equipment. In no event will Allen-Bradley

Company, Inc. be responsible or liable for indirect or consequential

damages resulting from the use or application of this equipment.

The illustrations shown in this manual are intended solely to illustrate

the text of this manual. Because of the many variables and

requirements associated with any particular installation, the Allen-

Bradley Company, Inc. cannot assume responsibility or liability for

actual use based on the illustrative uses and applications.

No patent liability is assumed by Allen-Bradley Company, Inc. with

respect to use of information, circuits, or equipment described in this

text.

Reproduction of the content of this manual, in whole or in part,

without written permission of the Allen-Bradley Company, Inc. is

prohibited.

Important User Information The information in this manual is organized in numbered chapters.

Read each chapter in sequence and perform procedures when you are

instructed to do so. Do not proceed to the next chapter until you have

completed all procedures.

Throughout this manual attention statements make you aware of

safety considerations:

Attentions help you:

• Identify a hazard

• Avoid the hazard

• Recognize the consequences

Important: Identifies information that is especially important for

successful application and understanding of this product.

SMC Dialog Plus, SMB, SCANport, and Accu-Stop are trademarks of Rockwell Automation.

DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.)

!ATTENTION: Identifies information about practices

or circumstances that can lead to personal injury or

death, property damage, or economic loss.

For Bulletin 150 SMC Smart Motor Controller technical support on start-up or existing

installations, contact your Allen-Bradley representative. In the United States and Canada, you

can also call 1-800-765-SMCS (765-7627) for assistance Monday through Friday from 8:00

a.m. to 12:00 noon and 1:00 p.m. to 4:30 p.m. (central time zone). Areas outside the United

States and Canada can call 001-414-382-4650 for assistance.

Table of Contents

Chapter 1 Product Overview 1-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Starting Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Selectable Kickstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Current Limit Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Energy Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Phase Rebalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . . . . . 1-8

Open Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Line Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Excessive Starts/Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Status Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Preset Slow Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SMB‰ Smart Motor Braking Option . . . . . . . . . . . . . . . . . . 1-14

Accu-Stop‰ Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Slow Speed with Braking Option . . . . . . . . . . . . . . . . . . . . . 1-15

Chapter 2 Installation Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Non-ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

toc–iv Table of Contents

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . 2-9

Fast Acting Current-limiting Fuses . . . . . . . . . . . . . . . . . . . . . . 2-10

Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Two-speed Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Multi-motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Connecting the Human Interface Module to the Controller . . . 2-13

Control Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Converter Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . 2-18

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Accessory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Chapter 3 Wiring Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Fan Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Fan Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Control Terminal Designations . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Grounding Provision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Standard Controller Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 3-7

Chapter 4 Programming Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Keypad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Programming Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Parameter Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Random Access Memory (RAM). . . . . . . . . . . . . . . . . . . . . . . . 4-6

Read-only Memory (ROM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Electrically Erasable Programmable

Read-only Memory (EEPROM) . . . . . . . . . . . . . . . . . . . . . . 4-6

Using Parameter Management . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Parameter Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Soft Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Advanced Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Table of Contents toc–v

Example Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Undervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Overvoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Jam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Chapter 5 Calibration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Motor Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Chapter 6 Metering Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Viewing Metering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Chapter 7 Options Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Control Wiring for SCANport Control . . . . . . . . . . . . . . . . . . . . . . 7-5

Soft Stop, Pump Control, and

SMB Smart Motor Braking Options . . . . . . . . . . . . . . . . . . . . . . . 7-6

Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

SMB Smart Motor Braking Option . . . . . . . . . . . . . . . . . . . . . . . 7-14

Preset Slow Speed and Accu-Stop Options . . . . . . . . . . . . . . . . 7-15

Preset Slow Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Accu-Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Slow Speed with Braking Option . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Chapter 8 Serial Communications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Logic Control Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Control Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SMC Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Reference/Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Parameter Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Scale Factor Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Display Unit Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Datalinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Interfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Processing Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Remote I/O Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Example #1 – SLC 500 Controller without Block Transfer . . . . 8-5

1203-GD1 Communication Module Switch Settings . . . . . . . . 8-6

G File Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Example #1 - Ladder Logic Program . . . . . . . . . . . . . . . . . . . . 8-9

Example #2 - SLC 500 Controller with Block Transfer . . . . . . 8-10

1203-GD1 Communication Module Switch Settings . . . . . . . 8-10

Example #2 – Ladder Logic Program . . . . . . . . . . . . . . . . . . 8-15

toc–vi Table of Contents

Example #3 – PLC 5/20, 5/40, 5/60, and 5/80 . . . . . . . . . . . 8-18

1203-GD1 Communication Module Switch Settings . . . . . . . 8-19

I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Block Transfer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Block Transfer Datafiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Example #3 Ladder Logic Program . . . . . . . . . . . . . . . . . . . . 8-23

DeviceNet Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Example #1 SLC Controller with Explicit Messaging. . . . . . . . 8-24

