Manual SMC Dialog Plus Controller. Allen Bradley

SMC Dialog Plus Controller
Bulletin 150
User Manual
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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 AllenBradley 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: ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
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.)
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 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-ventilated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-3 2-3 2-4
Chapter 2 Installation
tociv
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 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
Chapter 4 Programming
Table of Contents
tocv
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 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Viewing Metering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 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 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
Chapter 6 Metering Chapter 7 Options
Chapter 8 Serial Communications
tocvi
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 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Control Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 24135 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Chapter 10 Troubleshooting
Table of Contents
tocvii
180360 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 5001000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Protective Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 6501000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 MOV Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 5001000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Power Module and Interface Board Resistance Check . . . . . . 10-13 24135 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 180-1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Appendix A Appendix B Appendix C Appendix D Figures Specifications Parameter Information Renewal Parts Accessories Figure 1.1 Figure 1.2 Figure 1.3 Figure 1.4 Figure 1.5 Figure 1.6 Figure 1.7 Figure 1.8 Figure 1.9 Figure 1.10 Figure 1.11 Figure 1.12 Figure 1.13 Figure 1.14 Figure 1.15 Figure 1.16 Figure 1.17 Figure 2.1 Figure 2.2 Figure 2.3 Figure 2.4 Figure 2.5 Figure 2.6 Figure 2.7 Figure 2.8 Figure 2.9 Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Selectable Kickstart . . . . . . . . . . . . . . . . . . . . . . . 1-3 Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Dual Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Overload Trip Curves . . . . . . . . . . . . . . . . . . . . . . . 1-7 Restart Trip Curves after Auto Reset. . . . . . . . . . . . 1-7 Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 ScanPort Location . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Built-in Keypad and LCD . . . . . . . . . . . . . . . . . . . 1-11 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 Dimensions: 24, 35, and 54 Amp Controllers . . . . 2-4 Dimensions: 97 and 135 Amp Controllers . . . . . . . 2-5 Dimensions: 180 through 360 Amp Controllers . . . 2-6 Dimensions: 500 Amp Controller . . . . . . . . . . . . . . 2-7 Dimensions: 650-1000 Amp Controllers . . . . . . . . 2-8 Typical Wiring Diagram for Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . 2-9 SMC Dialog Plus Controller with Human Interface Module . . . . . . . . . . . . . . . . . . . 2-13 SMC Dialog Plus Controller with Communication Module . . . . . . . . . . . . . . . . . . . . 2-16 Converter Module Connection Interface . . . . . . . . 2-17
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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
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Figure 7.9 Figure 7.10 Figure 7.11 Figure 7.12 Figure 7.13 Figure 7.14 Figure 7.15 Figure 7.16 Figure 7.17 Figure 7.18 Figure 7.19 Figure 7.20 Figure 7.21 Figure 9.1 Figure 10.1 Figure 10.2 Figure 10.3 Figure 10.4 Figure 10.5 Figure 10.6 Figure 10.7 Figure 10.8 Figure 10.9 Tables Table 2.A Table 2.B Table 2.C Table 2.D Table 3.A Table 3.B Table 3.C Table 3.D Table 3.E Table 4.A Table 5.A
SMB Smart Motor Braking Sequence of Operation 7-14 Typical Wiring Diagram for the Preset Slow Speed Option . . . . . . . . . . . . . . . . . . 7-15 Typical Retrofit Wiring Diagram . . . . . . . . . . . . . . 7-16 Typical Wiring Diagram for Applications Requiring an Isolation Contactor . . . . . . . . . . . . . 7-17 Typical Wiring Diagram for Applications Requiring a Bypass Contactor . . . . . . . . . . . . . . . 7-18 Typical Wiring Diagram for Hand-Off-Auto (SCANport) Control . . . . . . . . . . . . 7-19 Preset Slow Speed Option Sequence of Operation . . . . . . . . . . . . . . . . . . . . 7-20 Accu-Stop Option Sequence of Operation . . . . . . 7-21 Typical Wiring Diagram for the Slow Speed with Braking Option . . . . . . . . . . . . . 7-22 Typical Retrofit Wiring Diagram for the Slow Speed with Braking Option . . . . . . . . . . . . . 7-23 Typical Wiring Diagram for the Slow Speed with Braking Option with an Isolation Contactor . . 7-24 Typical Wiring Diagram for the Slow Speed with Braking Option with a Bypass Contactor . . . . 7-25 Slow Speed with Braking Option Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . 10-2 Removal of Control Module (24135A) . . . . . . . . 10-7 Removal of Control Module (180360A) . . . . . . . 10-9 Removal of Protective Cover (5001000A) . . . . 10-12 Removal of Control Module (5001000A) . . . . . 10-10 MOV Fuse Replacement . . . . . . . . . . . . . . . . . . 10-13 Pin Locations for Power Module Resistance Check . . . . . . . . . . . . . . . . . . . . . . . 10-22 Pin Locations for Power Pole Resistance Check (1801000A) . . . . . . . . . . . . . . . . . . . . . 10-24 Gate and Thermistor Lead Identification (1801000A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Maximum Heat Dissipation. . . . . . . . . . . . . . . . . . . 2-2 Minimum Ventilation Openings . . . . . . . . . . . . . . . 2-3 Recommended Fuses . . . . . . . . . . . . . . . . . . . . . 2-10 Converter Module Selection Guide . . . . . . . . . . . . 2-16 Lug Wire Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Lug Wire Capacity and Tightening Torque . . . . . . . 3-4 Heatsink Fan Control Power . . . . . . . . . . . . . . . . . . 3-4 Control Wiring and Tightening Torque . . . . . . . . . . 3-4 Parameter Linear List . . . . . . . . . . . . . . . . . . . . . . 4-4 Motor Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
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Table of Contents
Table 8.A Table 8.B Table 8.C Table 10.A Table 10.B Table 10.C Table 10.D Table 10.E Table B.1
Logic Control Data . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SMC Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Fault Code Cross-reference . . . . . . . . . . . . . . . . . . 9-2 SMC Fault Display Explanation . . . . . . . . . . . . . . 10-3 Motor Will Not Start No Output Voltage to the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Motor Rotates (but does not accelerate to full speed) . . . . . . . . . 10-4 Motor Stops While Running . . . . . . . . . . . . . . . . . 10-4 Miscellaneous Situations . . . . . . . . . . . . . . . . . . . 10-5 Parameter Text/Display Unit Cross Reference. . . . . B-5
Chapter
Product Overview
Description
The SMC Dialog Plus controller offers a full range of starting modes as standard: Soft Start with Selectable Kickstart Current Limit Start with Selectable Kickstart Dual Ramp Start Full Voltage Start
Other features that offer further user benefit include: Expanded protective features Metering Communication capability
Innovative starting and stopping options provide enhanced performance: Soft Stop Pump Control Preset Slow Speed SMB Smart Motor Braking Accu-Stop Slow Speed with Braking
These modes, features, and options are further described in this chapter.
Operation
The SMC Dialog Plus controller can operate three-phase squirrel cage motors rated 11000A; 200480V AC or 200600V AC; 50/60 Hz. Depending upon the catalog number ordered, the controller will accept a control power input of either 100240V AC or 24V AC/DC. If the control power input option is 100240V AC, the controllers microprocessor will self-adjust to the input control voltage.
1-2
Product Overview
Starting Modes
Soft Start
This mode has the most general application. The motor is given an initial torque setting, which is user-adjustable from 0 to 90% of locked rotor torque. From the initial torque level, the output voltage to the motor is steplessly increased during the acceleration ramp time. The acceleration ramp time is user-adjustable from 0 to 30 seconds. If the SMC Dialog Plus controller senses that the motor has reached the up-to-speed condition during the voltage ramp operation, the output voltage automatically switches to full voltage.
Figure 1.1 Soft Start
Percent Voltage
100%
Initial Torque
Start Time (seconds)
Run
Product Overview
1-3
Selectable Kickstartx
This feature provides a boost at startup to break away loads that require a pulse of high torque to get started. This is intended to provide a pulse of current that is 550% of full load current. Selectable kickstart is user-adjustable from 0.0 to 2.0 seconds.
Figure 1.2 Selectable Kickstart
Percent Voltage Kickstart 100%
Initial Torque
Run
Current Limit Starty

This starting mode provides a fixed reduced voltage start; it is used when limiting maximum starting current is necessary. The Current Limit level is user-adjustable from 50 to 600% of the motor full load ampere rating; and the current limit time is user-adjustable from 0 to 30 seconds. If the SMC Dialog Plus controller senses that the motor has reached the up-to-speed condition during the current limit starting mode, the output voltage automatically switches to full voltage.
Figure 1.3 Current Limit Start
Percent Full Load Current
600%
50%

x y Kickstart is also available with Current Limit Start. The Current Limit Start mode design is based on a motor with a locked rotor current rating that is 600% of the full load current rating.
1-4
Product Overview
Starting Modes (cont.)
Dual Ramp Startx

This starting mode is useful on applications that have varying loads (and therefore varying starting torque requirements). Dual Ramp Start allows the user to select between two separate Soft Start profiles with separately adjustable ramp times and initial torque settings.
Figure 1.4 Dual Ramp Start
Percent Voltage Ramp #2 100% Initial Torque #2 Initial Torque #1 Ramp #1 Start #1 Start #2 Time (seconds) Run #1 Run #2
Full Voltage Start

This starting mode is used for applications requiring across-the-line starting. The output voltage to the motor will reach full voltage within 1/4 second.
Figure 1.5
100%
Full Voltage Start
Percent Voltage
Time (seconds)
Dual Ramp Start is available only with the standard controller.
Product Overview
1-5
Energy Saver
The Energy Saver feature is typically used in applications where the motor is lightly loaded or unloaded for extended periods of time. With the Energy Saver feature enabled, the SMC Dialog Plus controller continuously monitors motor load with its internal feedback circuitry. Because SCRs control the output voltage, motor power losses may be reduced by decreasing the motor terminal voltage. Notes: (1) The Energy Saver feature is not available when a bypass contactor is used. (2) When Energy Saver and Phase Rebalance are both enabled, Phase Rebalance takes precedence in operation.
Phase Rebalance
With the Phase Rebalance feature enabled, the SMC Dialog Plus controller continuously monitors the incoming three-phase line voltage and automatically adjusts the output voltage to balance the three phase currents drawn by the motor. Notes: (1) Phase Rebalance requires that the Bulletin 825 converter module is utilized. (2) Phase Rebalance is not active during bypass operation. (3) When Phase Rebalance and Energy Saver are both enabled, Phase Rebalance takes precedence in operation.
Protection and Diagnostics
The SMC Dialog Plus controller provides the protective and diagnostic features described below.
Overload
The SMC Dialog Plus controller meets applicable requirements as a motor overload protective device. Thermal memory provides added protection and is maintained even when control power is removed. The built-in overload algorithm controls the value stored in Parameter 11, Motor Thermal Usage; an Overload Fault will occur when this value reaches 100%. The programming parameters below provide application flexibility and easy setup.
Parameter Overload Class Overload Reset Motor FLC Service Factor Range Off, 10, 15, 20, 30 Manual Auto 1.0999.9 Amps 0.011.99
ATTENTION: During slow speed and/or braking operations, current waveforms exhibit non-sinusoidal characteristics. These non-sinusoidal characteristics inhibit the controllers current measurement capability. To compensate for additional motor heating that may result, the controller uses motor thermal modeling, which increments motor thermal usage. This compensation takes place when these options are in use: Preset Slow Speed, Smart Motor Braking, Accu-Stop, and Slow Speed with Braking.
1-6
Product Overview
Protection and Diagnostics (cont.)
Notes: (1) The factory default setting for Overload Class, which is Off, disables overload protection. An overload trip class and the motors full load current rating must be programmed to enable overload protection. (2) The current sensing capability of the SMC Dialog Plus controller is disabled during bypass operation. Using a Bulletin 825 converter module in these applications is recommended to provide current feedback. Otherwise, a separate overload relay is required. (3) Motors with full load current ratings of 5 Amps and below may require the use of the converter module (Cat. No. 825-MCM20) for improved current measurement accuracy. (4) Automatic reset of an overload fault requires the start input to be cycled in a 2-wire control scheme. This applies to the following firmware releases: 1.07 (standard), 1A07L (Soft Stop) and 1B05L (Pump Control) or earlier. Figure 1.6 and Figure 1.7 provide the overload trip curves for the available trip classes.
Product Overview
1-7
Figure 1.6
Class 10
1000.0 10000.0
Overload Trip Curves

Class 20
10000.0 10000.0
Class 15
Class 30
Approximate Trip Time (seconds)
10.0
100.0

1 2 3 4 5 6 7 8 9 10
100.0
1000.0
1000.0
1000.0
100.0
100.0
1.0
10.0
10.0
10.0
0.1 1 2 3 4 5 6 7 8 9 10
1.0 1 2 3 4 5 6 7 8 9 10
1.0
1.0 1 2 3 4 5 6 7 8 9 10
Multiples of FLC
Multiples of FLC
Multiples of FLC
Multiples of FLC
Approximate trip time for 3-phase balanced condition from cold start.
Approximate trip time for 3-phase balanced condition from cold start.
Figure 1.7 Restart Trip Curves after Auto Reset

100000
1000
Seconds
100
10
Class 10 Class 15 Class 20 Class 30

1
Auto Reset Times: Class 10 = 90s Class 15 = 135s Class 20 = 180s Class 30 = 270s
1000%
0 100%
Percent Full Load Current Setting
1-8
Product Overview
Stall Protection and Jam Detection

The SMC Dialog Plus controller provides both stall protection and jam detection for enhanced motor and system protection. Stall protection is user-adjustable from 0.0 to 10.0 seconds (in addition to the ramp time programmed). Jam detection allows the user to determine the jam level (up to 999% of the motors FLC rating) and the delay time (up to 10.0 seconds) for application flexibility.
Figure 1.8 Stall Protection
600% Percent Full Load Current
Programmed Start Time Time (seconds)
Stall
Figure 1.9 Jam Detectionx
Percent Full Load Current
User Programmed Trip Level
100%
Running Time (seconds)
Jam
Jam detection is disabled during slow speed and braking operation.
Product Overview
1-9
Open Gate
An open gate fault indicates that improper SCR firing, typically caused by an open SCR gate, has been detected on one of the power poles. Before the controller shuts down, it will attempt to start the motor a total of three times.
Line Faults
The SMC Dialog Plus controller continually monitors line conditions for abnormal factors. Pre-start protection includes: Power Loss (with phase indication) Line Fault (with phase indication) Power loss Missing load connection Shorted SCR Running protection includes: Line Fault (no phase indication) Power loss Missing load connection Shorted SCR Additional programmable parameters are provided for the following protective features: Undervoltagex can be adjusted from 0 to 99% of the programmed line voltage and has a programmable delay time of 0 to 99 seconds. Overvoltagex can be adjusted from 0 to 199% of the programmed line voltage and has a programmable delay time of 0 to 99 seconds. Phase reversaly protection can be toggled either On or Off. Voltage unbalancex protection can be programmed for trip levels of 0 to 25% with a programmable delay time of 0 to 99 seconds.
Underloadz
Utilizing the underload protection of the SMC Dialog Plus controller, motor operation can be halted if a sudden drop in current is sensed. The SMC Dialog Plus controller provides an adjustable underload trip setting from 0 to 99% of the programmed motor full load current rating. Trip delay time can be adjusted from 0 to 99 seconds.
x y z Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation. Phase reversal protection is functional only at pre-start. Underload protection is disabled during slow speed and braking operations.
1-10
Product Overview
Excessive Starts/Hour
The SMC Dialog Plus controller allows the user to program the allowed number of starts per hour (up to 99). This helps eliminate motor stress caused by repeated starting over a short time period.
Overtemperature
The SMC Dialog Plus controller monitors the temperature of the SCRs by using internal thermistors. When the power poles maximum rated temperature is reached, SCR firing is inhibited. An overtemperature condition can indicate inadequate ventilation, high ambient temperature, overloading, or excessive cycling. After the SCR temperature is reduced to allowable levels, the fault can be cleared (see page 9-1 for instructions).
Metering
Power monitoring parameters include: Three-phase current Three-phase voltage Power in kW Power usage in kWH Power factor Motor thermal capacity usage Elapsed time
Notes: (1) The current sensing capability of the SMC Dialog Plus controller is disabled during bypass operation. A Bulletin 825 converter module is required to maintain the three-phase current, kW, kWH, and motor thermal capacity measurements. (2) Current measurement is not available during the slow speed and/or braking operations of the Preset Slow Speed, SMB Smart Motor Braking, Accu-Stop and Slow Speed with Braking control options. (3) Voltage measurement is not available during the braking operation of the SMB Smart Motor Braking, Accu-Stop, and Slow Speed with Braking control options. (4) The power factor parameter is provided as a displacement power factor value. Power factor measurement is disabled during bypass operation. (5) The elapsed time and kWH values are automatically saved to memory every 12 hours. (6) Motor thermal capacity usage is determined by the builtin electronic thermal overload protection system. An overload fault occurs when this value reaches 100%.
Product Overview
1-11
Communication
A serial interface port (called SCANport) is provided as standard, which allows connection to the Bulletin 1201 human interface modules and the Bulletin 1203 communication modules.
Figure 1.10 SCANport Location
SCANport
!
Programming
ATTENTION: Only one peripheral device can be connected to the SCANport. The maximum output current through the SCANport is 100 ma.
Setup is easy with the built-in keypad and two-line, sixteen character backlit LCD. Parameters are organized in a four-level menu structure, using a text format for straightforward programming.
Figure 1.11 Built-in Keypad and LCD
Status Indication
Three programmable hard contact outputs are provided as standard. The first two contacts are Form C and programmable for Normal/Upto-speed. The third contact is programmable as Normal/Fault.
1-12
Product Overview
Control Options
The SMC Dialog Plus controller offers the control options described below. Important: The options listed in this section are mutually exclusive and must be specified when ordering. An existing controller may be upgraded to another control option by replacing the control module. Consult your nearest/local Allen-Bradley sales office.
Soft Stop Option

This option can be used in applications that require an extended coastto-rest. The voltage ramp down time is user-adjustable from 0 to 60 seconds and is adjusted independently from the 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 1.12 Soft Stop Option
Percent Voltage
100%
Kickstart
Coast-to-rest Soft Stop
Initial Torque
Start
Run Time (seconds)
Soft Stop
ATTENTION: Soft Stop is not intended to be used as an emergency stop. Refer to the applicable standards for emergency stop requirements.
Product Overview
1-13
Pump Control Option

This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor. The microprocessor 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 030 seconds, and the stopping time is programmable from 0120 seconds.
Figure 1.13 Pump Control Option
100% Motor Speed
Pump Start
Run Time (seconds)
Pump Stop
ATTENTION: Pump stopping is not intended to be used as an emergency stop. Refer to the applicable standard for emergency stop requirements.
ATTENTION: Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system. Therefore, select the lowest stopping time setting that will satisfactorily stop the pump.
Preset Slow Speed Option

This option can be used in applications that require a slow speed jog for general purpose positioning. Preset Slow Speed provides either 7% of base 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.
1-14
Product Overview
Figure 1.14 Preset Slow Speed Option
Forward
15% High 7% Low
Time (seconds) 10% Low 20% High Reverse
Start
Run
!
Control Options (cont.)
ATTENTION: Slow speed running is not intended for continuous operation due to reduced motor cooling.
SMB Smart Motor Braking Option

This option can be used in applications that require reduced stopping times. The SMC Dialog Plus controller incorporates a microprocessor-based system that applies braking current to a standard squirrel cage induction motor without any additional equipment. This option offers a user-adjustable braking current setting from 0% to 400% of the motors full load current rating. Further, it provides automatic shut-off at zero speed detection.
Figure 1.15 SMB Smart Motor Braking Option
100% Smart Motor Braking Motor Speed
Coast-to-rest
Start
Run Time (seconds)
Brake Automatic Zero Speed Shut-off
Product Overview
1-15
Note: All braking current settings in the range of 1100% will provide 100% braking current to the motor. ATTENTION: SMB Smart Motor Braking is not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements.
Accu-Stop Option
This option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options. For general purpose positioning, the Accu-Stop option provides a brake from full speed to the preset slow speed setting, then brakes to stop.
Figure 1.16 Accu-Stop Option
100%
Motor Speed
7% or 15%
Braking Slow Speed
Slow Speed Braking/Coast
Slow Speed
Start
Run Time (seconds)
Accu-Stop
1-16
Product Overview
Slow Speed with Braking Option

