® smc PLUS™ Smart Motor Controller (Bulletin 150) Installation Manual for 180A, 240A, 360A Controllers ‘This manual describes the installation, set-up, 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 for 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 Option 150-808 SMB™ Smart Motor Braking Option @® Rockwell Automaton Allen-Bradley 150-809 Accu-Stop™ Option © 150-810 Slow Speed with Braking Option 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. SMC PLUS, SMB and Accu Stop are trademarks of len Bradley CoImportant User Information Manual’s Purpose This manual describes the installation, set up, operation, and use of the SMC PLUS™ Controller (hereafter referred to as “controller. Simple troubleshooting is also included. A knowledge of electrical procedures and terminology is needed ‘when using this manual NOTE: This manual provides information only for the 180A, 240A and 360A controllers. For information concerning the 24A, 35A, 54A, 97A and 135A controllers refer to Publication 150-811. For information concerning the 500A, 650A, 720A, 850A and 1000A controllers refer to Publication 150-813. ATTENTION: Identifies information about practices or circumstances that can lead to esona injury or death, property damage or ‘Avtentions help yout © identify a hazard © avoid a hazard © recognize the consequences Important: Identifies information that is especially important for successful application and understanding of the product. Table of Contents Chapter Title Page 1 Catalog Number Identification Catalog Number Identification Specifications .. Standard Adjustments. Options : 2 Installation & Wiring Inspection BA Enclosures Bt Ventilated Enclosures - Bt Non-ventilated Enclosures - a Mounting ....c.etscssee 24 Dimensions 22 Wiring 22 Power Lugs Bs Control Power . wees 2-3] Fan Power... a ‘Typical Connection . [2-4) Typical Connection: Isolation Contactor : : Raatrofit Application 2.22.22... [25] By-Pass Mode 125) Shunt Trip Circuit Breaker . 26 Programmable Controller and ‘Sensor Interface Power Factor Capacitors . Fast Acting Current Limiting Fuses Motor Overtoad Protection Protective Module... ‘Typical Applications: Single Speed, Reversing . 28 Two-Speed Motor Chapter Title Page 3° Set-Up Procedures: SMC PLUS Controller without Options Protective Features Start Fault Stalled Motor . a Temperature Fault 3-1 Line Fault . = B2 Factory Settings -- [52] Start Sequence = [BZ] Normal Stop Sequence . [32 Overload Trips 132 Fault Trips bs 33. ‘Customer Settings - 3-3. Set-Up Procedures for : Soft Start [33] Current Limit 35. Full Voltage Starting 36 4° Troubleshooting ‘Troubleshooting Troubleshooting Tables Control Module Replacement .... Power Pole Resistance Check ... Renewal PartsChapter 1 Catalog Number Identification Catalog Number Tw foiowing is an explanation ofthe catalog numbering system forthe Identification Ballin 130 SMC PLUS™ Smart Motor Conver, Figure 1.1 - Open Type/Non-Combination Controllers Figure 1.2 - Combination Controllers 150-A180 NBDA-8L4 Bulletin Numbor —! 160 Soli-State Controter Rating 180 amperes 5-150 np @ 4e0v 5-150 hp @ 600 Control A1e0 A240 Badamperes 5-200hp @ 480 5.250 hp @ o00v A960 360 amperes 5-300 @ 480 | 5.350 hp @ 600V Type of Enclosure Nv “Open J NEMA 2 B NEMA 1 Vent. F NEMA 4 Input Line Voltage BD 200-480 volts, -phase, 0 and 60 Hz CD 200-600 volts, 3-phase, 50 and 60 Hz Optional Functions, ——___| {Gnlyone option may be added to standard unt) scsi ewer Sat ctor raking 8 Pimpcon! aera Sipm Preset Sim Speed F Stow Speed win Braking Options, ——______ 8L4 Max. 480 volt, ine mounted Protective Module '8L6 Max. 600 volt, ine mounted Protective Modula ‘8M4 Max. 480 volt load mounted Protective Module ‘8M6 Max. 600 volt, load mounted Protective Module 884 Max. 480 volt, ne and ioad mounted Protective Module 886 Max. 600 voll, ine