1203-GK5 Communication Module Switch Settings . . . . . . . . 8-24

Example Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

SMC Dialog Plus Controller Logic Command Addresses . . . . . 8-29

Explicit Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

Explicit Message Request (Get Attribute Multiple) . . . . . . . . . 8-29

Explicit Message Response (Get Attribute Multiple) . . . . . . . . 8-29

Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Sequence of Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Setting up the Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Example Ladder Logic Program . . . . . . . . . . . . . . . . . . . . . . . 8-32

Chapter 9 Diagnostics Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Protection Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Clear Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Fault Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Fault Auxiliary Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Fault Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Line Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Phase Reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Overvoltage and Undervoltage Protection . . . . . . . . . . . . . . . . 9-3

Voltage Unbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Open Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Excess Starts/Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Controller Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Comm Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Chapter 10 Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Control Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

24–135 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Table of Contents toc–vii

180–360 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

500–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Protective Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

650–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

MOV Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

500–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Power Module and Interface Board Resistance Check . . . . . . 10-13

24–135 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

180-1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23

Appendix A Specifications

Appendix B Parameter Information

Appendix C Renewal Parts

Appendix D Accessories

Figures Figure 1.1 Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Figure 1.2 Selectable Kickstart . . . . . . . . . . . . . . . . . . . . . . . 1-3

Figure 1.3 Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Figure 1.4 Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1.5 Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1.6 Overload Trip Curves . . . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1.7 Restart Trip Curves after Auto Reset. . . . . . . . . . . . 1-7

Figure 1.8 Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figure 1.9 Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figure 1.10 ScanPort Location . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1.11 Built-in Keypad and LCD . . . . . . . . . . . . . . . . . . . 1-11

Figure 1.12 Soft Stop Option . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Figure 1.13 Pump Control Option . . . . . . . . . . . . . . . . . . . . . . 1-13

Figure 1.14 Preset Slow Speed Option . . . . . . . . . . . . . . . . . . 1-13

Figure 1.15 SMB Smart Motor Braking Option. . . . . . . . . . . . . 1-14

Figure 1.16 Accu-Stop Option . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Figure 1.17 Slow Speed with Braking Option . . . . . . . . . . . . . 1-15

Figure 2.1 Dimensions: 24, 35, and 54 Amp Controllers . . . . 2-4

Figure 2.2 Dimensions: 97 and 135 Amp Controllers . . . . . . . 2-5

Figure 2.3 Dimensions: 180 through 360 Amp Controllers . . . 2-6

Figure 2.4 Dimensions: 500 Amp Controller . . . . . . . . . . . . . . 2-7

Figure 2.5 Dimensions: 650-1000 Amp Controllers . . . . . . . . 2-8

Figure 2.6 Typical Wiring Diagram for Power

Factor Correction Capacitors . . . . . . . . . . . . . . . . . 2-9

Figure 2.7 SMC Dialog Plus Controller with

Human Interface Module . . . . . . . . . . . . . . . . . . . 2-13

Figure 2.8 SMC Dialog Plus Controller with

Communication Module . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2.9 Converter Module Connection Interface . . . . . . . . 2-17

toc–viii Table of Contents

Figure 2.10 Current Transformer Connection

to Converter Module . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 3.1 Wiring Terminal Locations (24 to 54 Amp) . . . . . . . 3-1

Figure 3.2 Wiring Terminal Locations (97 and 135 Amp) . . . . 3-1

Figure 3.3 Wiring Terminal Locations (180 to 360 Amp) . . . . . 3-2

Figure 3.4 Wiring Terminal Locations (500 Amp). . . . . . . . . . . 3-2

Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp) . . . . 3-3

FIgure 3.6 97A and 135A Fan Terminations . . . . . . . . . . . . . . 3-5

Figure 3.7 180A to 500A Fan Terminations. . . . . . . . . . . . . . . 3-5

Figure 3.8 650A to 1000A Fan Terminations. . . . . . . . . . . . . . 3-5

Figure 3.9 SMC Dialog Plus Controller Control Terminals . . . . 3-6

Figure 3.10 Grounding Provision . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure 3.11 Typical Wiring Diagram for Standard Controller . . . 3-7

Figure 3.12 Typical Wiring Diagram for Two-Wire Control or

Programmable Control Interfacing . . . . . . . . . . . . . 3-8

Figure 3.13 Typical Wiring Diagram for

Dual Ramp Applications . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3.14 Typical Wiring Diagram for Start-Stop

Control via the SCANport . . . . . . . . . . . . . . . . . . . 3-10

Figure 3.15 Typical Wiring Diagram for

Retrofit Applications. . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3.16 Typical Wiring Diagram for

Isolation Applications . . . . . . . . . . . . . . . . . . . . . 3-12

Figure 3.17 Typical Wiring Diagram for

Bypass Applications . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure 3.18 Typical Wiring Diagram for Bypass

with Isolation Applications . . . . . . . . . . . . . . . . . . 3-14

Figure 3.19 Typical Wiring Diagram for

Shunt Trip Applications . . . . . . . . . . . . . . . . . . . . 3-15

Figure 3.20 Typical Wiring Diagram for Single

Speed Reversing Applications . . . . . . . . . . . . . . . 3-16

Figure 3.21 Typical Wiring Diagram for

Two-speed Applications . . . . . . . . . . . . . . . . . . . 3-17

Figure 3.22 Typical Wiring Diagram for

Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 3-18

Figure 4.1 Menu Structure Hierarchy . . . . . . . . . . . . . . . . . . . 4-2

Figure 4.2 Memory Block Diagram . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 7-1 Typical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 7-6