The Slow Speed with Braking option provides a jog speed for process set-up and braking-to-stop at the end of the cycle.
Figure 1.17 Slow Speed with Braking Option
100% Coast-to-rest Motor Speed 7% or 15% Braking
Slow Speed
Start
Run Time (seconds)
Stop
ATTENTION: Accu-Stop and Slow Speed with Braking are not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements.
Chapter
Installation
Receiving
It is the responsibility of the user to thoroughly inspect the equipment before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are damaged, it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill. Should 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 requested to make a visual inspection of the equipment. Remove all packing material, wedges, or braces from within and around the controller. Remove all packing material from the heat sink. After unpacking, check the item(s) nameplate catalog number against the purchase order. The controller should remain in its shipping container prior to installation. If the equipment is not to be used for a period of time, it must be stored according to the following instructions in order to maintain warranty coverage. Store in a clean, dry location. Store within an ambient temperature range of 20C to +75C (4F to +167F). Store within a relative humidity range of 0% to 95%, noncondensing. Do not store equipment where it could be exposed to a corrosive atmosphere. Do not store equipment in a construction area.
Unpacking
Inspecting Storing
2-2
Installation
General Precautions
In addition to the precautions listed throughout this manual, the following statements, which are general to the system, must be read and understood. ATTENTION: The controller contains ESD (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to applicable ESD protection handbooks. ATTENTION: 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 excessive ambient temperatures, may result in malfunction of the system. ATTENTION: Only personnel familiar with the controller and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage.
!
Heat Dissipation
The following table provides the maximum heat dissipation at rated current for the controllers. For currents lower than rated value, heat dissipation will be reduced.
Table 2.A Maximum Heat Dissipation
180A 660 240A 935 360A 1170 500A 1400 650A 2025 720A 2250 850A 2400 1000A 2760
SMC Rating Max. Watts
24A 110
35A 150
54A 200
97A 285
135A 410
Enclosures
The open-style design of the SMC Dialog Plus controller requires that it be installed in an enclosure. The internal temperature of the enclosure must be kept within the range of 0C to 50C.
Installation
2-3
Ventilated Enclosures
For Type 1 (IP42) enclosures, the following guidelines are recommended to limit the maximum controller ambient temperature. There should be a clearance of at least six inches (15 cm) above and below the controller. This area allows air to flow through the heatsink. Ventilation openings are required above and below this air space. The ventilation outlet should be placed at least six inches (15 cm) above the controller with the ventilation inlet placed near the bottom of the enclosure. A filter is required to prevent contaminants from entering the enclosure. Use the table below to determine the minimum ventilation openings and fan/blower requirements.
Table 2.B Minimum Ventilation Openings
Top Cutout xz 65 cm
2
SMC Rating 2454A 97 and 135A 180A 240A 360A 500A 650A 720A 850A 1000A
x y z
Bottom Cutout xz 65 cm
2
Fan Size x 110 CFM 110 CFM 100 CFM 250 CFM (2) 250 CFM 275 CFM (3) 240 CFM (3) 240 CFM (3) 240 CFM (3) 240 CFM
(10 in2) 233 cm2 (36 in2) 13 51 (5 20) 13 51 (5 20) 13 51 (5 20) 13 41 (5 16)
y y
(10 in2) 233 cm2 (36 in2)

y y y y
y y
13 76 (5 30) 13 76 (5 30) 13 76 (5 30) 13 76 (5 30)
Cutout size assumes 50% blockage (filters, louvers, etc.) Cutout size is the same as required for the particular fan or blower being used. Dimensions are in centimeters (inches in parentheses).
Non-ventilated Enclosures
For Type 12 (IP54) or non-ventilated enclosures, it is recommended that a bypass contactor be used. This will allow the SMC Dialog Plus controller to bring the motor up-to-speed. After the controller is up to full voltage, it is bypassed. Note that the Energy Saver, Phase Rebalance, some metering functions, and some protective features of the controller may no longer be available. See Figure 3.17 on page 313 for this configuration.
2-4
Installation
Mounting
The controller is convection cooled. Additionally, units rated for 97A and above are fan cooled. It is important to locate the controller in a position that allows air to flow vertically through the power module. The controller must be mounted with heatsink fins in a vertical plane and have a minimum of six inches (15 cm) free space above and below the controller.
Dimensions
Figure 2.1 Dimensions: 24, 35, and 54 Amp Controllers
C D
.28 in. (7.14 mm)
4 Mtg. Holes
.22 in. (5.56 mm)
4 Mtg. Holes G F B
Ground Screw
E A
(10-32)
Unit mm in. mm in. mm in.
A Width 154 6-1/16 214 8-7/16 244 9-39/64
B Height 180 7-3/32 240 9-39/64 290 11-22/64
C Depth 185 7-19/64 195 7-11/16 225 8-7/8
D 50 1-31/32 60 2-23/64 90 3-35/64
E 140 5-33/64 200 7-7/8 230 9-1/64
F 160 6-5/16 200 7-7/8 240 9-29/64
G 140 5-33/64 180 7-3/32 200 7-7/8
H 10 13/32 20 51/64 25 63/64
J 20 51/64 30 1-3/16 45 1-25/32
Approx. Ship. Wt. 4.5 kg 10 lbs. 6.8 kg 15 lbs. 11.3 kg 25 lbs.
24A Controller 35A Controller 54A Controller
All dimensions are approximate and are not intended for manufacturing purposes. Refer to the nearest Allen-Bradley sales office for complete dimension drawings.
Installation
2-5
Figure 2.2 Dimensions: 97 and 135 Amp Controllers

A E C Power Terminal H M10 Bolt 6 Places G D
Ground Screw (M6) .281 in. ( 7.14 mm) 4 Mtg. Holes Fan Terminals
Unit mm in. mm in.
A Width 248 9-49/64 248 9-49/64
B Height 336 13-15/64 336 13-15/64
C Depth 256.2 10-3/32 256.2 10-3/32
D 128 5-3/64 128 5-3/64
E 220 8-21/32 220 8-21/32
F 250 9-27/32 250 9-27/32
G 40.4 1-39/64 40.4 1-39/64
H 14 9/16 14 9/16
Approx. Ship. Wt. 10.4 kg 23 lbs. 11.8 kg 26 lbs.
97A Controller 135A Controller
2-6
Installation
Mounting (cont.)
A P D E .281 (7.1) Dia. 6 Mtg. Holes .281 (7.1) Rad. 2 Key Holes F
Figure 2.3 Dimensions: 180 through 360 Amp Controllers

C Q N
G Terminal Detail J B H 1.02 (25.9) .136 (3.5) Dia. #8-32 UNC-2B .413 (10.5) Dia.
.984 (25) .531 (13.5) 2.250 (57) M 180, 240, and 360 Amp Dbl. Lug Mtg. L Ground Nut (1/4-20)
1.161 (29.5)
Unit
A Width
B Height
C Depth
Approx. Ship. Wt. 25 kg 55 lbs. 30 kg 65 lbs.
180A Cont.
mm in. mm
273 10.750 273 10.750
580 22.063 580 22.063
294.2 11.583 294.2 11.583
245 9.647 245 9.647
5 .207 5 .207
81 3.195 81 3.195
221 8.695 221 8.695
361 14.195 361 14.195
453 17.817 453 17.817
56 2.213 56 2.213
251 9.880 251 9.880
167 6.562 167 6.562
35 1.375 35 1.375
19.3 .76 19.3 .76
8.4 .250 8.4 .250
28 1.1 28 1.1
4.7 .187 4.7 .187
240 360A Cont.
in.
Installation
2-7
Figure 2.4 Dimensions: 500 Amp Controller

.531 in. (13.5 mm) for 1/2 Bolts Typ. M N E P F J
.312 in. (7.9 mm) 6 Mtg. Holes Q H B Q Ground Nut (1/4-20) C D
Unit
mm in.
A Height
B Width
C Depth
Approx. Ship. Wt. 40.8 kg 90 lbs.
588.4 23-11/64
508 20
310.7 12-15/64
183 7-13/16
51.4 2-1/32
50.8 2
469.9 18-1/2
489 19-1/4
19 3/4
196.9 7-3/4
393.7 15-1/2
38.9 1-17/32
18.6 47/64
17.5 11/16
136 5-11/32
2-8
Installation
Mounting (cont.)
Figure 2.5 Dimensions: 650-1000 Amp Controllers

A
D .56 Dia. ( 14.2) 2 Lifting Holes .5 Dia. ( 12.7) 6 Holes C G E F H M N L
Q .105 Steel Sheet (2.67)
.75 Dia. ( 19.1) 2 Holes 2.0 (50.8) .688 (17.5) 1.312 (33.3)
4.0 (101.6) .515 (13.1) Dia. Typ. 1.312 (33.3)
B J K
650720 Amp
2.5 (63.5) .64 (16.3) Typ. .64 (16.3)
5.0 (127) .688 (17.5) .67 (17)
.64 (16.3) 8501000 Amp Grounding Lug (wide range: #6 solid to 250 MCM stranded)
Typical Line and Load Bus
Unit 650 and 720A Controller 850 and 1000A Controller mm in. mm in.
A Width 32.0 812.8 32.0 812.8
B Height 60.0 1524.0 60.0 1524.0
C Depth 15.83 402.1 15.83 402.1
D 30.25
E 6.0
F 12.13 308.0 12.13 308.0
G .875 22.22 .875 22.22
H .875 22.23 .875 22.23
J 2.0 50.8 2.0 50.8
K 58.25
L 9.935
M 5.475
N .75 19.05 .75 19.05
P 329 13 383 15
317.5 246.1 12.5 375 14.75 9.69 246.1 9.69
768.35 152.4 30.25 6.0
1479.55 252.35 139.06 58.25 9.935 5.475
768.35 152.4
1479.55 252.35 139.06
All dimensions are approximate and are not intended for manufacturing purposes. Refer to the nearest Allen-BradleyAllen-Bradley sales office for complete dimension drawings.
Installation
2-9
Power Factor Correction Capacitors
The controller can be installed on a system with power factor correction (PFC) capacitors. The capacitors must be located on the line side of the controller. This must be done to prevent damage to the SCRs in the SMC Dialog Plus controller. When discharged, a capacitor essentially has zero impedance. For switching, sufficient impedance should be connected in series with the capacitor bank to limit the inrush current. One method for limiting the surge current is to add inductance in the capacitors conductors. This can be accomplished by creating turns or coils in the power connections to the capacitors. 250V 6 inch diameter coil, 6 loops 480600V 6 inch diameter coil, 8 loops
Take care in mounting the coils so that they are not stacked directly on top of each other; stacking will cause a canceling 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 further instructions, consult the PFC capacitor vendor.
Figure 2.6 Typical Wiring Diagram for Power Factor Correction Capacitors
IC
L1/1 T1/2
L2/3
T2/4
Motor
L3/5
T3/6
Branch Circuit Protection
SMC Dialog Plus
Customer supplied Not required
Power Factor Correction Capacitors
2-10
Installation
Fast Acting Current-limiting Fuses
Short-circuit protection guidelines are provided in Appendix A of this manual. Enhanced SCR protection may be obtained with the use of fast acting current-limiting fuses. Table 2.C provides a listing of fuses that are coordinated to protect the controller SCRs in the event of a ground fault or short-circuit at the connected load. If SCR fusing is not used, the controller power modules may be damaged and require replacement. Supplementary SCR fusing, however, is not required by the NFPA 70 (National Electric Code).
Table 2.C Recommended Fuses
Fuse Manufacturer Cat. No. x Bussman SPP-4F60 170M 3610-63 SPP-4F100 170M 3612-100 SPP-4F150 170M 3614-160 SPP-4F300 170M 3617-315 SPP-4F300 170M 3617-315 SPP-4F400 170M 3619-400 SPP-6F400 170M 5608-400 SPP-6F600 170M 5612-630 SPP-6F800 170M 6613-900 SPP-6F800 170M 6613-900 SPP-5F600 y 170M 5612-630 y SPP-7F1200 170M 6615-1100 SPP-6F800 y 170M 6613-900 y
x y
SMC Rating 24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A
Shawmut A70P70 A70P100 A70P200 A70P300 A70P300 A70P400 A70P500 A70P800 A70P1000 A70P1000 A70P1200 A70P1000 y A70P1000 y
Edison (Brush) XL70F080 XL70F125 XL70F200 XL70F300 XL70F300 XL70F400 XL70F500 XL70F600 XL70F500 y XL70F500 y XL70F600 y
Ferraz A070F060 A070F100 A070F150 A070F300 A070F300 A070F400 A070F400 A070F800 A070F800 A070F800 A070F800 A070F1200 A070F1200
Littlefuse L70S60 L70S100 L70S150 L70S300 L70S300 L70S400 L70S400 L70S600 L70S800 L70S500 L70S500 L70S800 L70S800
Note: Fuse size listed is for 230V, 460V, or 575V. Fuse manufacturers cross reference of the fuse Cat. Nos. listed here may not provide proper coordination. Two fuses per phase are required for these controller ratings.
ATTENTION: The fast acting current-limiting fuses specified in Table 2.C may not provide branch circuit protection. Branch circuit protection in accordance with applicable electrical codes may require additional fusing (or a circuit breaker) even though fast acting current-limiting fuses are used. ATTENTION: Applications requiring extended acceleration times or high duty cycles may experience nuisance tripping of the coordinated fast acting currentlimiting fuses. This type of fuse has a limited thermal capacity that is less than that of the SCRs they are designed to protect. This makes them susceptible to thermal fatigue.
Installation
2-11
Protective Modules
Protective modules containing metal oxide varistors (MOVs) and capacitors can be installed on controllers rated 24A to 360A to protect the power components from electrical transients and/or high electrical noise. The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs. The capacitors in the protective modules are used to shunt noise energy away from the controller electronics. Surge protection is provided as standard for controllers rated 5001000A. ATTENTION: When installing or inspecting the protective module, make sure that the controller has been disconnected from the power source. The protective module should be inspected periodically for damage or discoloration. Replace if necessary.
!
Motor Overload Protection
Thermal motor overload protection is provided as standard (though it must be programmed) with the SMC Dialog Plus controller. If the overload trip class is less than the acceleration time of the motor, nuisance tripping may occur. ATTENTION: Overload protection should be properly coordinated with the motor.
!
Bypass
Three special applications require consideration: bypass, two-speed motors, and multi-motor protection.
In a bypass configuration, the SMC Dialog Plus controller loses current sensing capability. It is recommended that a Bulletin 825 converter module be used to provide current feedback to the SMC Dialog Plus controller for these applications to maintain the thermal memory and to maintain the SMC Dialog Plus controllers power monitoring capability. It is possible, however, to use a traditional electromechanical overload relay for bypass configurations.
Two-speed Motors
The SMC Dialog Plus controller has overload protection available for single speed motors. When the SMC Dialog Plus controller is applied to a two-speed motor, the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed.
Multi-motor Protection
If the SMC Dialog Plus controller is controlling more than one motor, individual overload protection is required for each motor.
2-12
Installation
Human Interface Module
The Bulletin 1201 human interface modules may be used to program and control the SMC Dialog Plus controller. The human interface modules have two sections: a display panel and a control panel. The display panel duplicates the 2-line, 16-character backlit LCD display and programming keypad found on front of the SMC Dialog Plus controller. Refer to Chapter 4 for a description of the programming keys; refer to Appendix D for a listing of human interface module catalog numbers that are compatible with the controller. The control panel provides the operator interface to the controller. Start The green start button, when pressed, will begin motor operation. Stop The red stop button, when pressed, will halt motor operation.
JOG
Jog The jog button is active only when a control option is present. Pressing the jog button will initiate the option maneuver (for example: Pump Stop).
ATTENTION: The Bulletin 1201 human interface modules stop push button is not intended to be used as an emergency stop. Refer to the applicable standards for emergency stop requirements.
All other controls available with the various human interface modules are non-functional with the SMC Dialog Plus controller.
Installation
2-13
Connecting the Human Interface Module to the Controller

Figure 2.7 shows the connection of the SMC Dialog Plus controller to a human interface module. See Figure 3.14 on page 3-10 for the control wiring diagram that enables start-stop control from a human interface module.
Figure 2.7 SMC Dialog Plus Controller with Human Interface Module
11
12
13
14
15
16
17
18
19
20
Bulletin 1202 Latching Mechanism Cable Pull back moving part (connector body) to disconnect cable from the SCANport connection.
21
22
23
24
25
26
27
28
29
30
Control Enable
To enable motor control from a connected human interface module, follow the procedure below with the connected human interface modules programming keys. Note: Series A and Series B human interface modules require different procedures. Be sure to use the correct table.
2-14
Installation
Human Interface Module (cont.)
Series A Human Interface Modules

Description Action Display
STOPPED 0.0 AMPS
1.
Press any key to access the Choose Mode function. Scroll with the Up/Down keys until the Program option appears. Press the Enter key to access the Program option. Scroll with the Up/Down keys to the Linear List option. Press the Enter key to access the Linear List programming group. Scroll with the Up/Down keys to parameter number 85 Logic Mask. Press the Select key to move the cursor to the second line to modify the parameter.x Press the Up key until the value 4 appears.
CHOOSE MODE _____
2.
or
CHOOSE MODE PROGRAM
3.
PROGRAM _____
4.
or
PROGRAM LINEAR LIST
5.
VOLTS PHASE A-B 0 VOLTS 1
6.
or
LOGIC MASK 0
85
7.
LOGIC MASK 0
85
8.
LOGIC MASK 4
85
9.
Press the Enter key to accept the new setting.
LOGIC MASK 4
85
Zero and 4 are the only valid settings.
Note: If a human interface module is disconnected from the SMC Dialog Plus controller while the Logic Mask is set to 4, a Comm Fault will occur.
Installation
2-15
Series B Human Interface Modules

STOPPED 0.0 AMPS
1.
Press any key to access the Choose Mode function. Scroll with the Up/Down keys until the Control Logic option is presented. Press the Enter key to access Control Logic options. Press the Select key to access the settings available. Use the Up/Down keys to obtain the Enable option. Press the Enter key to accept.
CHOOSE MODE _____
2.
or
CHOOSE MODE CONTROL STATUS
3.
CONTROL LOGIC DISABLE
4.
CONTROL LOGIC DISABLE
5.
or
CONTROL LOGIC ENABLE
6.
CONTROL LOGIC ENABLE
Note: If a human interface module is disconnected from the SMC Dialog Plus controller while Control Logic is enabled, a Comm Fault will occur.
2-16
Installation
Communication Modules
The Bulletin 1203 communication module allows the user to connect the SMC Dialog Plus controller to various networks and communication protocols. The figure below shows how the controller and the communication module connect.
Figure 2.8 SMC Dialog Plus Controller with Communication Module
11
12
13
14
15
16
17
18
19
20
Bulletin 1202 Latching Mechanism Cable Pull back moving part (connector body) to disconnect cable from the SCANport connection.
21
22
23
24
25
26
27
28
29
30
V+ VG
Communication Module
Converter Modules
The Bulletin 825 converter module provides three-phase current feedback to the SMC Dialog Plus controller for metering and overload protection during phase rebalance and bypass operation. Select the converter module based on the motor full load current (FLC) rating. Table 2.A details the information for proper selection.
Table 2.A Converter Module Selection Guide
Cat. No. 825-MCM20 825-MCM180 825-MCM630
Motor FLC Range 112.5A 9100A 64360A
Installation
2-17
Figure 2.9 shows the connection between the controller and the module.
Figure 2.9 Converter Module Connection Interface
L1 L2 L3 Converter Module T1 T2 T3
Cable (provided as standard with the converter module)
150-NFS Fanning Strip
21 22 23 24 25
26 27 28 29
30
x y
The converter module rating must be programmed in the calibration group for proper current measurement scaling. Cable length is three meters. Only the cable provided with the converter module is compatible with the SMC Dialog Plus controller. Use of any other cable may result in faulty controller operation.
2-18
Installation
Converter Modules (cont.)
For applications in which the motors full load current rating is greater than 360A, three additional current transformers with 5A secondaries are required. The figure below illustrates the connection of the current transformers to the converter module.
Figure 2.10 Current Transformer Connection to Converter Module
Current Transformer
L1
L2
L3 Converter Module
T1
T2
T3
x y z
The current transformer (CT) ration must be programmed in the calibration group for proper current measurement scaling. See page 5-2 for instructions on programming this parameter. Another current transformer connects L2 and T2, and another connects L3 and T3. The converter module, Cat No. 825-MCM20, must be used in these applications.
Electromagnetic Compatibility (EMC)

.
ATTENTION: This product has been designed for Class A equipment. Use of the product in domestic environments may cause radio interference, in which case, the installer may need to employ additional mitigation methods.
The following guidelines are provided for EMC installation compliance.
Enclosure
Install the product in a grounded metal enclosure.
Grounding
Connect a grounding conductor to the screw or terminal provided as standard on each controller. Refer to Figure 2.1 through Figure 2.5 for grounding provision location.
Installation
2-19
Wiring
Wire in an industrial control application can be divided into three groups: power, control, and signal. The following recommendations for physical separation between these groups is provided to reduce the coupling effect. Different wire groups should cross at 90 inside an enclosure. Minimum spacing between different wire groups in the same tray should be six inches (16 cm). Wire runs outside an enclosure should be run in conduit or have shielding/armor with equivalent attenuation. Different wire groups should be run in separate conduits. Minimum spacing between conduits containing different wire groups should be three inches (8 cm).
Accessory Requirements
When connection of the Bulletin 825 converter module or Bulletin 1202 communication cable is required, a ferrite core suppressor (FairRite PN 2643802702 or equal) should be used in conjunction. Mount the suppressor as close to the controller as practical, wrapping the cable twice through the suppressor.
2-20
Installation
Chapter
Wiring
Terminal Locations
The SMC Dialog Plus controller wiring terminal locations are shown in Figure 3.1 through Figure 3.4. Make wiring connections as indicated in the typical connection diagrams. Connect the line to terminals L1/1, L2/3, and L3/5. Connect the load to terminals T1/2, T2/4, and T3/6. For controllers rated 24135A, a grounding screw is provided to ground the heatsink per applicable codes. For controllers rated 180A1000A, a grounding lug is provided on the mounting plate.
Figure 3.1 Wiring Terminal Locations (24 to 54 Amp)
L1 1 L2 3 L3 5
Input Power Connections Control Circuit Connections
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
ESC.
SEL.
2 T1
4 T2
6 T3
Output Power Connections
Figure 3.2 Wiring Terminal Locations (97 and 135 Amp)

Input Power Connections Control Circuit Connections
Fan Power Connections
3-2
Wiring
Terminal Locations (cont.)