and load mounted Protective Module Accessories for Field Mounting 150-NBéL Protective Module with wire leads (max. 480V) SO-NGEL Protective Module with wir leads (max. 600V) $S0-NT2 IEC ine and load terminal cover 49B-LFt Terminal Lug Kit uta number —! | 1524 Combnaton Conor wean dscomoct 1528 Combinalen Conrler wan ube ssoomec fn elaton conser 52H Conbiaton Conta Sen eneut rater 1538 Combination Contoter ‘itn eret rater tnd alan contactor Controle Rating Wr Senda cy ype of Enctosure ——___} vr NEMAT? B NEMA Vent, Voltage Rating —__ H’ 200 volts, 50/60 He A 240 ols, 50/60 He 8 480 volts, 50/60 Hz 1600 vols, 50/60 Hz Horsepower — cat. HP Cat. HP cat. HP [No Rating No. Rating «=o, Rating 8 a7 50 57 300 4 75 4% © 0 58350 faa io 0 75 59400 er ie 50 100 60 450 eo 2 Bt 125 e500 jaa 28 52 150 62 600 4 30 54 200 6 700 4540 56 250 [Options (Only one option may be added to standard unit) AN Soft Stop B Pump Control Preset Slow Speed [2 SMa™ Smart Motor raking E AccuStop™ F Slow Speed with Braking 15 2H-WAB-54-A 4 150-812cons AD Chapter 7 Catalog Number Identification Specifications © Auuiliary Contact Rating: © Input Voltage ~ Power Module: = N.O.- 470 VA sealed, 4700 VA inrush, 7 240V max. 24V min, = 200-480 V AC, 3-phase, +10%, -15% — N.C. 275 VA sealed, 2750 VA inrush, ~ 200-600 V AC, phase, +10%, 15% 2AOY tone, 244 ai © Control Voltage - Control Module: © Diagnostics: = 100-240 V AC, I phase, +10%, -15%% = Start Fault = Stalled Motor © Input Frequency - Control and Power: eee ~ Temperature Fault = 50 and 60H Line Fault © Repetitive Peak Inverse Voltage Rating: . ‘on: = 1400V (Line voltage 200-480V) ver protection: — 1600V (Line voltage 200-600V) ~ ‘wor eee © Transient Protection (optional): Full Voltage Starting — 600%, 10 seconds ~ Metal Oxide Varistors, 220 joules © Operating ‘Temperature: °C w 450°C © Storage Temperature: H0°C 10 485°C © Relative Hun Options 5.95% (non-condensing) © Soft Stop: © Shock: = 210 60 seconds 30G shock peak acceleration for 11 ms © Preset Slow Speed: = Forward: 7% (LOW) or 15% (HIGH) speed Standard Adjustments Reverse: 10% (LOW) or 20% (HIGH) speed ~ Slow Speed Current adjustment (50 to © Soft Start: 450% of full load current) = 210 30 seconds © Pump Control: © Initial Torque: = Starting: 210 30 second ~ 5 10-90% locked rotor torque ~ Stopping: 2 to 120 seconds © Kickstart: © SMB Smart Motor Brake: ~ 500% current for 0.4 0 2 seconds = Braking Current 150 10 400% full load amperes © Current Limit: ~ 50 to 500% full load amperes © Aceu-Stop: ~ Slow Speed: 79 (LOW) and 15% (HIGH) © Vibration: ~ Slow Speed Current adjustment ~ 2.5 vibration for 60 minutes (50 to 450% of full load current) © Altude ~ Braking Current 150 to 400% full load current . = 2000 meters without derating © Noise and RF Immunity: — Surge transient 3KV peak, 1500 V showering are Slow Speed with Braking: = Slow Speed: 74% (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% )Chapter 2 Installation & Inspection 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 cartier as soon as possible after receipt of shipment. Enclosures Ventilated Enclosures ‘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 encloses, 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. A filter is required to prevent contaminants from entering the enclosure, ‘The minimum vent area should be 50 square inches. Deductions must be made for grill work or ventilation pattern. Use Figure 2.1 to determine ventilation openings and fan/blower requirements Figure 2.1 - Minimum Ventilation Openings ‘SHC PLUS Controle Current Size TSOA | 240K] 360K] ® Cutout size assumes 50% biockage fers, louvers, Cutout size (ninchesyattop ofdoor@ | 520 | Sad | Sao ay ‘Cutout size (in inches) at bottom of door D | _® oma | __ & Cutout sizes the same as Too CFM | 250 CFM | (@)2500FM | required for partouar fan Fan orblower