Figure 7.2 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . . 7-7

Figure 7.3 Typical Wiring Diagram for Applications

Requiring an Isolation Contactor . . . . . . . . . . . . . . 7-8

Figure 7.4 Typical Wiring Diagram for Applications

Requiring a Bypass Contactor . . . . . . . . . . . . . . . . 7-9

Figure 7.5 Typical Wiring Diagram for Two-wire Control

or Programmable Controller Interfacing . . . . . . . . 7-10

Figure 7.6 Typical Wiring Diagram for

Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-11

Figure 7.7 Soft Stop Option Sequence of Operation . . . . . . . 7-12

Figure 7.8 Pump Control Option Sequence of Operation . . . . 7-13

Table of Contents toc–ix

Figure 7.9 SMB Smart Motor Braking Sequence

of Operation 7-14

Figure 7.10 Typical Wiring Diagram for the

Preset Slow Speed Option . . . . . . . . . . . . . . . . . . 7-15

Figure 7.11 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . 7-16

Figure 7.12 Typical Wiring Diagram for Applications

Requiring an Isolation Contactor . . . . . . . . . . . . . 7-17

Figure 7.13 Typical Wiring Diagram for Applications

Requiring a Bypass Contactor . . . . . . . . . . . . . . . 7-18

Figure 7.14 Typical Wiring Diagram for

Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-19

Figure 7.15 Preset Slow Speed Option

Sequence of Operation . . . . . . . . . . . . . . . . . . . . 7-20

Figure 7.16 Accu-Stop Option Sequence of Operation . . . . . . 7-21

Figure 7.17 Typical Wiring Diagram for the

Slow Speed with Braking Option . . . . . . . . . . . . . 7-22

Figure 7.18 Typical Retrofit Wiring Diagram for the

Slow Speed with Braking Option . . . . . . . . . . . . . 7-23

Figure 7.19 Typical Wiring Diagram for the Slow Speed

with Braking Option with an Isolation Contactor . . 7-24

Figure 7.20 Typical Wiring Diagram for the Slow Speed

with Braking Option with a Bypass Contactor . . . . 7-25

Figure 7.21 Slow Speed with Braking Option Sequence

of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Figure 9.1 Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Figure 10.1 Troubleshooting Flowchart. . . . . . . . . . . . . . . . . . 10-2

Figure 10.2 Removal of Control Module (24–135A) . . . . . . . . 10-7

Figure 10.3 Removal of Control Module (180–360A) . . . . . . . 10-9

Figure 10.4 Removal of Protective Cover (500–1000A) . . . . 10-12

Figure 10.5 Removal of Control Module (500–1000A) . . . . . 10-10

Figure 10.6 MOV Fuse Replacement . . . . . . . . . . . . . . . . . . 10-13

Figure 10.7 Pin Locations for Power Module

Resistance Check . . . . . . . . . . . . . . . . . . . . . . . 10-22

Figure 10.8 Pin Locations for Power Pole Resistance

Check (180–1000A) . . . . . . . . . . . . . . . . . . . . . 10-24

Figure 10.9 Gate and Thermistor Lead Identification

(180–1000A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

Tables Table 2.A Maximum Heat Dissipation. . . . . . . . . . . . . . . . . . . 2-2

Table 2.B Minimum Ventilation Openings . . . . . . . . . . . . . . . 2-3

Table 2.C Recommended Fuses . . . . . . . . . . . . . . . . . . . . . 2-10

Table 2.D Converter Module Selection Guide . . . . . . . . . . . . 2-16

Table 3.A Lug Wire Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Table 3.B Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Table 3.C Lug Wire Capacity and Tightening Torque . . . . . . . 3-4

Table 3.D Heatsink Fan Control Power . . . . . . . . . . . . . . . . . . 3-4

Table 3.E Control Wiring and Tightening Torque . . . . . . . . . . 3-4

Table 4.A Parameter Linear List . . . . . . . . . . . . . . . . . . . . . . 4-4

Table 5.A Motor Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

toc–x Table of Contents

Table 8.A Logic Control Data . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Table 8.B SMC Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Table 8.C Fault Code Cross-reference . . . . . . . . . . . . . . . . . . 9-2

Table 10.A SMC Fault Display Explanation . . . . . . . . . . . . . . 10-3

Table 10.B Motor Will Not Start — No Output Voltage

to the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Table 10.C Motor Rotates

(but does not accelerate to full speed) . . . . . . . . . 10-4

Table 10.D Motor Stops While Running . . . . . . . . . . . . . . . . . 10-4

Table 10.E Miscellaneous Situations . . . . . . . . . . . . . . . . . . . 10-5

Table B.1 Parameter Text/Display Unit Cross Reference. . . . . B-5

Table of contents

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