Input Power Connections

Control Wiring Access Door Fan Power Connections TB3
Control Circuit Connections
Figure 3.4 Wiring Terminal Locations (500 Amp)

Input Power Connections Fan Power Connections
Wiring
3-3
Input and Output Power Connections
Fan Power Connections
Power Wiring
2454A The power modules for controllers rated 24A54A have internal mechanical-type lugs to accept line and load cables. Table 3.A and Table 3.B provide the lug wire capacity and tightening torque requirements.
Table 3.A Lug Wire Capacity
Metric 2.525 mm2 AWG #14#4
Table 3.B
Tightening Torque
Tightening Torque
Wire Size Torque
2.56 mm2 (1410 AWG) 2.80 N-m (25 Lb-in)
10 mm2 (8 AWG) 3.4 N-m (30 Lb-in)
1625 mm 2 (64 AWG) 3.95 N-m (35 Lb-in)
971000A Power lugs are available as optional kits. Each kit contains three lugs. The number of terminal lug kits required is listed in the table below. Table 3.C also provides the lug wire capacity and the tightening torque requirements.
3-4
Wiring
Terminal Locations (cont.)
Table 3.C
Lug Wire Capacity and Tightening Torque

Max. No. Lugs/Pole Line Side 3 6 6 9 6 Load Side 3 6 6 9 6 Tightening Torque Wire Lug 31 N-m (275 lb-in) 31 N-m (275 lb-in) 42 N-m (375 lb-in) 42 N-m (375 lb-in) 42 N-m (375 lb-in) Lug Busbar 31 N-m (275 lb-in) 31 N-m (275 lb-in) 45 N-m (400 lb-in) 45 N-m (400 lb-in) 45 N-m (400 lb-in)
SMC Rating
Lug Kit Cat. No.
Conductor Range
97 135A 180 360A 500A 650 720A 850 1000A
199-LF1 199-LF1 199-LG1 199-LG1 199-LJ1
16120 mm 2 (#64/0 AWG) 16120 mm 2 (#64/0 AWG) 25240 mm 2 (#4500 AWG) 50240 mm 2 (1/0500 AWG) 50240 mm 2 [(2) 1/0500 AWG]
Control Power
Control Voltage
Depending upon the catalog number ordered, the SMC Dialog Plus controller will accept a control power input of: 100240V AC, (15/+10%), 1 phase, 50/60 Hz 24V AC, (15/+10%), 1 phase, 50/60 Hz 24V DC, (20/+10%), 1 phase
Refer to the product nameplate. Connect control power to the controller at terminals 11 and 12. The control power requirement for the control module is 40 VA. For controllers rated 97A1000A, control power is also required for the heatsink fans as defined in Table 3.D. Depending on the specific application, additional control circuit transformer VA capacity may be required.
Table 3.D Heatsink Fan Control Power
Heatsink Fan VA 45 145 320
SMC Rating 97360A 500A 6501000A
Control Wiring
Table 3.E provides the control terminal wire capacity and the tightening torque requirements. Each control terminal will accept a maximum of two wires.
Table 3.E Control Wiring and Tightening Torque
Wire Size 0.752.5 mm2 (#18#14) Torque .8 N-m (7 lb-in.)
Wiring
3-5
Fan Power
Controllers rated 97A1000A have heatsink fan(s). Refer to Table 3.D for the control power VA requirements of the heatsink fans.
Fan Terminations
See Figure 3.2 to Figure 3.4 for fan power connection locations. ATTENTION: The fan jumpers have been factory installed for 110/120 VAC input. Refer to Figure 3.6 through Figure 3.8 for 220/240 VAC fan wiring. Note that 220/240 VAC fan wiring is not available for the 650A1000A controllers. After wiring for the 97A and 135A controllers is complete, replace control terminal strip cover.
Figure 3.6 97A and 135A Fan Terminations

Factory Set 110/120 VAC
1 2 3 4 1
Optional 220/240 VAC
To Supply Jumpers
2 3 4
To Supply Jumper
Figure 3.7 180A to 500A Fan Terminations

Factory Set 110/120 VAC To Supply Optional 220/240 VAC To Supply
Jumpers
Jumper
Figure 3.8 650A to 1000A Fan Terminations

Factory Set 110/120 VAC To Supply
Note: 220/240 VAC is not available.
3-6
Wiring
Control Terminal Designations
As shown in Figure 3.9, the SMC Dialog Plus controller contains 20 control terminals on the front of the controller.
Figure 3.9 SMC Dialog Plus Controller Control Terminals
1 1
1 2
1 3
1 4
1 5
1 6
1 7
1 8
1 9
2 0
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
3 0
Terminal Number 11 12 13 14 15 16 17 18 19 20
x y
Description Control Power Input Control Power Common Controller Enable Input x Logic Ground Dual Ramp/Option Input x Start Input x Stop Input x Auxiliary Relay Common N.O. Auxiliary Contact #1 (Normal/Up-to-speed) N.C. Auxiliary Contact #2 (Normal/Up-to-speed)
Terminal Number 21 22 23 24 25 26 27 28 29 30 Not Used Not Used Not Used Not Used
Description
Converter Module Fanning Strip Connection y Converter Module Fanning Strip Connection y Converter Module Fanning Strip Connection y Converter Module Fanning Strip Connection y N.O./N.C. Auxiliary Contact #3 (Normal/Fault) N.O./N.C. Auxiliary Contact #3 (Normal/Fault)
Do not connect any additional loads to these terminals. These parasitic loads may cause problems with operation, which may result in false starting and stopping. When control power is absent from terminals 11 and 12, this contact will be normally open. Upon application of control power, the contact will take the state, normally open or normally closed, as programmed.
Grounding Provision
Provision for connecting a field installed grounding conductor is provided on each controller. It is shown in Figure 3.10 and is located on the heatsink. This symbol is the ground connection identification symbol as defined by IEC Publication 417, Symbol 5019. If the protective conductor is not connected to the heatsink, the plating and/or paint must be cleaned from the four mounting holes or four star washers (tooth lock washers) must be used.
Figure 3.10 Grounding Provision
Wiring
3-7
Standard Controller Wiring Diagrams
Figure 3.11 through Figure 3.22 show typical wiring for the SMC Dialog Plus controller.
Figure 3.11 Typical Wiring Diagram for Standard Controller
L1/1 3-Phase L2/3 Input Power L3/5 Branch Protection Fast-acting SCR Fuses (optional) T3/6 T2/4 T1/2
Stop
Start
11 12 13 14 15 16 17 18 19 20
SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30
x y
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage.
3-8
Wiring
Standard Controller Wiring Diagrams (cont.)

3-Phase
Figure 3.12 Typical Wiring Diagram for Two-Wire Control or Programmable Control Interfacing
L1/1 L2/3 Input Power L3/5 Branch Protection Fast-acting SCR Fuses (optional) T3/6 T1/2 T2/4
Two-wire Device
11 12 13 14 15 16 17 18 19 20
x y
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. (1) Programmable controller interfacing in this diagram refers to hard-wiring between the PLCs output contacts and the SMC Dialog Plus controllers control terminals. For a wiring diagram related to programmable controller interfacing via the SMC Dialog Plus controllers SCANport, refer to Figure 3.14. The OFF state leakage current for a solid-state device must be less than 6 mA.
Notes:
(2)
Wiring
3-9
Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications

L1/1 3-Phase L2/3 Input Power L3/5 Branch Protection Fast-acting SCR Fuses (optional) T3/6 T2/4 T1/2
Stop
Ramp 1 Ramp 2 Start
11 12 13 14 15 16 17 18 19 20
SMC Dialog Plus Control Terminals
Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30
x y Note:
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. The Dual Ramp feature is available only with the standard control version.
3-10
Wiring
Figure 3.14 Typical Wiring Diagram for Start-Stop Control via the SCANport
Note: Use this wiring diagram when start-stop will come from either a Bulletin 1201 human interface module or a Bulletin 1203 communication module connected to the SMC Dialog Plus controllers SCANport.
L1/1 3-Phase L2/3 Input Power L3/5 Branch Protection Fast-acting SCR Fuses (optional)
T1/2 T2/4 T3/6
11 12 13 14 15 16 17 18 19 20
x y z
Customer supplied. If the Soft Stop, Pump Control, or the SMB Smart Motor Braking option is installed, place additional jumper to terminal 15. Refer to the controller nameplate to verify the rating of the control power input voltage.
Wiring
3-11
Figure 3.15 Typical Wiring Diagram for Retrofit Applications

L1/1 3-Phase Input Power L3/5 Branch Protection OL Existing Motor Starter T3/6 Fast-acting SCR Fuses SMC Dialog Plus Controller (optional) L2/3 T1/2 T2/4
Start Stop
M 11 12 13 14 15 16 17 18 19 20
Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals
Internal Auxiliary Contacts 26 27 28 29 30
21
22
23
24
25
x y z
Customer supplied. Overload protection should be disabled in the SMC Dialog Plus controller. Refer to the controller nameplate to verify the rating of the control power input voltage.
3-12
Wiring

3-Phase
Figure 3.16 Typical Wiring Diagram for Isolation Applications
L1/1 L2/3 L3/5 Branch Protection Isolation Contactor (IC) Fast-acting SCR Fuses (optional) Input Power
T1/2 T2/4 T3/6
IC
Stop
Start
11 12 13 14 15 16 17 18 19 20
Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals
21
22
23
24
25
x y
Wiring
3-13
Figure 3.17 Typical Wiring Diagram for Bypass Applications

L1/1 L2/3 L3/5 Branch Protection Bulletin 825 Converter Module T1/2 T2/4 T3/6
3-Phase Input Power
Fast-acting SMC SCR Fuses Dialog Plus (optional) Controller
BC
Bypass Contactor (BC)
Stop
Start
11 12 13 14 15 16 17 18 19 20
Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals To Bulletin 825 Converter Module 21 22 23 24 25 26 27 28 29 30 Internal Auxiliary Contacts
Fanning Strip
x y z
Customer supplied. The Bulletin 825 Converter Module is required when the SMC Dialog Plus controller will be providing motor overload protection during bypass operation. Refer to the controller nameplate to verify the rating of the control power input voltage.
3-14
Wiring
Figure 3.18 Typical Wiring Diagram for Bypass with Isolation Applications
Bulletin 825 Converter Module L1/1 L2/3 L3/5 Branch Protection Isolation Contactor (IC) T1/2 T2/4 T3/6
3-Phase Input Power
Fast-acting SCR Fuses SMC Dialog Plus (optional) Controller
Bypass Contactor (BC) BC
Stop
Start
11 12 13 14 15 16 17 18 19 20
Auxiliary contacts set for Up-to-speed
IC To Bulletin 825 Converter Module 21 22 23 24 25 26 27 28 29 30
Fanning Strip
x y Customer supplied.
Auxiliary contact set for Normal and N.O.
Refer to the controller nameplate to verify the rating of the control power input voltage.
Wiring
3-15
Figure 3.19 Typical Wiring Diagram for Shunt Trip Applications

Shunt Trip Circuit Breaker L1/1 3-Phase L2/3 Input Power L3/5 Branch Protection T3/6 Fast-acting SCR Fuses SMC Dialog Plus (optional) Controller T2/4 T1/2
Stop
Start
11 12 13 14 15 16 17 18 19 20
ST
21
22
23
24
25
26
27
28
29
30
Auxiliary contact set for Fault and N.O.

x y Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage.
3-16
Wiring

3-Phase
Figure 3.20 Typical Wiring Diagram for Single Speed Reversing Applications
L1/1 T1/2 L2/3 T2/4
Input Power L3/5 T3/6 Branch Protection R Bulletin 825 Fast-acting SMC Dialog Plus SCR Fuses Coverter Controller (optional) Module (optional)
Reversing Contactors
Stop
FOR
OFF REV
F R R F
R F
11 12 13 14 15 16 17 18 19 20
SMC Dialog Plus Control Terminals Internal Auxiliary Contacts
21
22
23
24
25
26
27
28
29
30
x y
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input rating. (1) (2) Minimum transition time for reversing direction is 1/2 second. Phase Reversal protection must be disabled in reversing applications.
Notes:
Wiring
3-17
Figure 3.21 Typical Wiring Diagram for Two-speed Applications

L 3-Phase Input Power Branch Protection L1/1 T1/2 H L2/3 T2/4 L3/5 T3/6 SMC Dialog Plus Controller Fast-acting SCR Fuses (optional) LOL Stop High Low L L H L 1 sec. H 1 sec. 11 12 13 14 15 16 17 18 19 20 H H L HOL Two-speed Motor Starter H H
x y z
Customer supplied. Two-speed, consequent pole installations. Refer to the controller nameplate to verify the rating of the control power input voltage.
3-18
Wiring
Figure 3.22 Typical Wiring Diagram for Hand-Off-Auto (SCANport) Control
L1/1 3-Phase L2/3 Input Power
T1/2 T2/4
Branch Protection
L3/5 T3/6 Fast-acting SCR Fuses SMC Dialog Plus (optional) Controller
11 12 13 14 15 16 17 18 19 20
21
22
23
24
25
x y
Chapter
Programming
Overview
This chapter provides a basic understanding of the programming keypad built into the SMC Dialog Plus controller. This chapter also describes programming the controller by modifying the parameters. The keys found on the front of the SMC Dialog Plus controller are described below.
Escape Pressing the Escape key causes the programming system to move up one level in the menu structure.
Keypad Description
ESC
Select
SEL
The Select key has two functions: Pressing the Select key alternately causes the top or bottom line of the display to become active (indicated by flashing first character). In parameter modification with series A FRN 3.00 or greater and series B human interface modules, Select moves the cursor from the least significant digit to the most significant. These keys are used to increment and decrement a parameter value or to scroll through the different modes, groups, and parameters.
Up/Down Arrows
Enter
When pressed, a mode or group will be selected, or a parameter value will be entered into memory. After a parameter value has been entered into memory, the top line of display will automatically become active, allowing the user to scroll to the next parameter.
Programming Menu
Parameters are organized in a four-level menu structure for straightforward programming. Figure 4.1 details the programming menu structure and the four-level hierarchy.
4-2
Programming
Programming Menu (cont.)
Figure 4.1 Menu Structure Hierarchy
Power-up and Status Display
or
or
or
or
Choose Mode
OPERATION LEVEL
MODE LEVEL or
Control Status
Display read only
Program read/write
Password See page 4-5
Search read only See page 4-5
Control Logic Fault Queue or
Linear List
Metering See Chapter 6
Basic Setup
Advanced Setup
Faults
Calibrate See Chapter 5
Language
|
GROUP LEVEL
x y z { |
The SMC Dialog Plus controller does not support EEPROM, Link, Process, or Start-up modes. Steps back one level. Control Status and Search are only available when using a Series B Bulletin 1201 human interface module. Password protected. English is currently the only available language.
Programming
4-3
Figure 4.1 (Cont.) Menu Structure Hierarchy

or
Linear List
Metering See Chapter 6
Basic Setup
Advanced Setup
Faults
Calibrate See Chapter 5
Language GROUP LEVEL
Volts Phase AB Volts Phase BC Volts Phase CA Current Phase A Current Phase B Current Phase C Wattmeter Kilowatt Hours Elapsed Time Power Factor Mtr. Therm. Usage
SMC Option Starting Mode Ramp Time #1 Initial Torque #1 Curr. Limit Level Kickstart Time Stall Delay Energy Saver Aux Contacts 1&2 Aux Contact #3 Contact 3 Config (Option Setting) Parameter Mgmt
{
SMC Option Starting Mode Dual Ramp Ramp Time #1 Initial Torque #1 Ramp Time #2 Initial Torque #2 Curr. Limit Level Kickstart Time Stall Delay Energy Saver Aux Contacts 1&2 Aux Contact #3 Contact 3 Config (Option Setting) Undervolt Level Undervolt Delay Overvolt Level Overvolt Delay Jam Level Jam Delay Unbalance Level Unbalance Delay Rebalance Underload Level Underload Delay Phase Reversal Starts per Hour Restart Attempts Restart Delay ETM Reset Parameter Mgmt {
Clear Fault Fault Buffer #1 Fault Buffer #2 Fault Buffer #3 Fault Buffer #4 Fault Buffer #5
Overload Class Overload Reset Motor HP Rating Motor kW Rating Line Voltage Motor FLC Service Factor Motor Code Letter LRC Ration Converter Rating CT Ratio Calibration Enter Calib. Amps Current Phase A { Parameter Mgmt.
PARAMETER LEVEL
x y z {
Steps back one level. English is currently the only available language. For further information on parameters, see Appendix B. For further information on parameter management, see pages 4-6 and 4-7.
4-4
Programming
Programming Menu (cont.)
Table 4.A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Parameter Linear List

Description Volts Phase AB Volts Phase BC Volts Phase CA Current Phase A Current Phase B Current Phase C Wattmeter Kilowatt Hours Elapsed Time Power Factor Mtr. Therm Usage Factory Use Factory Use SMC Option ETM Reset Factory Use Parameter Mgmt. Clear Fault Fault Buffer #1 Fault Buffer #2 Fault Buffer #3 Fault Buffer #4 Fault Buffer #5 Factory Use Factory Use Factory Use Factory Use Starting Mode Dual Ramp Ramp Time #1 Initial Torque #1 Ramp Time #2 Initial Torque #2 Curr. Limit Level Kickstart Time Overload Class Stall Delay Energy Saver Aux Contacts #1&2 Aux Contact #3 Contact 3 Config Stop Time Factory Use Slow Speed Sel. Parameter No. 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 Description Slow Speed Dir. Slow Accel Cur. Slow Running Cur. Braking Current Factory Use Factory Use Stopping Current Undervolt Level Undervolt Delay Overvolt Level Overvolt Delay Jam Level Jam Delay Unbalance Level Rebalance Underload Level Underload Delay Phase Reversal Starts per Hour Restart Attempts Restart Delay Factory Use Factory Use Factory Use Line Voltage Motor FLC Factory Use Mtr. Code Letter Factory Use Converter Rating CT Ratio Calibration Enter Calib. Amps Language Select Motor HP Rating Motor kW Rating LRC Ratio Factory Use Factory Use Service Factor Logic Mask Unbalance Delay S/W Version Overload Reset
Parameter No.
Programming
4-5
Password
The SMC Dialog Plus controller allows the user to limit access to the programming system through password protection. This feature is a disabled with a factory-set parameter with a default setting of 0. To modify the password or login after a password is programmed, complete the procedure below.
STOPPED 0.0 AMPS
1.
Press any key to go from the status display to the Choose Mode menu. Scroll with the Up/ Down keys until the Password option appears. Press the Enter key to access the Password menu.
CHOOSE MODE DISPLAY
2.
or
CHOOSE MODE PASSWORD
3.
PASSWORD |MODIFY Options:Login, Modify Logout
4.
Press the Enter key.
ENTER PASSWORD _____
5.
Press the Up/Down keys to enter the desired number. If you are modifying the password, make a note of it as displayed. Press the Enter key after you have completed modifying the password.x
or
ENTER PASSWORD #####
6.
CHOOSE MODE PASSWORD
After you have completed the programming process, re-enter the Password mode to log out. This will eliminate unauthorized access to the programming system.
Note: If you lose or forget the password, contact your nearest Allen-Bradley sales office. You can also call 1-800-765SMCS (765-7627) for assistance.
Search
The Search mode allows the user to view only those parameters that have settings other than the factory default values. This mode is available only when using Bulletin 1201 human interface module.
4-6
Programming
Parameter Management
Before you begin programming, its important to understand how the controller memory is: structured within the SMC Dialog Plus controller used on power-up and during normal operation
Refer to Figure 4.2 and the explanations below.