size D_ Non-Ventilated Enclosures ‘or blower belng Used, ATTENTION: When thermal overload relays are installed in the same enclosure, « barrier should be provided around the relay to deflect the forced airflow away from the relay. ‘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. jure 2.2 ~ Maximum Heat pation “SMC PLUS Controller Current Size 780 0K ‘608 Maxionum Watts 660 | 1170 For NEMA Type 12 or noa-ventilated enclosures, itis 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 2.13 for this configuration. Mounting It is important to locate the controler 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 2.3Chapter 2 _ Installation & Wiring Figure 2.3 - Dimension Drawings for 180A, 240A, and 360A SMC PLUS Controller ~— c+ 4 ——+ =—— >>| Noe 281 (7.1) DIA 16 «| wef ily | rte: Necks I oa ne. PO el 7 $ 281.0.1) BAD. aa! ‘2KEY HOLES > . 6 W 8 4 136 (35) OIA | errs feag UNC-28 413 (10.5) 1A, | ey 4 i Ls Geses tl =| et pee ee 20 — “ en TERMINAL DETAIL A B c ] vot] win [nce] on |?) ef fe fe] pK de wiirater [270 | soo | 268 | a | at6 a | ev [on | aa] se] on ween | toa | aeaea | rosea [oovee | twee | sane | bases | terme [ireaee [orem | e708 TAsprox Ship. Wt ' ‘A aensions are approxima and are nto be used for Unit a N a ae neoe construction purposes, Refer to nearest Sales Office or aimetor | 167 | 95 | 25h 20k the Sales Depart at Wao, Wisconch, or completo Grnenoon swe Inch 16-37/64 | 1-98 sSibs | 65Ibs sis Coke Figure 2.4 Wiring Terminal Locations Wirirg The controler wiing terminal locations are shown in oe Figure 2.4. Make wiring connections 3s indicated inthe un] [uae | [136 typical connection diagrams shown in Figures 2.10, = =a 211, 212,213, 2.14, 215, 2.17 and 2.18. Connect the {reat Power | line to terminals Li, L2/, and L3/5, Connect the load nnect to terminals T1/2, T2/4, and T3/6. Make sure power ‘wing i firmly secured to prevent movement. A | provision is available for grounding the isolated = | heatsink per applicable codes ‘Connections ‘Use Figure 2.5 as a guide for power wiring. Figure 2.5 ~ Power Wiring and Tightening Torque (Wire-to-Lug and Lug-to-Busbar) Output Power Wire Size Torque Connections | Metric 16120 mnt SiN [re] [Tea] Lr AWG 6-40 275iChapter 2 Installation & Wiring 23 Power Lugs ower lugs are available as optional kits. Each terminal Ing kit, identified as Allen-Bradley Bulletin 199-LFI, contains three lugs. ‘The number of terminal lug kits required is listed in Figure 2.6 below. Each Jug kit contains three lugs. Figure 2.6 - Pewer Wiring and Power Lug Connections Fan Power ‘To gain access to the fan connection, see Figure 2.8. ATTENTION: The fan jumpers have been factory installed for 110/120 V AC input. Refer to Figure 2.8 for optional 220/240 V AC fan wiring. No.of Terminal Lug Kits Required tine side | Load Sice 780A trough ae 2 2 Control Power Connect control power to the controller at terminals 10, and 60. The control terminal access door must be removed in order to wire control terminals. The control power requirement is 75 VA (30 VA for conteal ‘module and 45 VA for fan.). Additional contro! circuit transformer VA capacity may be required depending ‘on the specific application. After control wiring is ‘completed, replace control terminal access door. Use the following figure as a guide for control wiring, Figure 2.7 - Control Wiring and Tightening Torque Wire Size] Torus Matic | 154mm?) 08 Nm awe | aa? | 7LB.IN, The wiring of the control circuit depends on the specific application. Typical connections for a number of applications are shown in Figures 2.10 through 2.15, 2.17 and 2.18, NOTE: Jumpers have been factory installed for 110/120 V AC input. igure 2.8 — Jumper Locations of 110/120 V AC and 220/240 V AC Fan Wiring <— To Supply —se Jumpers oe 13] 14] 15 reso 1 set Fan Power Factory: stonz0 Vac <— To Supply —>= ie