Figure 4.2 Memory Block Diagram
EEPROM
RAM
ROM
Random Access Memory (RAM)

This is the work area of the controller after it is powered up. When you modify parameters in the Program mode, the new values are stored in RAM. When power is applied to the controller, parameter values stored in the EEPROM are copied to RAM. RAM is volatile and the values stored in this area are lost when the controller is powered down.
Read-only Memory (ROM)

The SMC Dialog Plus controller comes with factory default parameter values. These settings are stored in nonvolatile ROM and are displayed the first time you enter the Program mode.
Electrically Erasable Programmable Read-only Memory (EEPROM)

The SMC Dialog Plus controller provides a nonvolatile area for storing user-modified parameter values in the EEPROM.
Programming
4-7
Using Parameter Management

Description Saving to EEPROM To ensure that the newly modified parameters are not lost if control power is removed from the controller, store the values into EEPROM. Recalling from EEPROM Parameters stored in EEPROM can be manually brought to RAM by directing the controller to recall the values stored in its EEPROM. Recalling Defaults After parameter values have been modified and saved to EEPROM, factory default settings can still be re-initialized. Action Display
PARAMETER MGMT STORE IN EE
PARAMETER MGMT RECLL FRM EE
PARAMETER MGMT DEFAULT INT
4-8
Programming
Parameter Modification
All parameters are modified using the same method. The basic steps to performing parameter modification are described below. Note: Parameter values modified while the motor is operating are not valid until the next start sequence begins.
Description 1. Press any key to go from the status display to the Choose Mode menu. Scroll with the Up/Down keys until the Program option appears. Press the Enter key to access the Program menu. Scroll with the Up/Down keys until the option you want to use (Basic Setup, Advanced Setup, etc.) appears. For this example, Basic Setup will be used. Press Enter to select the Basic Setup group. or Action Display
STOPPED 0.0 AMPS
CHOOSE MODE DISPLAY
2.
CHOOSE MODE PROGRAM
3.
PROGRAM METERING
4.
or
PROGRAM BASIC SETUP
5.
SMC OPTION STANDARD
6.
Scroll to the next parameter by using the Up key.
STARTING MODE SOFT START Options:Soft Start, Current Limit STARTING MODE SOFT START
7.
To modify the parameter, press the Select button to move the cursor to the second line. Scroll to the option of your choice by using the Up/Down keys. For this example, we will choose Current Limit. Press the Enter key to accept the new setting.
8.
or
STARTING MODE CURRENT LIMIT
9.
STARTING MODE CURRENT LIMIT
10. Scroll to the next parameter by using the Up key. Continue the process until all desired settings are entered. 11. Press the Enter key to save the new settings to EEPROM.
x y z {
RAMP TIME # 1 10 SEC
If the Choose Mode menu does not provide the Program option, then you must enter your password. The first parameter displayed advises the user if any control option (i.e., Pump Control) is resident. This parameter is factory set and cannot be modified by the user. The display will indicate that the second line is now active by flashing the first character. If the LCD display does not provide a flashing cursor, then the controller is in the Display mode. You will now notice that the cursor has returned to flashing the first character of the first line.
Programming
4-9
Soft Start
The following parameters are specifically used to adjust the voltage ramp supplied to the motor.
Parameter Starting Mode This must be programmed for Soft Start. Ramp Time #1 x This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed. Initial Torque #1 The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter. Kickstart Time A boost of 550% full load current is provided to the motor for the programmed time period.
x
Option Soft Start, Current Limit
0 to 30 seconds
0 to 90% locked rotor torque
0.0 to 2.0 seconds
If the controller senses that the motor has reached full speed before completing the voltage ramp, it will automatically switch to providing full voltage to the motor.
Current Limit Start
To apply a fixed reduced output voltage to the motor, the following parameters are provided for user adjustment:
Parameter Starting Mode This must be programmed for Current Limit. Ramp Time #1 x This programs the time period that the controller will hold the fixed, reduced output voltage before switching to full voltage. Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor. Kickstart Time A boost of 550% full load current is provided to the motor for the programmed time period.
x
Option Soft Start, Current Limit
0 to 30 seconds
50 to 600% full load current
0.0 to 2.0 seconds
If the controller senses that the motor has reached full speed before completing the current limit start, it will automatically switch to providing full voltage to the motor.
4-10
Programming
Dual Ramp Start
The SMC Dialog Plus controller provides the user with the ability to select between two Soft Start settings. The parameters below are available in the Advanced Setup programming mode to obtain Dual Ramp control:
Parameter Advanced Setup The user must select the Advanced Setup programming mode to obtain access to the Dual Ramp parameters. Starting Mode This must be programmed for Soft Start. Dual Ramp x This allows the user the option to choose between two Soft Start profiles defined by: 1. Ramp Time #1/Initial Torque #1 and 2. Ramp Time #2/Initial Torque #2. When this feature is turned on, the ramp time/initial torque combination is determined by a hard contact input to terminal 15. When this input signal is low, ramp time/initial torque #1 are selected. When this input is high, ramp time/initial torque #2 are selected. Ramp Time #1 This programs the time period during which the controller will ramp the output voltage up to full voltage for the first Soft Start setup. Initial Torque #1 This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup. Ramp Time #2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Soft Start setup. Initial Torque #2 The initial reduced output voltage level for the second Soft Start setup is established and adjusted with this parameter.
x
Option
No, Yes
0 to 30 seconds
0 to 30 seconds
The Dual Ramp feature is available only with the standard controller.
Full Voltage Start
The SMC Dialog Plus controller may be programmed to provide a full voltage start (output voltage to the motor reaches full voltage within 1/4 second) with the following programming:
Parameter Starting Mode This must be programmed for Soft Start. Ramp Time #1 This must be programmed for 0 seconds for a full voltage start. Initial Torque #1 This must be programmed for 90% for a full voltage start. Kickstart Time This must be programmed for 0.0 seconds for a full voltage start. Option
Programming
4-11
Basic Setup
The Basic Setup programming group provides a limited parameter set, allowing quick start-up with minimal adjustment. If the user is planning to implement some of the advanced features (i.e., Dual Ramp, Phase Rebalance, etc.), then the Advanced Setup programming group should be selected. It provides all the Basic Setup parameter set plus the advanced set.
Parameter SMC Option Displays the type of controller. This is factory set and not adjustable. Starting Mode Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application. Ramp Time #1 This sets the time period during which the controller will ramp the output voltage. Initial Torque #1 x The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter. Current Limit Level y This parameter provides adjustability for the reduced output voltage level provided to the motor. Kickstart Time A boost of 550% of full load current is provided to the motor for the programmed time period. Stall Delay Allows the user to program the stall protection delay time. The delay time begins after the start time has timed out. Energy Saver The Energy Saver feature monitors the motor load, phasing back the voltage output to the motor when the motor is lightly loaded or unloaded. Aux Contacts 1&2 Form C contacts are provided as standard with the SMC Dialog Plus controller. These contacts are located at terminals 18, 19 and 20. Aux Contacts 1&2 allows the user to configure the operation of the contacts. Aux Contact 3 A third auxiliary contact is provided between terminals 29 and 30. Aux Contact 3 allows the user to program the operation of the contact. Contact 3 Config This parameter provides the user with the ability to program the powered up state of the third auxiliary contact. Parameter Mgmt z The newly programmed parameters values can be saved to memory, or the factory default parameter values can be recalled.
x y z
Option Standard
Soft Start, Current Limit
0 to 30 seconds 0 to 90% of locked rotor torque 50 to 600% full load current 0.0 to 2.0 seconds
0.0 to 10.0 seconds
Off, On
Normal, Up-to-speed
Normal, Fault
N.O., N.C.
Ready, Default Init., Recll Frm EE, Store In EE
Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter. Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter. The new programmed parameter values will not be stored to the EEPROM without the users direction in Parameter Management: Store In EE.
4-12
Programming
Advanced Setup
While the Basic Setup group allows the user to get started with a minimum number of parameters to modify, the Advanced Setup group allows full access to the SMC Dialog Plus controllers powerful parameter set. Following is a listing of the additional setup parameters provided. Note: All of the Basic Setup parameters are available in the Advanced Setup group. The parameters shown below are in addition to the parameters in Basic Setup.
Parameter Dual Ramp x Allows the user the option to choose between two Soft Start profiles. Ramp Time #2 Determines the soft start time for the second ramp of the Dual Ramp feature. Initial Torque #2 Provides the initial torque setting for the second ramp of the Dual Ramp feature. Undervoltage Level Determines the trip level as a percentage of line voltage. Undervoltage Delay y Provides a delay period prior to a trip occurrence. Overvoltage Level Determines the trip level as a percentage of line voltage. Overvoltage Delay y Provides a delay period prior to a trip occurrence. Jam Level z Determines the trip level as a percentage of the motors full load current. Jam Delay Provides a delay period prior to a trip occurrence. Unbalance Level Allows the user to set the voltage unbalance trip level. Unbalance Delay y Provides a delay period prior to a trip occurrence. Rebalance { Allows the user access to enable the Rebalance feature. See page 1-5 for a description. Underload Level y Determines the trip level as a percentage of the motors full load current. Underload Delay Provides a delay period prior to a trip occurrence.
x y z {
Option Off, On
0 to 30 seconds
0 to 99% (0 is the Off setting) 0 to 99 seconds 0 to 199% (0 is the Off setting) 0 to 99 seconds 0 to 999% (0 is the Off setting) 0.0 to 10.0 seconds 0 to 25% (0 is the Off setting) 0 to 99 seconds Off, On
0 to 99% (0 is the Off setting) 0 to 99 seconds
The Dual Ramp feature is available only with the standard controller. The delay time must be set to a value greater than zero when Undervoltage, Overvoltage, and Unbalance are enabled. For Jam and Underload detection to function, the Motor FLC must be programmed in the Calibration group. See Chapter 5 for instructions. To enable Rebalance, the Converter Rating parameter in the Calibrate programming group must be set for 20, 180, or 630.
Programming
4-13
Parameter Phase Reversal This parameter allows the user to enable phase reversal protection. Starts Per Hour Allows the user to limit the number of starts during a one hour period. Restart Attempts x Determines the number of attempts the controller will make to automatically restart the motor after a fault. Restart Delay x Provides a delay period prior to a restart attempt. ETM Reset Allows the user to reset the accumulated value of the elapsed time meter. Parameter Management y The newly programmed parameter values can be saved to memory, or the factory defaults parameter values can be recalled.
x y The Auto Restart feature is not available.
Option Off, On
099 (0 is the Off setting)
0 to 5
0 to 60 seconds
Off, On
Ready, Default Init., Recll Frm EE, Store In EE
The new programmed parameter values will not be stored to the EEPROM without the users direction in parameter management: Store In EE
Example Settings
Undervoltage x
With Line Voltage programmed for 480V and the Undervoltage level programmed for 80%, the trip value is 384V.
Overvoltagex
With Line Voltage programmed for 240V and the Overvoltage level programmed for 115%, the trip value is 276V.
Jam y
With Motor FLC programmed for 150 Amps and the Jam level programmed for 400%, the trip value is 600 Amps.
Underload y
With Motor FLC programmed for 90 Amps and the Underload level programmed for 60%, the trip value is 54 Amps.
x y The average value of the three phase-to-phase voltages is utilized. The largest value of the three phase currents is utilized.
4-14
Programming
Chapter
Calibration
Overview
The Calibrate programming group allows the user to set parameters to calibrate the controller to the connected motor. It is important to correctly input the data to achieve the best performance from your controller. ATTENTION: For overload protection, it is critical that the data be entered as it appears on the motor nameplate.
!
Motor Data Entry
In the Program mode, enter the correct values into the Calibrate group:
Parameter Overload Class The factory default setting disables overload protection. To enable it, enter the desired trip class in this parameter. See pages 1-5 and 1-7 for further details and trip curves. Overload Reset Allows the user to select either a manual or auto reset after an overload fault. Motor HP Rating xy Enter the value from the motors nameplate. Motor kW Rating xy Enter the value from the motors nameplate. Line Voltage x Enter the system voltage in this parameter. This must be done to ensure optimum motor performance and correct operation of undervoltage and overvoltage protection. Motor FLC x Enter the value from the motors nameplate. Service Factor Enter the value from the motors nameplate.
x y
Option
Display
Off, 10, 15, 20, 30
OVERLOAD CLASS _____
Manual, Auto
OVERLOAD RESET MANUAL
0.06,553.5 HP
MOTOR HP RATING #### HP
0.06,553.5 kW
MOTOR KW RATING #### KW
19,999V
LINE VOLTAGE #### VOLTS
1.0999.9A
MOTOR FLC ###.# AMPS
0.011.99
SERVICE FACTOR #.##
Refer to the SMC Dialog Plus controller nameplate for maximum ratings. Exceeding these could result in damage to the controller. The controllers programming system will not allow both HP and kW to be programmed.
5-2
Calibration
Motor Data Entry (cont.)

Parameter Motor Code Letter x Enter the value from the motors nameplate. If the motor nameplate does not provide this, consult the motor manufacturer. See Table 5.A for code letter definitions. LRC Ratio x IEC motors do not provide a motor code letter. Consult the motor manufacturer for the motors locked rotor current/full load current ratio. Converter Rating If a Bulletin 825 converter module will provide current feedback to the controller, enter the converters rating to ensure proper current measurement scaling. CT Ratio For controllers using external current transformers with the 20A converter module for current feedback, current transformers with 5A secondaries are required. Enter the current transformer ratio in this parameter.
x
Option
Display
AV
MOTOR CODE LETTER #
0.019.9
LRC RATIO ##.#
None, 20, 180, 630
CONVERTER RATING ###
5 through 1200:5
CT RATIO #### : 5
The controllers programming system will not allow both Motor Code Letter and LRC Ratio to be programmed.
Table 5.A
Motor Codes
kVA/HP x 03.15 3.153.55 3.554.0 4.04.5 4.55.0 5.05.6 5.66.3 6.37.1 7.18.0 8.09.0 Letter Designation L M N P R S T U V kVA/HP x 9.010.0 10.011.2 11.212.5 12.514.0 14.016.0 16.018.0 18.020.0 20.022.4 22.4 and up
Letter Designation A B C D E F G H J K
x
Locked kVA per horsepower range includes the lower figure up to, but not including, the higher figure. For example, 3.14 is designated by letter A and 3.15 by letter B.
Calibration
5-3
Calibration Procedure
For current measurement accuracy, use the procedure below to calibrate the SMC Dialog Plus controller to the connected motor. A clamp-on ammeter, which provides a true rms measurement and has a published accuracy of 1% (Fluke model 33 or equal), is required to perform this procedure. Notes: (1) If you plan to use the Bulletin 825 converter module for current feedback to the SMC Dialog Plus controller, this calibration procedure is not necessary. (2) An unbalanced three-phase system may affect the accuracy of the calibration. (3) It is recommended that Parameter #36, Overload Class, is programmed to OFF during the calibration procedure. Calibration requires the motor to be operated at full speed. Additionally, the motor must be connected to its load in order that the motor draw as near to its full load current (FLC) rating as possible. This is necessary so that maximum accuracy is achieved for current measurements at overload trip levels.
Description 1. Check all power and control wiring connections to the controller and motor. Apply a start command to the controller and check for motor rotation to full speed. Using the clamp-on ammeter, measure the three-phase motor currents. Place the ammeter around the phase with the largest current draw. x In the Calibrate group, scroll to the Calibration parameter. Monitor the clamp-on ammeter and verify that the motor current is stable. Press the Select key. Toggle the Up/Down keys to the Activate setting. Press the Enter key to accept. Monitor the ammeter display for the next 2 seconds and record the average value. During this time period, the SMC Dialog Plus controller samples motor response data. Access the next parameter using the Up key. Press the Select key. Enter the clamp-on meter value monitored in step 4. Press the Enter key to accept. The SMC Dialog Plus controller is now calibrated. Action Display
AT SPEED ###.# AMPS
2.
AT SPEED ###.# AMPS
3.
CALIBRATION OFF
4.
CALIBRATION ACTIVATE
5.
ENTER CALIB. AMPS 0.0 AMPS
6.
ENTER CALIB. AMPS ###.# AMPS
The currents should measure a minimum of 70% of the motors full load current rating in order to achieve the best results in accuracy.
5-4
Calibration
Calibration Procedure (cont.)

Description 7. You can scroll to the next parameter to view the current measurement in phase A. Scroll to the next parameter to save the Calibrate group settings. Press the Select key. Scroll with the Up/Down keys to Store In EE selection. Press the Enter key to save the settings to EEPROM. Action Display
CURRENT PHASE A ###.# AMPS
8.
PARAMETER MGMT READY
9.
! !
ATTENTION: After calibration is completed, program the desired overload class and save the setting to the controllers EEPROM. ATTENTION: This method of current measurement is not applicable to multi-motor installations or resistive heating loads. Utilization of the Bulletin 825 converter module is required for these applications if current measurement is required.
Chapter
Metering
Overview
While the SMC Dialog Plus controller operates your motor, it also monitors several different parameters, providing a full function meteringx package. To access the metering information, follow the procedure below.
AT SPEED ###.# AMPS
Viewing Metering Data
1.
Press any button to access the Choose Mode menu. Scroll with the Up/Down keys until the Display option is shown. Press the Enter key to select the Display option. Scroll with the Up/Down keys until the Metering option is displayed. Press the Enter key to access the Metering group.
Refer to page 1-10 for details on the metering functions.
CHOOSE MODE _____
2.
or
CHOOSE MODE DISPLAY
3.
CHOOSE GROUP _____
4.
or
CHOOSE GROUP METERING
5.
6-2
Metering
Viewing Metering Data (cont.)