Jumper 2 30/1] 12] 13] 14| 15 Optional 2209240 VAC Fan Power © Customer Wires Fan to Control Voltage Supply Figure 2.9 - Control Terminal Access Door Control terminal access door FAN POWER, 219 4 alo ” 8 LILI Ud24 Typical Connection NOTE: Fortwo wire contol, remove “slopisart pushbuttons and connect two wire >| y dumper fi Optional ‘220/240 V'AC Fan Power Chapter 2 Installation & Wiring Figure 2.10 shows a typical connection for standard control module. See page 3-2 for a description of the start sequence. Figure 2.10 - Typical Connection Diagram for Standard Unit [10] 20) 30 | a0 [ 50] 60] 70] e0[ 90] 80 : ‘Auxiliary ‘SMC PLUS Controt Terminate LJ 11 [| Contacte Typical Connection with Isolation Contactor Figure 2.11 shows a typical connection of standard unit for use with an isolation contactor. Starting and stopping of the load is controlled by the controller. The controller also controls the electromechanical contactor. The contactor provides isolation between the motor and the ower lines when the controller is “OFF” ATTENTION: When not using an isolation contactor, hazardous voltages are present a the load terminals ofthe controller when the controller is tumed off. Warning labels must be attached to the motor terminal box, the controller enclosure, and the control station, Additional eireuitry must be included to provide automatic isolation, Figure 2.11 ~ Typical Connection Diagram of Standard Unit with Isolation Contactor Power input ni NOTE: Fortwo wie cont romovestopian emmee _—| Ce ‘Pushbuttons and connect two wire device between 2S femal 0 ara so LY MoH D Customer Suppiod ® Customer wies fan to contol voltage supply. ‘Jumpers are arranged for 110120 V LD AC fan power. © i ee © Set ausiary contacts fer normal setting. [Fan Power @ fs] 122 ton on ona o 1c] 40 | 50 | smc tus contot terminate Lid | 0] 70] #0] 20 Auxiliary | geomet ®Chapter 2 Installation & Wiring a Typical Connection Figure 2.12 shows a ypical connection diagram for use ina retrofit application. In this for Retrofit. sbeme the controller provides contol ofthe load when the electromechanical starter is Terrie cruized, ‘This method of controlling the load can be used in applications where the Application Ssting conizol scheme iso 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 controler is “OFE” Ifa 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 2.12 - Typical Connection Diagram for Retrofit Applications of Standard Unit NOTE: Fortwo wire control, remove stopstart - pushbutons and connect two wire device between Power out ferminals 10 and £0. D Customer Supplied ® Customer wies fan to contol voltage supply. d ‘Jumpers are arranged for 10/120 V AC fan 2m A] cxwtnil nor Bb SMC PLUS pone: ru sete Convener Steaua contacts for normal sting : (OAS, es AN _2 ———~ Sater a ‘conor ee TeSupply 14 Jumper si] 42] 13] 44] 18 AT a eo Start D fre is [| ope Optional ry zz0raso VAG Fan Power © _ austen, 20 | 30 | 40 [50] 60 | 70 80[ 90] Contacts 10 SMC PLUS Control Terminals U4}! a 103 oats on Inedace bow) By-Pass Mode By using the consoller as shown in Figure 213 below, a soft start characteristic can be provided. Once the motor has reached full speed, the auxiliary contact onthe SMC energizes the bypass contactor. NOTE: The controller is ty-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 2.13 - Typical Application Diagram of a By-Pass Contactor with Standard Unit NOTE: Fortwo wire contol, replace stop button with 2-vire deviee and hard wire over int terminals 10 and 40, 1-97 on frag Tao} fot " © Customer Sppled sre == {Customer wires fan to contol votage ee a ee 3 supp, Jumpers ee aang or enn, eases || | onto n0/20'V AC tan power. son er @Selauitry contact for uptoepeed eto seta. Ik ‘To Supply >| yom f C1 Optional z2nr240 VAC Fan Power 80] 90| Auary 5 omtacts smc PLUS contro! Terminals Lab) Tg