6.
Description Scroll through the Metering parameters with the Up/Down keys to access the desired information.
Action
Display
VOLTS PHASE AB ### VOLTS
or
VOLTS PHASE BC ### VOLTS VOLTS PHASE CA ### VOLTS CURRENT PHASE A ###.# AMPS CURRENT PHASE B ###.# AMPS CURRENT PHASE C ###.# AMPS WATTMETER ##### kW KILO-WATT HOURS ##### kWH ELAPSED TIME ##### HOURS POWER FACTOR .## MTR. THERM USAGE ## %
Chapter
Options
Overview
The SMC Dialog Plus controller offers a variety of unique control options that provide enhanced motor starting and stopping capabilities. (See pages 1-12 through 1-15 for brief descriptions of each option.) Note: Only one option can reside in a controller.
The control buttons available with the Bulletin 1201 human interface modules are compatible with the SMC Dialog Plus controllers control options. The following table details the functionality of each button with regards to each option. Notes: (1) Control logic must be enabled prior to initiating control commands to the SMC Dialog Plus controller. Refer to pages 2-14 and 2-15 for instructions. (2) The control terminals must be wired according to Figure 3.14 on page 3-10.
Option Soft Stop Action Operation The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop.
JOG
The jog button, when pressed, will initiate a soft stop maneuver.
Pump Control
The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop.
JOG
The jog button, when pressed, will initiate a pump stop maneuver.
7-2
Options Option Preset Slow Speed Action Operation The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop.
JOG
The jog button, when pressed, will initiate slow speed motor operation from a stopped status. The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop.
Smart Motor Braking
JOG
The jog button, when pressed, will initiate a brake stop.
Accu-Stop
The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop.
JOG
Slow Speed with Braking
With a stopped status, the jog button, when pressed, will initiate slow speed motor operation. From an at speed condition, the jog button, when pressed, will initiate braking to slow speed operation. The controller will maintain slow speed operation as long as the jog button is pressed. The green start button, when pressed, will commence motor acceleration to full speed. The red stop button, when pressed, will provide a coast stop.
JOG
With a stopped status, the jog button, when pressed, will initiate slow speed motor operation. From an at speed condition, the jog button, when pressed, will initiate a brake stop.
ATTENTION: The Bulletin 1201 human interface modules stop push button is not intended to be used as an emergency stop. Refer to applicable standards for emergency stop requirements.
Options
7-3
Programming Parameters
The following table provides the option-specific parameters that are provided with each control option. These parameters are in addition to those already discussed in the Basic Setup, Advanced Setup, Metering, and Calibration groups. Diagrams supporting the options described below are shown later in this chapter.
Option Soft Stop Parameter SMC Option This parameter identifies the type of control present and is not user programmable. Soft Stop Time Allows the user to set the time period for the soft stopping function. Pump Control SMC Option This parameter identifies the type of control present and is not user programmable. Pump Stop Time Allows the user to set the time period for the pump stopping function. Starting Mode Allows the user to program the SMC Dialog Plus controller for the type of starting that best fits the application. Preset Slow Speed SMC Option This parameter identifies the type of control present and is not user programmable. Slow Speed Select Allows the user to program the slow speed that best fits the application. Slow Speed Direction This parameter programs the slow speed motor rotational direction. Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation. Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting. Range
Soft Stop
060 seconds
Pump Control
0120 seconds
Pump Start, Soft Start, Current Limit Start
Preset Slow
Low: 7% forward, 10% reverse High: 15% forward, 20% reverse Forward, Reverse
0450% of full load current
7-4
Options
Programming Parameters (cont.)

SMB Smart Motor Braking SMC Option This parameter identifies the type of control present and is not user programmable. Braking Current x Allows the user to program the intensity of the braking current applied to the motor. SMC Option This parameter identifies the type of control present and is not user programmable. Slow Speed Select Allows the user to program the slow speed that best fits the application. Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation. Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting. Braking Current x Allows the user to program the intensity of the braking current applied to the motor. Stopping Current x Allows the user to program the intensity of the braking current applied to the motor from slow speed operation. SMC Option This parameter identifies the type of control present and is not user programmable. Slow Speed Select Allows the user to program the slow speed that best fits the application. Slow Accel Current Allows the user to program the required current to accelerate the motor to slow speed operation. Slow Running Current Allows the user to program the required current to operate the motor at the slow speed setting. Braking Current x Allows the user to program the intensity of the braking current applied to the motor. SMB Braking
Accu-Stop
Accu-Stop
Low: 7% High: 15% 0450% of full load current
Slow Speed with Braking
Slow Speed Brake
Low: 7% High: 15% 0450% of full load current
All braking/stopping current settings in the range of 1100% will provide 100% braking current to the motor.
Options
7-5
Control Wiring for SCANport Control Soft Stop, Pump Control, and SMB Smart Motor Braking Options
Refer to Figure 3.14 on page 3-10 for the applicable wiring diagram to achieve start-stop control via the SCANport. Figure 7.1 through Figure 7.6 show the different wiring for the Soft Stop, Pump Control, and SMB Smart Motor Braking options.
Figure 7.1 Typical Wiring Diagram
Control Power
Stop Option Stop Start
11
12
13
14
15
16
17
18
19
20
Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30
x y z
Customer supplied. Soft Stop, Pump Stop, or Brake. Refer to the controller nameplate to verify the rating of the control power input voltage.
Note: Refer to Chapter 3 for typical power circuits.
7-6
Options
Figure 7.2 Typical Retrofit Wiring Diagram
Control Power OL M Stop Option Stop Start
11
12
13
14
15
16
17
18
19
20
Auxiliary contacts set for Normal
x y z {
Customer supplied. Overload protection should be disabled in the SMC Dialog Plus controller. Refer to the controller nameplate to verify the rating of the control power input voltage. Soft Stop, Pump Stop, or Brake.
Options
7-7
Figure 7.3 Typical Wiring Diagram for Applications Requiring an Isolation Contactor
Control Power IC Stop Option Stop Start
11
12
13
14
15
16
17
18
19
20
x y z
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. Soft Stop, Pump Stop, or Brake.
7-8
Options
Figure 7.4 Typical Wiring Diagram for Applications Requiring a Bypass Contactor
Control Power
BC
Stop Option Stop Start
11
12
13
14
15
16
17
18
19
20
Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals To Bulletin 825 Converter Module 21 22 23 24 25 Fanning Strip Internal Auxiliary Contacts 28 29 30
26
27
x y z
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. Soft Stop, Pump Stop, or Brake.
Options
7-9
Figure 7.5 Typical Wiring Diagram for Two-wire Control or Programmable Controller Interfacing
Control Power
Two-wire device
11
12
13
14
15
16
17
18
19
20
x y
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. (1) (2) Refer to Chapter 3 for typical power circuits. The OFF state leakage current for a solid-state device must be less than 6 mA.
Notes:
7-10
Options
Soft Stop, Pump Control, and SMB Smart Motor Braking Options (cont.)
L1/1 3-Phase L2/3 Input Power L3/5 Branch Protection Fast-acting SCR Fuses (optional)
T1/2 T2/4 T3/6
Control Power 100-240 VAC H A xoo xoo oox
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
x y
Options
7-11
Soft Stop Option
Figure 7.7 Soft Stop Option Sequence of Operation
100% Motor Speed Coast-to-rest
Start Push Buttons Start Closed Open Stop Closed Open Soft Stop Closed Open Auxiliary Contacts
Run Time (seconds)
Soft Stop
Soft Stop Operation Normal Coast-to-rest Operation Up-to-speed
ATTENTION: The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine.
7-12
Options
Pump Control Option
Figure 7.8 Pump Control Option Sequence of Operation
100%
Coast-to-rest
Motor Speed
Start Push Buttons Start Closed Open Stop Closed Open Pump Stop Soft Stop Closed Open Auxiliary Contacts
Run Time (seconds)
Soft Stop
Pump Stop Operation Normal Coast-to-rest Operation Up-to-speed
Options
7-13
SMB Smart Motor Braking Option
Figure 7.9 SMB Smart Motor Braking Sequence of Operation
100%
Smart Motor Braking Coast-to-rest
Motor Speed
Start Push Buttons Start Closed Open Stop

Brake Soft Stop
Run
Brake Time (seconds) Automatic Zero Speed Shut-off
Closed Open Closed Open
Auxiliary Contacts Smart Motor Braking Operation Normal Coast-to-rest Operation Up-to-speed
7-14
Options
Preset Slow Speed and Accu-Stop Options
Figure 7.10 through Figure 7.14 shows the different wiring for the Preset Slow Speed and Accu-Stop options.
Figure 7.10 Typical Wiring Diagram for the Preset Slow Speed Option
Control Power
Stop Option Command Start
11
12
13
14
15
16
17
18
19
20
x y z
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage Slow Speed or Accu-Stop.
Options
7-15
Figure 7.11 Typical Retrofit Wiring Diagram

Control Power OL M Stop Option Command Start
11
12
13
14
15
16
17
18
19
20
x y z {
Customer supplied. Overload protection should be disabled in the SMC Dialog Plus controller. Refer to the controller nameplate to verify the rating of the control power input voltage. Slow Speed or Accu-Stop.
7-16
Options
Figure 7.12 Typical Wiring Diagram for Applications Requiring an Isolation Contactor
Control Power IC Stop Option Command Start
11
12
13
14
15
16
17
18
19
20
x y {
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. Slow Speed or Accu-Stop.
Options
7-17
Figure 7.13 Typical Wiring Diagram for Applications Requiring a Bypass Contactor
Control Power
BC
Stop Option Command Start
11
12
13
14
15
16
17
18
19
20
Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals To Bulletin 825 Converter Module 21 22 23 24 25 Fanning Strip Internal Auxiliary Contacts 28 29 30
26
27
x y {
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input voltage. Slow Speed or Accu-Stop.
7-18
Options
Preset Slow Speed and Accu-Stop Options (cont.)

3-Phase
L1/1 L2/3 Input Power L3/5 Branch Protection Fast-acting SCR Fuses (optional)
T1/2 T2/4 T3/6
Hand Stop
Hand Start
Option Command
11 12 13 14 15 16 17 18 19 20
Internal Auxiliary Contacts
21
22
23
24
25
26
27
28
29
30
x y z
Customer supplied. Slow Speed or Accu-Stop. Refer to the controller nameplate to verify the rating of the control power input voltage.
Options
7-19
Preset Slow Speed Option
Figure 7.15 Preset Slow Speed Option Sequence of Operation
100% 7 or 15% Motor Speed
Slow Speed Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts
Start
Run Time (seconds)
Coast
Normal
Up-to-speed
7-20
Options
Accu-Stop Option
100% Motor Speed
Figure 7.16 Accu-Stop Option Sequence of Operation
Braking
Slow Speed Braking/Coast Slow Speed
Slow Speed Push Buttons Start Closed Open Stop Closed Open Accu-Stop Closed Open Auxiliary Contacts Normal
Start
Run Time (seconds)
Accu-Stop
If Stopping Current is set to 0%. Up-to-speed
When Accu-Stop push button is closed, start/stop function is disabled.
Options
7-21
Slow Speed with Braking Option
Figure 7.17 through Figure 7.21 show the different wiring for the Slow Speed with Braking option.
Figure 7.17 Typical Wiring Diagram for the Slow Speed with Braking Option
Control Power Stop Brake Slow Speed Start
11
12
13
14
15
16
17
18
19
20
x y
7-22
Options
Figure 7.18 Typical Retrofit Wiring Diagram for the Slow Speed with Braking Option
Control Power Stop OL M Brake Slow Speed Start
11
12
13
14
15
16
17
18
19
20
x y z
Customer supplied. Overload protection should be disabled in the SMC Dialog Plus controller. Refer to the controller nameplate to verify the rating of the control power input voltage.
Options
7-23
Figure 7.19 Typical Wiring Diagram for the Slow Speed with Braking Option with an Isolation Contactor
Control Power Stop IC Brake Slow Speed Start
11
12
13
14
15
16
17
18
19
20
x y
7-24
Options
Figure 7.20 Typical Wiring Diagram for the Slow Speed with Braking Option with a Bypass Contactor
Control Power Stop
BC
Brake Slow Speed Start
11
12
13
14
15
16
17
18
19
20
Auxiliary contacts set for Up-to-speed SMC Dialog Plus Control Terminals To Bulletin 825 Converter Module 21 22 23 24 25 Fanning Strip
Internal Auxiliary Contacts 28 29 30
26
27
x y
Options
7-25
Figure 7.21 Slow Speed with Braking Option Sequence of Operation
100% Motor Speed
Braking
Slow Speed Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Normal
Start
Run Time (seconds)
Brake
Up-to-speed
Chapter
Serial Communications
Overview
The SMC Dialog Plus controller can be started and stopped through programmable logic controllers using an optional communication module. Additionally, parameter data can be read to the logic controller through data transfer. The amount of information that can be transferred from the SMC Dialog Plus controller is determined by the DIP switch settings on the communication module. Note: Parameter values modified while the motor is operating are not valid until the next start sequence begins.
Logic Control Data
The information in Table 8.A provides the logic control information that can be sent to the SMC Dialog Plus controller through the logic controllers output image table.
Table 8.A
Logic Bits x Description Definition
Logic Control Data
15
14
13
12
11
10
0 X Stop y Start z Option Command { Clear Faults z 1 = Stop 0 = Not Stopped 1 = Start 0 = Not Start 1 = Option Init. 0 = Not Option Init. 1 = Clear Faults 0 = Not Clear Faults
X X X
Bits 415 are not used

x y z { Only one bit may be asserted at any given time. The stop bit will take priority in operation when more than one bit is asserted. Other bits will be ignored until the stop bit is reset. A 0 to 1 transition is required for a valid command. Assert the Option Command bit to initiate an option maneuver such as Pump Stop.
Control Wiring
Refer to Figure 3.14 on page 3-10 for the applicable wiring diagram to achieve start-stop control via the SCANport.
8-2
Control Enable
Per factory programming, stop is the only control command active on the SMC Dialog Plus controller when the SCANport is utilized. To enable motor control from a programmable logic controller through a communication module, follow the programming procedure below.
STOPPED 0.0 AMPS
1.
Press any key to access the Choose Mode function. Scroll with the Up/Down keys until the Program option appears. Press the Enter key to access the Program option. Scroll with the Up/Down keys to the Linear List option. Press the Enter key to access the Linear List programming group. Scroll with the Up/Down keys to parameter number 85 - Logic Mask. Press the Select key to move the cursor to the second line to modify the parameter. Press the Up key until the value 4 appears. x
CHOOSE MODE _____
2.
or
CHOOSE MODE PROGRAM
3.
PROGRAM _____
4.
or
PROGRAM LINEAR LIST
5.
VOLTS PHASE AB 0 VOLTS 1
6.
or
LOGIC MASK 0 85
7.
LOGIC MASK 0 85
8.
LOGIC MASK 4 85
9.
Press the Enter key to accept the new setting.
LOGIC MASK 4 85
Zero and 4 are the only valid settings.
Note: If a communication module is disconnected from the SMC Dialog Plus controller while control is enabled (Logic Mask = 4), a Comm Fault will occur.
8-3
SMC Status Data
The information in Table 8.B provides the SMC Dialog Plus controller status information that can be sent to the logic controllers input image table.
Table 8.B
Logic Bits Description Definition
SMC Status Data
15
14
13
12
11
10
0 X Enabled x Running Not Used Not Used 1 = Enabled 0 = Not Enabled 1 = Running 0 = Not Running 1 = Starting 0 = Not Starting 1 = Stopping 0 = Not Stopping 1 = Faulted 0 = Not Faulted 1 = At Speed 0 = Not at Speed
X X X X
Starting Stopping Fault At Speed
Bits 915 are not used

x When control power is applied, this bit is always set to 1.
Reference/Feedback
The SMC Dialog Plus controller does not support the analog reference feature of SCANport. The SCANport analog feedback feature, however, is supported. The feedback word will always be equal to Parameter number 4, Current Phase A. Refer to Appendix B, Table B.1 for a complete listing of the SMC Dialog Plus controllers parameters and groups. In addition to the range of adjustments, the parameters units are provided. The parameter values of the SMC Dialog Plus controller are stored as unscaled numbers. When reading parameter data in the PLC/SLCs input image table, divide this number by the scale factor shown in Appendix B, Table B.1 to arrive at the proper value. When writing from the PLC/SLCs output image table to the SMC Dialog Plus controller, the scale factor must be taken into consideration to ensure that the proper value is sent.
Parameter Listing
Scale Factor Conversion
8-4
Display Unit Equivalents
Some parameter setting options use a text description when viewed from the built-in LCD display or a human interface module. An example is the parameter, Starting Mode, which has the available settings of Soft Start and Current Limit. Table B.2, found in Appendix B provides the required display unit decimal equivalent for use when sending a command from a logic controller to the SMC Dialog Plus controller. The SMC Dialog Plus controller does not offer Datalinks. Refer to the appropriate communication module manual for detailed information regarding communication module installation, DIP switch settings, block transfer instructions, and communication module troubleshooting. The typical time for the SMC Dialog Plus controller to process a single parameter data request (i.e., block transfer) via the SCANport is approximately 100 msec. Keep this value in mind when determining the message length of multiple parameter value read or write operations.
Datalinks Interfacing
Processing Time
8-5
Remote I/O Examples
Example #1 SLC 500 Controller without Block Transfer

This example demonstrates discreet control of an SMC Dialog Plus controller from an SLC 500 logic controller. Additionally, the SLC controller reads the Current Phase A from the SMC Dialog Plus controller via the analog feedback word. Many of the selections shown are example-specific. Some changes by the user may be necessary to apply the concepts of this example to a specific application. System Configuration
SLC 5/02 or higher 1747-SN Scanner
L1 1
L2 3
L3 5
11
12
13
14
15
16
17
18
19
20
Remote I/O Link

30
21
22
23
24
25
26
27
28
29
2 SH 1 Re m I/O Re m I/O STS Re m I/O AC T V+ VG H ea lth SC AN bus STS FA ULT
1203-GD1 Communication Module
Bulletin 1202 SCANport Cable
Note: It is critical that during the system design phase that each device on the Remote I/O link is allocated a unique segment of the SLCs I/O image table. This is accomplished by coordination of the devices rack address, rack size, and starting group address.
8-6
Remote I/O Examples (cont.)
1203-GD1 Communication Module Switch Settings

The following information is provided to explain the required 1203GD1 communication module switch settings for this example. Refer to the 1203-GD1 manuals for further details related to the switch settings. Example Information
Description SMC Rack Address: Starting Group Address: Last Rack: Hold Last State: Fault on Comm Loss: Fault Controller: R I/O Baud Rate: Block Transfer: Logic Cmd/Status: Reference/Feedback: Datalinks:
x y
Switch Setting 02 0 No Yes Yes No 115k Nox Yesx Yesx Noxy SW1: Switches 1 & 2 (Not Used), Switches 3-6 & 8 (On), Switch 7 (Off) SW2: Switches 1 & 2 (On) SW2: Switch 3 (Off) SW2: Switch 4 (On) SW2: Switch 5 (On) SW2: Switch 6 (Off) SW2: Switch 7 (On), Switch 8 (Off) SW3: Switch 1 (Off) SW3: Switch 2 (On) SW3: Switch 3 (On) SW3: Switch 4-8 (Off)
This configuration requires a 1/4 rack size allocation. The SMC Dialog Plus controller does not support Datalinks.
Switch Settings
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Not Used Not Used On On On On Off On Starting Module Group (0) Starting Module Group (0) Last Rack Setting (Off) Hold Last State (On) Fault on Comm Loss (On) Fault Controller (Off) R I/O Baud Rate (115k) R I/O Baud Rate (115k)
8 7 6 5 4 3 2 1
Block Transfer On Logic Cmd/Sts On Reference/Fdbk Off Datalink A Off Datalink B Off Datalink C Off Datalink D Off Truncate Last Datalink Off
SW1
SW2
SW3
8-7
G File Configuration
The SLC system uses G files to configure the R I/O link. G files are configured through the SLC programming software. The configuration is based on the devices connected to the R I/O link. For this example, the following G file configuration map for the scanners I/O image file of the SMC Dialog Plus controller applies.
Addressx G1:0 G1:1 G1:2
x
15 xxxx 0000 0000 xxxx 0001 0001
Data xxxx 0000 0000
0 xxxx 0000 0000
Description Word 0 cannot be edited Logical device address (rack 2, start group 0) Logical image size (1/4 rack)
Words 3 and 4 do not require configuration since the communication module does not support Complimentary I/O.
I/O Addressing
The 1203-GD1 communication module uses 1-slot addressing. Based on the module switch settings as described above, the discrete I/O can be mapped to the PLC I/O Image as shown below. SLC I/O Image Table Map
SLC I/O Group Number 0 1
x
Output Image Logic Command Referencex
Input Image Logic Status Feedback
The output image word that maps to the Reference word (O: 1.17, in this example) must have the value 0 to insure proper SMC Dialog Plus controller operation.
Addressing Format
I : 1 0/12 I for input or O for output Slot number Word number Input or output number (bit identifier: 015)
8-8
SMC Dialog Plus Controller Logic Control Addressesx

Bit Description Stop Start Option Command Clear Fault I or O O O O O Sloty 1 1 1 1 Wordz 16 16 16 16 Bit{ 00 01 02 03 Address O:1.16/00 O:1.16/01 O:1.16/02 O:1.16/03
SMC Dialog Plus Controller Status Addresses x

Bit Description Enabled Running Starting Stopping Fault At Speed I or O I I I I I I Slot y 1 1 1 1 1 1 Wordz 16 16 16 16 16 16 Bit | 00 01 04 05 07 08 Address I:1.16/00 I:1.16/01 I:1.16/04 I:1.16/05 I:1.16/07 I:1.16/08
SMC Dialog Plus Controller Feedback Addressx

I or O I
x
Sloty 1
Wordz 17
Address I:1.17
The addresses shown are example-specific. Addresses for any given installation can be determined, based upon the 1203-GD1 communication module switch settings for: rack address, starting group number, block transfer, logic command/status, and reference/feedback by applying the I/O addressing format for SLC-500 controllers. The 1747-SN scanner resides in slot 1. Based on the 1203-GD1 communication module switch settings (rack 2, starting group 0). Refer to the 1747-SN User Manual, Publication 1747-6.6. Refer to Table 8.A. Refer to Table 8.B.
y z { |
8-9
Example #1 - Ladder Logic Program

First Rung: When the Machine START push button is pressed, the SLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog Plus controller will start if no STOP command is being issued by the SLC or any other control device. (The start button is a normally open contact in this example.) Machine START Push Button : 1.8 SMC START Command : 1.16
Second Rung: When the Machine STOP push button is pressed, the SLC sends a STOP command to the SMC Dialog Plus controller. (The stop button is a normally closed contact in this example.) The branch provides a logic latched" circuit which exerts the STOP command until the feedback from the SMC Dialog Plus controller indicates that it has received the command and has responded appropriately. Machine STOP Push Button : 1.8 1 SMC STOP Command : 1.16 0
SMC STOP Command : 1.16
SMC Running Bit : 1.16
0 1 Third Rung: The SMC Dialog Plus controller's Current Phase A value returned by the analog feedback word (I:1.17 in this example) is moved every scan to integer file 7, element 2.
MOV
MOVE Source: Dest: I:1.17 N7:2
8-10
Example #2 - SLC 500 Controller with Block Transfer

This example demonstrates a block transfer of the SMC Dialog Plus controllers metering group (parameters 111) to an SLC500. Many of the selections shown are example-specific. Some changes by the user may be necessary to apply the concepts of this example to a specific application. System Configuration
SLC 5/02 or higher 1747-SN Scanner
L1 1
L2 3
L3 5
11
12
13
14
15
16
17
18
19
20
Remote I/O Link

30
21
22
23
24
25
26
27
28
29

Description SMC Rack Address: Starting Group Address: Last Rack: Hold Last State: Fault on Comm Loss: Fault Controller: RIO Baud Rate: Block Transfer: Logic Cmd/Status: Reference/Feedback: Datalinks:
x
Switch Setting 0 0 Yes Yes Yes Yes 57k Yes Yes No Nox SW1, Switches 1 & 2 (Not Used), Switches 3-8 (On) SW2, Switches 1 & 2 (On) SW2, Switch 3 (On) SW2, Switch 4 (On) SW2, Switch 5 (On) SW2, Switch 6 (On) SW2, Switches 7 & 8 (Off) SW3, Switch 1 (On) SW3, Switch 2 (On) SW3, Switch 3 (Off) SW3, Switches 4-8 (Off)
The SMC Dialog Plus controller does not support Datalinks
8-11
SLC Image Table Map

SLC Word 0 1
x
Output Image Block Transfer Logic Command
Input Image Block Transfer Logic Status
Rack Size 1/4
Start at Group 0x
Set SW2, Switches 1 and 2 to On.
Switch Settings
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Not Used Not Used On On On On On On Starting Module Group (0) Starting Module Group (0) Last Rack Setting (On) Hold Last State (On) Fault on Comm Loss (On) Fault Controller (On) RIO Baud Rate (57 K) RIO Baud Rate (57 K)
8 7 6 5 4 3 2 1
SW1
SW2
Software Configuration Settings RIO Configuration Using G Files The block transfer operation requires that the G File of the 1747-SN scanner module be configured. The scanners G File settings are based on the devices that you have on the RIO link. It consists of setting logical device starting addresses and the logical device image size of each physical device/ adapter with which the scanner communicates. The G File is configured as part of the I/O configuration procedure for the processor file. You edit the data offline under the I/O configuration menu only. After the 1747-SN specialty I/O module is assigned to a slot, access the SPIO CONFIG [F9] menu instruction in the Advanced Programming Software (APS). The configuration settings are set as follows: 1. [F5], ADVNCD SETUP to specify input size, output size, scanned input, scanned output, M0 and M1 file sizes. This SMC Dialog application example utilizes the following settings: Maximum Input Words: 32 (fixed, cannot modify) Maximum Output Words: 32 (fixed, cannot modify) Scanned Input Words: 32 (default valuex) Scanned Output Words: 32 (default valuex) M0 Length: 3300 (size is set for block transfer operation) M1 Length: 3300 (size is set for block transfer operation)
x Setting the scanned input and scanned output words to less than 32 can reduce the processor scan time by transferring only part of the input and output image that your application requires. It is important that you do not set either of these values to 0.
SW3
8-12
2. [F7], G FILE SIZE to specify the number of words required for the I/O module, 3 for standard operation, 5 if using complementary I/O. (In this application example, G File size = 3.) 3. [F6], MODIFY G FILE Word 0 of the G File is configured automatically by the processor according to the particular specialty I/O module. Word 0 cannot be edited. Word 1, Primary/Normal Logical Device Address Specifies the logical starting address of each primary/normal RIO link device. The logical address consists of the logical rack number (0, 1, 2, or 3) and starting logical group (0, 2, 4, or 6). Each bit in this word represents a logical address. To specify an address (in binary mode), you place a 1 at the bit corresponding to the starting logical address of each logical device. (For this SMC Dialog example application, Word G1/16 = 1, indicating logical rack 0, starting group 0.) Word 2, Primary/Normal Device Logical Image Size Specifies the logical image size (amount of scanner I/O image) of the devices set in Word 1. As with Word 1, these bits correspond to RIO logical rack and logical group numbers. To specify image size (in binary mode), you place a 1 at each group a device occupies. (This SMC Dialog example is using 1/4 rack size, Word G1/33 = 1.) Word 3 and Word 4 refer to Complementary I/O Configuration (if G File size is set to 5), which is not used in this sample application. Please reference the RIO Scanner User Manual (Publication 1747-6.6) and the Advanced Programming Software (APS) User Manual (Publication 1746-6.4) for further information on any of the above settings or operations. SLC 500 Ladder Logic Program Terms used:BTBlock Transfer BTR Block Transfer Read BTW Block Transfer Write The sample ladder logic program that follows performs a consecutive parameter value read of the SMC Dialog Plus controllers metering group (parameters 111) by using a BTW/BTR pair. The BTW operation defines to the Bulletin 1203 communication module the type of parameter read/write operation (Continuous Parameter Value Read for this example) and identifies the parameters to be polled. Execution of the BTR operation allows the communication module to respond, providing the requested data. Notes: (1) The ladder logic program does not contain error checking and handling. Refer to the SLC 500 and 1747-SN scanner manuals for this documentation. (2) For this example, Allen-Bradleys APS programming software is used.
8-13
BT Control Buffer Layout The following table maps integer files starting at N10:0 with the associated M0 file location as defined in the sample ladder logic program that follows. BT Control Datafile
Control Flags BT Length BT Logical Addressx
Address N10:0
x
0
y
1 64
2 0
BT logical address format: logical rack/group/slot (slot is always 0 for the 1203-GD1) Logical address examples Logical Rack 0, Group 0, Slot 0 = 0 Logical Rack 2, Group 4, Slot 0 = 240 This word is set by the ladder logic program. Refer to the 1747-SN scanner manual for Control Flag Definitions.
BTW Datafile Format A four-word data file is required to accomplish a Continuous Parameter Value Read. For the example that follows, the BTW Datafile will begin at address N10:10. BTW Datafile
Message Length PLC Decimal Value Number of Parameter Values to Read Starting Parameter Number
Address N10:10
x
0 4
1 1x
2 11
3 1
This is a fixed value, associated with the Continuous Parameter Value Read function.
Data Path for the BTW Rung 2:6 of the sample ladder logic program that follows executes a COP instruction to the M0 file to load the necessary data for the BTW.
Address N10:0 N10:10 N10:20 N10:30 N10:40 N10:50 N10:60 N10:70 0123456789 Address M0:1.100 M0:1.110 M0:1.120 M0:1.130 M0:1.140 M0:1.150 M0:1.160 M0:1.170 0123456789
8-14
BTR Datafile Format A BTR Datafile must also be defined to accept the data read during the BTR operation. For this example, the BTR Datafile will begin at address N10:110. BTR Datafile
Header Word PLC Decimal Value Number of Parameter Values to Read Starting Parameter Number
Address N10:110 N10:120

x
0 15 #7
1
x
2 11 #9
3 1 #10
4 #1 #11
5 #2
6 #3
7 #4
8 #5
9 #6
#8
1 -32767
Message OK: Message Error:
Note: The values of parameters 111 read from the SMC Dialog Plus controller are loaded into addresses N10:114 through N10:124. Data Path for the BTR Rung 2:5 of the sample ladder logic program that follows executes a COP instruction to copy the data obtained from the BTR to program-defined integer file.
Address M1:1.100 M1:1.110 M1:1.120 M1:1.130 M1:1.140 M1:1.150 M1:1.160 M1:1.170 0123456789 Address N10:100 N10:110 N10:120 N10:130 N10:140 N10:150 N10:160 N10:170 0123456789
8-15
Example #2 Ladder Logic Program

Rung 2:0 This rung clears the Virtual BT Command word on the first scan.
First Scan S:1
MOV MOVE Source 15 Dest
0 N10:0 128
Rung 2:1 Copy the BT Status Bits from the 1747-SN into the Virtual BT Status Buffer.
MOV MOVE Source Dest
M1:1.100 * N10:100 0
Rung 2:2 This rung sets up the BT buffer for a BTW. User Logic BTR_Avail BTW_Avail Virtual BT_Enable Bit Virtual BTW = 0 BTR = 1
B3:0 1
I:1.0 10
I:1.0 13
N10:0 15
N10:0 U 7 Virtual BT_Enable Bit N10:0 L 15
Rung 2:3 This rung turns off the Virtual BT_Enable when a BTW has completed. Virtual BTW = 0 BTR = 1 Virtual BT Done Bit Virtual BT_Enable Bit
N10:0 7
N10:100 13
N10:0 U 15
8-16
Example #2 Ladder Logic Program (cont.)
Rung 2:4 This rung sets up the BT buffer for a BTR and sets the Virtual BT_Enable. User Logic BTR_Avail Virtual BTW = 0 BTR = 1 N10:0 L 1 10 7 Virtual BT_Enable Bit N10:0 L 15
B3:0
I:1.0
Rung 2:5 This rung copies the BTR data from the 1747-SN, clears the Virtual BT_Enable, and clears the User Logic Bit. BTR_Avail Virtual Virtual BTW = 0 BT Done BTR = 1 Bit I:1.0 10 N10:0 7 N10:100 13 COP COPY FILE Source Dest Length Virtual BT_Enable Bit N10:0 U 15 User Logic B3:0 U 1 Rung 2:6 This rung copies the BT information to the 1747-SN for execution. COP COPY FILE Source Dest Length
#M1:1.100 #N10:100 74
#N10:0 #M0:1.100 74
Rung 2:7 END
8-17
The information in the data table listed below was obtained from a 150 Hp motor, 1800 RPM rated at 480 volts. The motor has been operating continuously for a period of 72 hours.
Parameter Description Voltage Phase AB Voltage Phase AB Voltage Phase AB Current Phase A Current Phase B Current Phase C
x
Parameter Number 1 2 3 4x 5x 6x
Display Value 470 474 469 120.0 120.0 120.0
Parameter Description Wattmeter Kilowatt Hours Elapsed Time Power Factor Motor Thermal Usage
Parameter Number 7x 8 9 10 x 11
Display Value 90.0 82 72 .92 80
Refer to Appendix B and apply the scale factor to above parameters in the data table below.
Data (Radix = BINARY) 0000 Data 0000 0000
Address B3:0 Address N10:0 N10:10 N10:20 N10:30 N10:40 N10:50 N10:60 N10:70 N10:80 N10:90 N10:100 N10:110 N10:120 N10:130 N10:140 N10:150 N10:160 N10:170 N10:180 N10:190 N10:200 M0:1 M0:2 M0:3 M0:4 M1:1 M1:2 M1:3 M1:4 Address G1:0
(Radix = BINARY) 128 4 0 0 0 0 0 0 0 0 0 15 900 0 0 0 0 0 0 0 0 64 1 0 0 0 0 0 0 0 0 64 1 82 0 0 0 0 0 0 0 0 11 0 0 0 0 0 0 0 0 0 11 72 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 1 92 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 470 80 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 474 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 469 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1200 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1200 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1200 0 0 0 0 0 0 0 0
File Length: 3300 File Length: 0 File Length: 0 File Length: 0 File Length: 3300 File Length: 0 File Length: 0 File Length: 0 Data (Radix = BINARY) 2020 0001 000F
8-18
Example #3 PLC 5/20, 5/40, 5/60, and 5/80

This example demonstrates PLC control of an SMC Dialog Plus controller with the Pump Control option. Use of the Option Command bit to initiate the pump stop maneuver is also shown. Finally, the SMC fault bit is monitored as a conditional logic input for the block transfer of the associated fault code stored in the SMC Dialog Plus controllers Parameter 19, Fault Buffer #1. Many of the selections shown are example-specific. Some changes by the user may be necessary to apply the concepts of this example to a specific application. System Configuration
PLC 5/20, 5/40. 5/60, or 5/80
L1 1
L2 3
L3 5
11
12
13
14
15
16
17
18
19
20
Remote I/O Link

30
21
22
23
24
25
26
27
28
29
Note: It is critical that during the system design phase that each device on the Remote I/O link is allocated a unique segment of the PLCs I/O image table. This is accomplished by coordination of the devices rack address, rack size, and starting group address.
8-19

Description SMC Rack Address: Starting Group Address: Last Rack: Hold Last State: Fault on Comm Loss: Fault Controller: R I/O Baud Rate: Block Transfer: Logic Cmd/Status: Reference/Feedback: Datalinks:
x y
Switch Setting 02 0 No Yes Yes No 115k Yesx Yesx Nox Noxy SW1: Switches 1 & 2 (Not Used), Switches 3-6 & 8 (On), Switch 7 (Off) SW2: Switches 1 & 2 (On) SW2: Switch 3 (Off) SW2: Switch 4 (On) SW2: Switch 5 (On) SW2: Switch 6 (Off) SW2: Switch 7 (On), Switch 8 (Off) SW3: Switch 1 (On) SW3: Switch 2 (On) SW3: Switch 3 (Off) SW3: Switch 4-8 (Off)
This configuration requires a 1/4 rack size allocation. The SMC Dialog Plus controller does not support Datalinks.
Switch Settings
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
Not Used Not Used On On On On Off On Starting Module Group (0) Starting Module Group (0) Last Rack Setting (Off) Hold Last State (On) Fault on Comm Loss (On) Fault Controller (Off) R I/O Baud Rate (115k) R I/O Baud Rate (115k)
8 7 6 5 4 3 2 1
SW1
SW2
I/O Addressing
The 1203-GD1 communication module uses 1-slot addressing. Based on the module switch settings as described above, the discrete I/O can be mapped to the PLC I/O Image as shown below.
PLC I/O Group Number 0 1 Output Image Block Transfer Logic Command Input Image Block Transfer Logic Status
SW3
8-20
Addressing Format
I : 02 0/12 I for input or O for output 2-digit I/O rack number I/O group number (07) Input or output number (octal bit address: 07, 1017)
Communication Module Block Transfer Status Word Addressesx

Bit Description Block Transfer Ready (BT_READY) Block Transfer Write in Progress (BTW_IN_PROG) Block Transfer Read Available (BTR_AVAIL) Block Transfer Wait (BT_WAIT) Block Transfer Error (BT_ERROR) Block Transfer Write Available (BTW_AVAIL) I or O I I I I I I Rack 02 02 02 02 02 02 Group 0 0 0 0 0 0 Bit y 10 11 12 13 14 15 Address I:020/10 I:020/11 I:020/12 I:020/13 I:020/14 I:020/15
SMC Dialog Plus Controller Logic Control Addressesx

Bit Description Stop Start Option Command Clear Fault I or O O O O O Rack 02 02 02 02 Group 1 1 1 1 Bitz 00 01 02 03 Address O:021/00 O:021/01 O:021/02 O:021/03
SMC Dialog Plus Controller Status Addresses x

Bit Description Enabled Running Starting Stopping Fault At Speed
x
I or O I I I I I I
Rack 02 02 02 02 02 02
Group 1 1 1 1 1 1
Bit{ 00 01 04 05 07 10 |
Address I:021/00 I:021/01 I:021/04 I:021/05 I:021/07 I:021/10
The addresses shown are example-specific. Addresses for any given installation can be determined, based upon the 1203-GD1 communication module switch settings for: rack address, starting group number, block transfer, logic command/status, and reference/feedback by applying the I/O addressing format for PLC-5 controllers. Refer to Figure 3.1 of the Bulletin 1203 Remote I/O Communication Module. Refer to Table 8.A. Refer to Table 8.B. This is the octal address representation for this bit.
y z { |
8-21
Block Transfer Instructions

Block transfer operations with the 1203-GD1 communication module require coordinated block transfer write (BTW) and block transfer read (BTR) instructions to achieve successful data transmissions. BTW
BLOCK TRNSFR WRITE Rack: 02 Group: 0 Module: 0 Control Block: BT11:0 Data File: N10:10 Length: 64 Continuous: N (EN) (DN) (ER)
BTR
BLOCK TRNSFR WRITE Rack: 02 Group: 0 Module: 0 Control Block: BT11:1 Data File: N10:90 Length: 64 Continuous: N (EN) (DN) (ER)
Rack The number reported here should correspond to the communication modules rack assignment as selected via DIP switch group one (SW1). Group The number reported here should correspond to the communication modules starting group address via DIP switch group two (SW2), switches 1 and 2. Module In all cases (with regards to the 1203-GD1 communication module) the number 0 should be reported here. Control Blockx For this example a block transfer file type (BT) of one element is used for the control block. An integer file (type N) of five contiguous words could also be used. Data Filex The first word of the data file (integer, Type N) selected for the BTW or BTR block is reported here. Length The block transfer message length (number of words) is reported here.
x It is critical that care is given to all file assignments to ensure that no overlapping or overwriting occurs.
8-22
Block Transfer Datafiles

The tables below provide the necessary data file configuration for a parameter value read of the SMC Dialog Plus controllers Fault Buffer #1. BTW Datafile:
Message Length PLC Decimal Value Parameter Number
Address N10:10
x
0 3
1 769x
2 19
This is a fixed value, associated with the Parameter Value Read function.
BTR Datafile:
Header Word 1 PLC Decimal Value Parameter Number Parameter Value
Address N10:10
x y z
0 6x
1
y
2 1
3
z
There is no significance to the number returned to Header Word 1. Message OK: Message Error: 769 -31999
If a message error occurs, the error code will be presented here. See Table 5.A of the Bulletin 1203 Remote I/O Communication Module Reference Manual, Publication 1203-5.0, for a listing of the error codes and descriptions.
8-23
Example #3 Ladder Logic Program

First Rung: When the Machine START push button is pressed, the PLC sends a START command to the SMC Dialog Plus controller. The SMC Dialog Plus controller will start if no STOP command is being issued by the PLC or any other control device. (The start button is a normally open contact in this example.) Machine SMC START START Push Button Command : 016 : 021
11
01
Second Rung: When the Machine STOP push button is pressed, the PLC sends an OPTION command (pump stop" in this example) to the SMC Dialog Plus controller. (The stop button is a normally closed contact in this example.) The branch provides a logic latched" circuit which exerts the OPTION command until the feedback from the SMC Dialog Plus controller indicates that it has returned to a stopped" status (not running). SMC Machine OPTION STOP Command Push Button : 021 : 016 12 02
SMC OPTION Command : 021
SMC Running Bit : 021
02 01 Third Rung: The SMC Fault Bit initiates a PLC block transfer write to the communication module, requesting a parameter value read (SMC Dialog Plus controller Parameter 19, Fault Buffer #1, in this example). SMC Fault Bit : 021 07 BT Read Available BTR_AVAIL : 020 12 BT Error BT_ERROR BT Write Available BTW_AVAIL : 020 15
BTW
BLOCK TRNSFR WRITE Rack: Group: Module: Control Block: Data File: Length: Continuous: (EN) 02 0 0 BT11:0 N10:10 3 N (DN) (ER)
: 020 14 Fourth Rung: A block transfer read occurs whenever the communication module's BT Read Available status bit is true, in this example, the communication module responds to the PLC request (BTW in the third rung) by supplying the value stored in Parameter 19. BT Read Available BTR_AVAIL : 020 12
BTR
BLOCK TRNSFR READ Rack: Group: Module: Control Block: Data File: Length: Continuous: (EN) 02 0 0 BT11:1 N10:90 4 N (DN) (ER)
8-24
DeviceNet Examples
Example #1 SLC 500 Controller with Explicit Messaging

This example demonstrates discreet control of the SMC Dialog Plus controller in addition to use of the explicit messaging function for transferring parameter data to an SLC500. The DeviceNet Manager (revision 3.001) software is used in this example for network and node configuration. RSView is used as the man-machine interface in this example. Many of the selections shown are example-specific. Some changes by the user may be necessary to apply the concepts of this example to a specific application. System Configuration
4 SLC 5/02 or higher SDN Scanner 1747-SN Scanner
L1 1
L2 3
L3 5
11
12
13
14
15
16
17
18
19
20
Remote I/O Link DeviceNet trunk

30
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28
29
GK5 1203-GD1 Communication Module
Notes: 1) 1747-SDN scanner firmware revision 3.01 or later required. 2) 1203-GK5 module firmware revision 1.9 or later required. 1203-GK5 Communication Module Switch Settings The following information is provided to explain the required 1203GK5 communication module switch settings for this example. Refer to the 1203-GK5 manual for further details related to the switch settings.
8-25
Example Information
Description Node Address: Data Rate: Datalinks: Zero data to logic command on fault: Fault on comm loss: Fault on PLC/SLC program/idle modes: 13 125k No x Yes Yes Yes Switch Setting SW2, Switches 1, 3 & 4 (On) Switches 2, 5 & 6 (Off) SW2, Switches 7 & 8 (Off) SW1, Switches 1 - 4 (Off) SW1, Switch 6 (Off) SW1, Switch 7 (Off) SW1, Switch 8 (Off)
The SMC Dialog Plus controller does not support Datalinks.
Switch Settings
8 7 6 5 4 3 2 1
Disabled Datalink A (Off) Disabled Datalink B (Off) Disabled Datalink C (Off) Disabled Datalink D (Off) Not Used (Off) Zero Data (Off) Fault on Comm Loss (Off) Fault on Program/Idle (Off)
8 7 6 5 4 3 2 1
Node Address 13 (On) Node Address 13 (Off) Node Address 13 (On) Node Address 13 (On) Node Address 13 (Off) Node Address 13 (Off) Data Rate = 125k (Off) Data Rate = 125k (Off)
SW1
I/O Mapping
The SMC Dialog Plus controllers first two words of data are preconfigured in the 1203-GK5 communication module as follows:
Word 1 2
Output Data Logic Command Reference x
SW2
Input Data Logic Status Feedback y
x y
The SMC Dialog Plus controller does not utilize this feature; a value of zero should be given. The feedback word is the value of parameter 4, Current Phase A.
8-26
After you have your network project configured in the DeviceNet Manager software, perform a Network Who; the following screen will appear:
Notice that the SMC Dialog Plus controller is identified as node 13, which was configured by setting the DIP switches on the 1203-GK5 communication module. Double-click the Master (node 0) on the DeviceNet network; the following screen will appear:
Select the Edit Scan List option by clicking on the button; the following screen will appear:
8-27
Notice that the SMC Dialog Plus controller (node 13) has an active status. This means that it is active in the scan list and will communicate with the 1747-SDN scanner on the network. You will also notice that Yes is listed twice under the Mapped column. The left Yes indicates that input data is mapped from the SMC Dialog Plus controller to the SLC-500. The right Yes indicates that output data from the SLC-500 is mapped to the SMC Dialog Plus controller. Configure the 1747-SDN if No is displayed. To view the actual areas inside the SLC-500 processor where the device data will be transferred to and from, select the Datatable Map by clicking on the button; the following screen will appear:
8-28
This indicates that the SMC Dialog Plus controllers input data is mapped to words 7 and 8. By clicking the radio button next to Output, the output data mapping can be seen; the following screen will appear:
This indicates that the SLC-500s output data associated with the SMC Dialog Plus controller is mapped to words 7 and 8. Given this data table mapping, following are the individual logic command and status bit addresses for the SMC Dialog Plus controller:
SMC Dialog Plus Controller Logic Command Addressesx

Bit Description Stop Start Option Command Clear Fault Address O:1.7/00 O:1.7/01 O:1.7/02 O:1.7/03
Refer To Table 8.A
8-29
SMC Dialog Plus Controller Status Addressesy
Bit Description Enabled Running Starting Stopping Fault At Speed
Address I:1.7/00 I:1.7/01 I:1.7/04 I:1.7/05 I:1.7/07 I:1.7/08
Refer To Table 8.B
Explicit Messaging:
The 1747-SDN scanner module uses the M0 and M1 file areas for data transfer. Words 224 through 256 must be used to execute the Explicit Message Request and Response functions. The minimum data size for an Explicit Message Request is 6 words and the maximum is 32 words. Following is the data format to follow for a scattered parameter value read (Get Attribute Multiple) as used in this example:
Explicit Message Request (Get Attribute Multiple)
15 TXID PORT SERVICE CLASS INSTANCE ATTRIBUTE PARAMETER DATA PLACE HOLDER COMMAND SIZE MAC ID
0 word 0
word 31
8-30
Explicit Message Response (Get Attribute Multiple)
15 TXID PORT SERVICE PARAMETER DATA STATUS SIZE MAC ID
0 word 0
word 31
Transmission ID (TXID): The scanner uses this value to track the transaction to completion, and returns the value with the response that matches the request downloaded by the SLC-500 processor. The TXID data size is one byte. Command: This code instructs the scanner how to administer the request. A listing of these codes can be found in the 1747-SDN User Manual, Publication 1747-5.8. The Command data size is one byte. Status: The Status code provides the communication modules status and its response. Port: The physical channel of the scanner where the transaction is to be routed. The port setting can be zero (channel A) or one (channel B). The Port data size is one byte. Size: This identifies the size of the transaction body in bytes. The transaction body begins at word 3. The maximum size is 58 bytes. The Size data size is one byte. Service: This code specifies the type of request being delivered. The Service data size is one byte. Mac ID: The DeviceNet network node address of the device for which the transaction is intended is identified here. The slave device must be listed in the scanner modules scan list and be on-line for the Explicit Message transaction to be completed. Class: The desired DeviceNet class is specified here. The Class data size is one word. Instance: This code identifies the specific instance within the object class towards which the transaction is directed. The value zero is reserved to denote that the transaction is directed towards the class itself versus a specific instance within the class.
8-31
Attribute: This code identifies the specific characteristic of the object towards which the transaction is directed. The Attribute data size is one word.
Examples
The following table lists the most common codes for each given transaction type:
Transaction Type Single Parameter Read Single Parameter Write Scattered Parameter Read Scattered Parameter Write Service x 0E 10 32 34 Class x 0F 0F 93 93 Instance x Par. # y Par. # y 0 0 Attribute x 1 1 0 0
x y
The numerical values are in a hexidecimal format. This is the actual parameter number as listed in Appendix B of this manual.
Sequence of Events:
Use the following sequence of events as a guide for establishing explicit messages in your SLC ladder logic: 1. Put the Explicit Message Request data into an integer (N) file of the SLC-500 processor. 2. Use the file copy instruction (COP) to copy the Explicit Message Request data entered in step one to the M0 file, words 224 through 256. 3. Use the examine-if-closed instruction (XIC) to monitor bit 15 of the scanners Module Status Register for an indication that it has received a response from the 1203-GK5 communication module. 4. Copy the data from the M1 file, words 224 through 256, into a file in the SLC-500 processor using the file copy instruction (COP). 5. Use the move instruction (MOV) to copy a one-word file from the SLC-500 processor into word 224 of the M0 file. The upper byte of the word should contain the TXID value for this transaction and the lower byte should contain the value 4 which is the command for the scanner to clear its response buffer. After the move is completed, bit 15 of the scanners Module Status Register should go to a value of zero, allowing the next explicit message to be executed.
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Setting Up the Data File:

In this example, the data file for the Explicit Message Request begins at N11:0. Following is the structure for a Get Attribute Multiple of the SMC Dialog Plus controllers Metering group parameters (1 - 11). Please note that the data shown is in a hexadecimal format. The first three words are shown segmented into two bytes, corresponding to the upper and lower bytes shown in the Explicit Message Request table.
TXID Command Port Size Service MAC ID Class Instance Attribute File N11:0 0 01 01 1 00 2E 2 32 0D 3 0093 4 0000 5 0000 6 0001 7 0001 8 0002 9 0001
Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder
File N11:10
0 0003
1 0001
2 0004
3 0001
4 0005
5 0001
6 0006
7 0001
8 0007
9 0001
Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder Parameter Number Data Place Holder
File N11:20
0 0008
1 0001
2 0009
3 000A
4 000B
5 0001
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Note: There is no required value for the words identified as Data Place Holder.
Example Ladder Logic Program:

Rung 0: The 1747-SDN scanner module will map output data from its scanner output table (MO) and discrete outputs to each node only when its in the run mode. This is accomplished by setting bit 0 of the 1747-SDNs command word (word 0).
1747-SDN Enable Bit : 1
Rung 1: When the START command is initiated at the RSView station the SLC processor sets the output bit mapped to the SMC Dialog Plus controllers logic control word start bit. The branch provides a logic latched circuit which exerts the START command until input from the SMC Dialog Plus controllers status word indicates that it has received the command and has responded appropriately. The SMC Dialog Plus controller will start if no STOP command is being issued by the SLC or any other control device.
Start CMD From RSVIEW B3 SMC START Command : 1.7
SMC START Command : 1.7 1
SMC Running Bit : 1.7 1
Rung 2: When the STOP command is initiated at the RSView station, the SLC processor sets the output bit mapped to the SMC Dialog Plus controllers logic control word stop bit. The branch provides a logic latched circuit which exerts the STOP command until input from the SMC Dialog Plus controllers status word indicates that it has received the command and has responded appropriately.
Stop CMD From RSVIEW B3 272 SMC STOP Command : 1.7
SMC STOP Command : 1.7 0
SMC Running Bit : 1.7 1
8-34
Rung 3: When the FAULT RESET command is initiated at the RSView station, the SLC processor sets the output bit mapped to the SMC Dialog Plus controllers logic control word clear faults bit. The branch provides a logic latched circuit which exerts the FAULT RESET command until input from the SMC Dialog Plus controllers status word indicates that it has received the comand and has responded appropriately. The SMC Dialog Plus controllers CLEAR FAULT bit functions as long as all other logic control bits have been reset to zero.
FAULT RESET From RSVIEW B3 SMC CLEAR FAULT Command : 1.7
275
SMC CLEAR FAULT Command : 1.7 3
SMC Fault Bit : 1.7 7
Rung 4: When bit B3:0/0 is set, the 32 words beginning at N11:0 from the SLC processor are copied to the 1747-SDN scanners MO-file. The 1747-SDN scanner sends this message out over the DeviceNet trunkline. The unlatch branch instruction resets B3:0/0 to zero for the next processor scan.
Explicit Message Request COP Copy File Source Dest Length N11:0 M0:1.224 32
Initiate Explicit Message B3:0 0
B3 U 0
Rung 5: When the 1747-SDN scanner has an Explicit Message response available, it sets bit 15 of its status word (I:1/15 in this example). The Explicit Message response is then copied from the 1747-SDN scanners M1-file to the SLC processors N11 file, beginning at word 50. The branch copies a command byte of 4 into the 1747-SDN scanners MO-file which directs it to discard the response data to prepare it for the next Explicit Message operation.
Explicit Message Response Available :1 15 Explicit Message Response COP Copy File Source Dest Length MVM Masked Move Source Mask Dest M1: 1.224 N11: 50 32
EQU Equal Source A Source B N11: 0 257< N11: 50 257<
N11: 0 4< 00FFh 255< M0: 1.224 ?<
Chapter
Diagnostics
Overview
This chapter describes the fault diagnostics of the SMC Dialog Plus controller. Further, this section describes the conditions that cause various faults to occur.
Protection Programming
Many of the protective features available with the SMC Dialog Plus controller can be enabled and adjusted through the programming parameters provided. For further details on programming, refer to the Advanced Setup section in Chapter 4, Programming.
Fault Display
The SMC Dialog Plus controller comes equipped with a built-in twoline, 16-character LCD. The LCD displays the fault message on the first line and the fault code on the second line.
Figure 9.1 Fault Display
OVERLOAD F7
Note: The fault display will remain active as long as control power is applied. If control power is cycled, the fault will be cleared, the controller will re-initialize, and the display will show a status of Stopped. Important: Resetting a fault will not correct the cause of the fault condition. Corrective action must be taken before resetting the fault.
Clear Fault
You can clear a fault using any of several methods: Program the SMC Dialog Plus controller for a Clear Fault, which can be found in the Faults and Linear List groups. If a human interface module is connected to the controller, press the Stop button.
Note: The stop signal will not clear a fault if Control Logic is disabled (Logic Mask, parameter #85, equals 0).
9-2
Diagnostics
Clear Fault (cont.)
Cycle control power to the SMC Dialog Plus controller.
Notes: (1) An overload fault cannot be cleared in this way for firmware releases prior to the following: - Standard Option 1.07L - Soft Stop Option 1A07L - Pump Control Option 1B05L (2) A communication fault (F21) cannot be cleared in this way for firmware releases prior to 1.04C. Important: An overload fault cannot be reset until the Motor Thermal Usage, parameter 11, value is below 75%. See page 1-7 for further details.
Fault Buffer
The SMC Dialog Plus controller stores in memory the five most recent faults. Display the fault buffer by selecting the Faults group and scrolling through the fault buffer parameters. The information is stored as fault codes. To determine what faults have occurred, use the fault code cross-reference below.
Fault Codes
Table 9.A provides a complete cross-reference of the available fault codes and corresponding fault descriptions.
Table 9.A Fault Code Cross-reference
Description Power Loss A Power Loss B Power Loss C Undervoltage Overvoltage Stall Overload Controller Temp. Underload Volt Unbalance Line Fault A Fault Code F12/F27 F13/F28 F15/F29 F16 F19 F21 F23 F24 F25 F64 F128-138 Description Line Fault B Line Fault C Line Fault Phase Reversal Jam Comm Fault Open Gate A Open Gate B Open Gate C Excess Starts/Hr. System Faults
Fault Code F1/F30 F2/F31 F3/F32 F4 F5 F6 F7 F8 F9 F10 F11/F26
Fault Auxiliary Contact
The auxiliary contact is located at terminals 29 and 30. This contact can be programmed as either Normal or Fault. Note that the state that this contact takes upon power-up (normally open or normally closed) can be programmed. These parameters can be found in either Basic Setup, Advanced Setup, or the Linear List groups when modifying parameters in the Program mode.
Diagnostics
9-3
Fault Definitions
Power Loss
Power loss indicates that an input power phase is not present. The controllers LCD display will identify the missing phase. Note: If all three phases are absent when a start command is issued, the LCD will display Starting without motor rotation.
Line Fault x
Line fault with the affected phase displayed identifies three possible pre-start conditions. Phase loss Load loss Shorted SCR
Line fault with no phase indication is displayed when one of the following conditions occurs while the SMC Dialog Plus controller is in the run mode. Phase loss Load loss Shorted SCR
Phase Reversal
Phase reversal is indicated when the incoming power to the SMC Dialog Plus controller is in any sequence other than ABC. This prestart protective feature can be disabled.
Overvoltage and Undervoltage Protection x

Overvoltage and undervoltage protection are user-defined as a percentage of the programmed line voltage. The SMC Dialog Plus controller continuously monitors the three supply phases. The calculated average is then compared to the programmed trip level.
x Phase loss, overvoltage, and undervoltage protection are disabled during braking operation.
9-4
Diagnostics
Fault Definitions (cont.)
Voltage Unbalance x
Voltage unbalance is detected by monitoring the three phase supply voltages. The formula used to calculate the percentage voltage unbalance is as follows: Vu = 100 (Vd / Va) Vu: Percent voltage unbalance Vd: Maximum voltage deviation from the average voltage Va: Average voltage The controller will shut down when the calculated voltage unbalance reaches the user-programmed trip percentages.
Stall Protection
Stall protection is enabled at the end of the programmed ramp time after a motor has been started. If the controller senses that the motor is not up-to-speed at the end of ramp, it will shut down after the userselected delay time has elapsed.
Jam Detection y
Jam detection operates when the SMC Dialog Plus controller status is at speed. The controller will shut down when the motor current reaches the user-defined trip level, which is based on a percentage of the programmed motor full load current rating.
Overload Protection
Overload protection is enabled in the Calibration group by programming the: Overload class Overload reset Motor FLC Service factor
Refer to Chapter 5 for more information on calibration.
Underload y
Underload protection is available for undercurrent monitoring. The controller will shut down when the motor current drops below the trip level. This trip level, a percentage of the motors full load current rating, can be programmed.
x y Voltage unbalance protection is disabled during braking operation. Jam detection and underload protection are disabled during slow speed and braking operation.
Diagnostics
9-5
Open Gate
Open gate indicates that an abnormal condition that causes faulty firing (i.e., open SCR gate) has been sensed during the start sequence. The SMC Dialog Plus controller will attempt to start the motor a total of three times before the controller shuts down.
Excess Starts/Hour
Excess starts/hour is displayed when the number of starts in a one hour period exceeds the value programmed.
Controller Temp
Controller temp is an indication that a power poles maximum rated temperature has been reached. The controllers microprocessor monitors the temperature of the SCRs by using internal thermistors. When the controller detects an overtemperature condition, the microprocessor turns off the SCRs and displays the appropriate fault code. An overtemperature condition could indicate the presence of inadequate ventilation, high ambient temperature, overloading, or excessive cycling. If an overtemperature condition exists at start-up, the SCR gate signals will be inhibited and the controller will trip and indicate the fault. The fault can be immediately reset. However, the motor cannot be restarted until after the controller temperature falls below trip levels.
Comm Fault
The SMC Dialog Plus controller disables control through the serial communication port as the factory default. To enable control, the Logic Mask parameter (#85) found in the Linear List programming group must be set to 4. With Series B human interface modules, this can also be accomplished by enabling control logic through the Control Status programming group. If a Bulletin 1201 human interface module or Bulletin 1203 communication module is disconnected from the SMC Dialog Plus controller when control is enabled, a Comm Fault will occur.
9-6
Diagnostics
Chapter
10
Troubleshooting
Introduction
For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities, follow the local safety related work practices (for example, the NFPA 70E, Part II in the United States). Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments. ATTENTION: Hazardous voltage is present in the motor circuit even when the SMC Dialog Plus controller is off. To avoid shock hazard, disconnect main power before working on the controller, motor, or control devices such as Start-Stop push buttons. Procedures that require parts of the equipment to be energized during troubleshooting, testing, etc., must be performed by properly qualified personnel, using appropriate local safety work practices and precautionary measures. ATTENTION: Disconnect the controller from the motor before measuring insulation resistance (IR) of the motor windings. Voltages used for insulation resistance testing can cause SCR failure. Do not make any measurements on the controller with an IR tester (megger).
Note: The time it takes for the motor to come up to speed may be more or less than the time programmed, depending on the frictional and inertial characteristics of the connected load. Note: Depending on the application, the SMB Smart Motor Braking, Accu-Stop, and Slow Speed with Braking options may cause some vibration 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 options.
10-2
Troubleshooting
The following flowchart is provided to aid in quick troubleshooting.

Figure 10.1 Troubleshooting Flowchart
YES
Fault Displayed?
NO
Define Nature of Trouble
Motor will not start no output voltage to motor
Motor rotates but does not accelerate to full speed
Motor stops while running
Miscellaneous situations
See Table 10.A on page 10-3
See Table 10.B on page 10-4
See Table 10.C on page 10-4
See Table 10.D on page 10-4
See Table 10.E on page 10-5
Troubleshooting
10-3
Table 10.A SMC Fault Display Explanation

Display Power Loss x (with phase indication) Fault Code F1, F2, F3, F30, F31, & F32 F11, F12, F13, F26, F27, & F28 F15 and F29 F10 F16 Undervolt F4 Comm Fault System Faults MPU Comm Fault Curr Fdbk Loss
x y Prestart fault indication. To further define this fault, the user can clear the fault and re-initiate a start signal. If the fault condition is still present, the controller will display either a Power Loss or a Line Fault with the phase indicated.
Possible Causes Missing supply phase (as indicated) Converter module and/or cable failure Missing supply phase Motor not connected properly Shorted SCR Converter module and/or cable failure Missing supply phase Motor not connected properly Shorted SCR Supply unbalance is greater than the userprogrammed value The delay time is too short for the application Incoming supply voltage is not in the expected ABC sequence Supply voltage is less than user-programmed value The delay time is too short for the application Supply voltage is greater than userprogrammed value Motor overloaded Overload parameters are not matched to the motor Motor has not reached full speed by the end of the programmed ramp time Motor current has exceeded the user programmed jam level. Broken motor shaft Broken belts, toolbits, etc. Pump cavitation Open gate circuitry Loose gate lead (1801000A) Number of starts in a one hour period has exceeded the value programmed Controller ventilation blocked Controller duty cycle exceeded Fan failure (if used) Ambient temperature limit exceeded Failed thermistor Failed control module Communication disconnection at the serial port Internal control module hardware failure Internal control module hardware failure Converter module cable disconnection
Possible Solutions Check for open line (i.e., blown line fuse) Inspect converter module cable connections Check for open line (i.e., blown fuse) Check for open load lead Check for shorted SCR; replace if necessary Inspect converter module cable connections Consult the factory Check for open line ( i.e., blown fuse) Check for open load lead Check for shorted SCR; replace if necessary Check power system and correct if necessary Extend the delay time to match the application requirements Check power wiring Check power system and correct if necessary Correct the user-programmed value Extend the delay time to match the application requirements Check power system and correct if necessary Correct the user-programmed value Check motor overload condition Check programmed values for overload class and motor FLC Correct source of stall Correct source of jam Repair or replace motor Check machine Check pump system Perform resistance check; replace power module if necessary Check gate lead connections to the interface board Wait an appropriate amount of time to restart Turn off the Starts/Hr. feature Check for proper ventilation Check application duty cycle Replace fan Wait for controller to cool or provide external cooling Replace power module Replace control module Check for a communication cable disconnection to the SMC Dialog Plus controller Replace control module Replace control module Inspect converter module cable and connections
Line Fault x (with phase indication)
Line Fault y (no phase indication) Voltage Unbalance Phase Reversal
Overvolt Overload Stall Jam Underload
F5 F7 F6 F19 F9
Open Gate (with phase indication) Excess Starts/Hr.
F23-F25
F64
Controller Temperature
F8
F21 F128 & above F20
10-4
Troubleshooting
Table 10.B Motor Will Not Start No Output Voltage to the Motor
Display Fault displayed Display is blank Stopped 0.0 Amps Control voltage is absent Failed control module Pilot devices SMC Enable input is open at terminal 13 Terminal 15 is open on Soft Stop, Pump Control, and SMB Start-Stop control has not been enabled for the human interface module Control voltage Failed control module Two or three power phases are missing Possible Cause See fault description Possible Solutions See Table 10.A addressing fault conditions Check control wiring and correct if necessary Replace control module Check wiring Check wiring Check wiring
Starting
Follow the instructions on pages 2-13 and 2-14 to enable control capability Check control voltage Replace control module Check power system
Table 10.C Motor Rotates (but does not accelerate to full speed)
Display Fault displayed Mechanical problems Possible Cause See fault description Possible Solutions See Table 10.A addressing fault conditions Check for binding or external loading and correct Check motor Adjust the Current Limit Level to a higher setting Replace control module
Starting Inadequate Current Limit setting Failed control module
Table 10.D Motor Stops While Running

Display Fault displayed Display is blank Stopped 0.0 Amps Starting Control voltage is absent Failed control module Pilot devices Failed control module Two or three power phases are missing Failed control module Check control wiring and correct if necessary Replace control module Check power system Replace control module Possible Cause See fault description Possible Solutions See Table 10.A addressing fault conditions Check control wiring and correct if necessary Replace control module
Troubleshooting
10-5
Table 10.E Miscellaneous Situations

Situation Motor current and voltage fluctuates with steady load Possible Cause Motor Energy Saver Possible Solutions Verify type of motor as a standard squirrel cage induction motor Set Energy Saver Off, then restart. If problem stops, replace control module If problem persists, shut off all power to controller and check connections Check load conditions Shut off all power to controller and check for loose connections Increase starting time Lower initial torque setting Decrease current limit setting Lower kickstart time or turn off Decrease starting time Increase initial torque setting Increase current limit setting Increase kickstart time or turn off Check wiring and correct if necessary Replace fan(s) Verify the programmed stopping time and correct if or increase Verify the programmed stopping time and correct if necessary The Soft Stop option is intended to extend the stopping time for loads that stop suddenly when power is removed from the motor. Soft Stop ramps voltage down over a set 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 Preset Slow Speed and Accu-Stop options: Extended operation at slow speeds reduces motor cooling efficiency. Consult motor manufacturer for motor limitations. Smart Motor Braking option: Check duty cycle. Consult motor manufacturer for motor limitations. Identify fault and correct. Check for shorted SCR; replace if necessary. Ensure power terminals are secure.
Erratic operation Accelerates too fast Accelerates too slow Fan does not operate (971000A) Motor stops too quickly with Soft Stop option Motor stops too slowly with Soft Stop option
Erratic Load Loose connections Starting time Initial torque Current limit setting Kickstart Starting time Initial torque Current limit setting Kickstart Wiring Failed fan(s) Time setting
Stopping time setting Misapplication
Fluid surges with pumps still occur with the Soft Stop option
Misapplication
Motor overheats Duty cycle
Motor short circuit
Winding fault
10-6
Troubleshooting
Control Module Removal
! ! ! !
ATTENTION: To avoid shock hazard, disconnect main power before working on the controller, motor, or control devices (such as Stop/Start push buttons). ATTENTION: Make sure that wires are properly marked and that programmed parameter values are recorded. ATTENTION: When removing control module, make sure power module or interface board pins do not bend.
ATTENTION: The 500 amp device is equipped with two shields that must be in place when power is applied to the controller.
The control module is not intended for field repair. The entire module must be replaced if a failure occurs. Follow the applicable procedure for control module removal.
24135 Amp
Refer to Figure 10.2 for control module removal reference. 1. Remove all control wires and serial port cables. 2. Loosen six mounting screws. 3. Unplug control module from the power structure by pulling forward.
Figure 10.2 Removal of Control Module (24135A)
Troubleshooting
10-7
180360 Amp
Refer to Figure 10.3 for control module reference. 1. Remove controller access door and serial port cable. 2. Remove controller cover. 3. Remove all control wires and loosen six control module mounting screws. 4. Unplug control module from the interface board by pulling forward.
10-8
Troubleshooting
(1)
(2)
(3)
(4)
Troubleshooting
10-9
5001000 Amp
Refer to Figure 10.4 for control module removal reference. 1. Disconnect all control wires to control modules. 2. Loosen six control module screws. 3. Unplug control module from interface board by pulling forward.
(1)
(2)
10-10
Troubleshooting
Control Module Replacement
The gold interconnection pins on the power modules and interface boards are protected with a special contact lubricant. Do not clean or wipe these pins. ATTENTION: When installing the control module, make sure the power module or interface board pins are not bent.
To install a control module, reverse the order of the removal procedure.
Protective Cover Removal
6501000 Amp
Figure 10.5 Removal of Protective Cover (5001000A)
1 2
Troubleshooting
10-11
MOV Fuse Replacement
5001000 Amp
ATTENTION: To avoid shock hazard, disconnect mainpower before working on the controller, motor, or control devices such as Start/Stop push buttons. ATTENTION: Replacement of the fuse with anything other than the recommended part number may cause physical damage to the controller.
! !
1. Remove the fuse from the fuse holder with a fuse puller (Figure 10.6). 2. Push the replacement fuse into the fuse holder.
Figure 10.6 MOV Fuse Replacement
MOV Fuses
Power Module and Interface Board Resistance Check
If a power module needs to be checked, use the applicable procedure that follows. ATTENTION: To avoid shock hazard, disconnect main power before working on the controller, motor, or control devices such as Start/Stop push buttons. ATTENTION: Make sure that wires are properly marked and programmed parameter values are recorded.
! !
10-12
Troubleshooting
Power Module and Interface Board Resistance Check (cont.)
24135 Amp
Remove the control module per the instructions beginning on page 10-6. Refer to Figure 10.7 for power module pin identification. Shorted SCR Test 1. Using an ohmmeter, measure the resistance between the line and load terminals of each phase on the controller. The resistance should be greater than 10,000 ohms. Feedback Resistance 1. Measure resistance between pins 1 and 2. Resistance should be 19,000 ohms, +/5%. 2. Measure resistance between pins 7 and 8. Resistance should be 19,000 ohms +/5%. Gate Lead Resistance 1. Measure resistance between pins 2 and 3. Resistance should less than 100 ohms. 2. Measure resistance between pins 6 and 7. Resistance should be less than 100 ohms. Thermistor Resistance 1. Measure resistance between pins 4 and 5. Resistance should be less than 150 ohms.
If the power module fails any of the above tests, replace it.
Figure 10.7 Pin Locations for Power Module Resistance Check
2 3 7 6 4 5 1 8
Troubleshooting
10-13
180-1000 Amp
Remove the control module per the instructions beginning on page 10-6. Refer to Figure 10.8 for interface board pin identification. Shorted SCR Test Using an ohmmeter, measure the resistance between the line and load terminals of each phase on the controller. Resistance should be greater than 10,000 ohms. Feedback Resistance 1. Measure resistance between: pins J17 and J18 for phase L1/T1 pins J12 and J13 for phase L2/T2 pins J4 and J5 for phase L3/T3
Each resistance should be approximately 20K. 2. Measure resistance between: pins J14 and J21 for phase L1/T1 pins J9 and J20 for phase L2/T2 pins J1 and J19 for phase L3/T3
Each resistance should be approximately 20K. If any of the measurements read open, replace the interface board.
Figure 10.8 Pin Locations for Power Pole Resistance Check (1801000A)
J18 J16
J13 J11
J5 J3
J14 J15
J9 J10
J1 J2
J17 J24 J21 J6 J8 J23
J12 J22 J20 J7
J4 J19
Gate Lead Resistance 1. Measure resistance between: pins J16 and J18 for phase L1/T1 pins J11 and J13 for phase L2/T2
pins J3 and J5 for phase L3/T3 The resistance should be approximately 100.
10-14
Troubleshooting
Power Module and Interface Board Resistance Check (cont.)
2. Measure resistance between: pins J14 and J15 for phase L1/T1 pins J9 and J10 for phase L2/T2 pins J1 and J2 for phase L3/T3
The resistance should be approximately 100. If any of the resistances measure greater than 100, recheck the resistance values directly at the gate lead connectors as shown in Figure 10.9. Based on the results, one of the following actions will be required: 1. All resistance values are valid - Replace interface board. 2. Resistance(s) measure greater than 100 Replace corresponding power pole(s). Thermistor Resistance 1. Measure resistance between: pins J6 and J24 for phase L1/T1 pins J8 and J23 for phase L2/T2 pins J7 and J22 for phase L3/T3
The resistance should be less than 500. If any of the resistances measure greater than 500, recheck the resistance values directly at the thermistor lead connectors as shown in Figure 10.9. Based on the results, one of the following actions will be required: If all resistance values are valid, replace interface board. If resistance(s) measure greater than 500, replace the corresponding power pole(s).
Gate lead, phase L2-T2 Gate lead, phase L1-T1 Gate lead, phase L3-T3
Figure 10.9 Gate and Thermistor Lead Identification (1801000A)
Thermistor lead, phase L1-T1
Gate lead, phase L3-T3
Gate lead, phase L1-T1 Thermistor lead, phase L2-T2
Thermistor lead, Gate lead, phase L3-T3 phase L2-T2
Appendix
Specifications
Electrical Ratings Power Circuit Method of Connection Number of Poles Rated Operation Voltage (Ue) Rated Insulation Voltage (Ui) Rated Impulse Voltage (Uimp) Dielectric Withstand Repetitive Peak Inverse Voltage Rating Operating Frequency Utilization Category Protection Against Electrical Shock DV/DT Protection Transient Protection Short Circuit Protection SCPD Performance SCPD List Device Operational Current Rating (Ie) 24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A Fault Current Withstand Rating (A rms sym) 5000 5000 5000 10,000 10,000 10,000 18,000 18,000 30,000 30,000 42,000 42,000 85,000 80A 125A 200A 350A 500A 600A 700A 1000A 1200A 1600A 2000A 2500A 3000A Type 1 Maximum Fuse or Circuit Breaker Motor in delta or star, SCRs between windings and supply Equipment designed for three phase loads only 200480 VAC (15%, +10%) 200600 VAC (15%, +10%) N/A N/A 2200 VAC 200480 VAC: 1400V 200600 VAC: 1600V 50/60 Hz MG 1 N/A 200415VY (15%, +10%) 200500VY (15%, +10%) 500V~ 4000V 2500V~ 200415~: 1400V 200500V~: 1600V 50/60 Hz AC-53a IP 00 (open device) RC Snubber Network Metal Oxide Varistors: 220 Joules @ 24360A 220 Joules @ 480V, 5001000A 300 Joules @ 480V, 5001000A UL/CSA/NEMA IEC
A-2
Specifications Electrical Ratings Control Circuit Rated Operation Voltage x Rated Insulation Voltage Rated Impulse Voltage Dielectric Withstand Operating Frequency Protection Against Electrical Shock Power Requirements Control Module Heatsink Fan(s) 24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A Maximum Heat Dissipation (watts) Controller Rating: 24A 35A 54A 97A 135A 180A
x Refer to product nameplate.
UL/CSA/NEMA
IEC
100240 VAC (15%, +10%) 24 VAC (15%, +10%) 24 VDC (20%, +10%) N/A N/A 1600 VAC 50/60 Hz N/A
100240 V~ (15%, +10%) 24 V~ (15%, +10%) 24 VDC (20%, +10%) 240 V~ 3000 V 2000 Y~ 50/60 Hz IP20
40VA
45VA 45VA 45VA 45VA 45VA 145VA 320VA 320VA 320VA 320VA
110 150 200 285 490 660
Specifications Electrical Ratings Control Circuit Rated Operation Voltage x Rated Insulation Voltage Rated Impulse Voltage Dielectric Withstand Operating Frequency Protection Against Electrical Shock Power Requirements Control Module Heatsink Fan(s) 24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A Maximum Heat Dissipation (watts) Controller Rating: 24A 35A 54A 97A 135A 180A 110 150 200 285 490 660 45VA 45VA 45VA 45VA 45VA 145VA 320VA 320VA 320VA 320VA 40VA 100240 VAC (15%, +10%) 24 VAC (15%, +10%) 24 VDC (20%, +10%) N/A N/A 1600 VAC 50/60 Hz N/A UL/CSA/NEMA IEC
A-3
100240 V~ (15%, +10%) 24 V~ (15%, +10%) 24 VDC (20%, +10%) 240 V~ 3000 V 2000 Y~ 50/60 Hz IP20
A-4
Specifications
Other Ratings EMC Emission Levels Conducted Radio Frequency Emissions Radiated Emissions EMC Immunity Levels Electrostatic Discharge Radio Frequency Electromagnetic Field Fast Transient Surge Transient Overload Characteristics: Type Current Range Trip Classes Trip Current Rating Number of Poles Metering Accuracy Voltage Current kW kWH Displacement Power Factor Converter Module Output Cat. No.: 825-MCM20 825-MCM180 825-MCM630
x y
UL/CSA/NEMA
IEC
Class A Class A
8kV Air Discharge Per IEC 947-4-2 Per IEC 947-4-2 Per IEC 947-4-2
Solid-state thermal overload with phase loss 1.0999.9 Amps 10, 15, 20, and 30 120% of Motor FLC 3
2% 5% x y 10% 10% 3% z
78.8 mV/A 9.85 mV/A 1.231 mV/A
Assumes the Bulletin 825 converter module is utilized. The SMC Dialog Plus controller calculates the current values to two decimal place resolution while displaying only to tenths of Amps. The display accuracy provided is, therefore, reduced by the truncation. The affect of truncation on accuracy will be dependent on the magnitude of the value. Assumes a balanced supply.
Specifications Environmental Ratings Operating Temperature Range Storage and Transportation Temperature Range Altitude Humidity Pollution Degree UL/CSA/NEMA 0C50C (open) 0C40C (enclosed) 20C+75C 2000 meters 5%95% (noncondensing) 2 IEC
A-5
A-6
Specifications
Appendix
Parameter Information
Table B.1
Group Parameter Description Voltage Phase AB Voltage Phase BC Voltage Phase CA Current Phase A Current Phase B Metering x Current Phase C Wattmeter Kilowatt Hours Elapsed Time Power Factor Motor Thermal Usage Clear Fault Fault Buffer #1 x Fault Buffer #2 x Faults Fault Buffer #3 x Fault Buffer #4 x Fault Buffer #5 x SMC Option x Starting Mode Basic Setup Ramp Time #1 Initial Torque #1 Current Limit Level Kickstart Time
x Read-only capability.
Parameter List
Scale Factor 1 1 1 10 10 10 10 1 1 100 1 1 1 1 1 1 Minimum No, Yes Maximum Default Setting No User Setting
Parameter Number 1 2 3 4 5 6 7 8 9 10 11 18 19 20 21 22 23
Display Units Volts Volts Volts Amps Amps Amps kW kWH Hours %
14 28 30 31 34 35
Seconds % LRT % FLC Seconds
1 1 1 10
Standard, Soft Stop, Pump Control, Preset Slow Speed, Smart Motor Braking, Accu-Stop, or Slow Speed with Braking Soft Stop, Current Limit 0 0 50 0.0 30 90 600 2.0 Soft Start 10 70 50 0.0 (Off)
B-2
Table B.1 (cont.) Parameter List

Group Parameter Description Stall Delay Energy Saver Aux. Contacts 1 and 2 Aux. Contact 3 Contact 3 Config Parameter Mgmt. Parameter Number 37 38 39 40 41 17 Display Units Seconds Scale Factor 10 Minimum 0.0 Off, On Normal, Up-to-speed Normal, Fault N.O., N.C. Ready, Default Init. Recll Frm EE,Store In EE Maximum 10.0 Default Setting 0 (Off) Off Normal Normal N.O. Ready User Setting
Control Options Soft Stop Soft Stop Time Pump Control Starting Mode Pump Stop Time Preset Slow Speed Basic Setup (cont.) Slow Speed Select Slow Speed Direction Slow Accel Current Slow Running Current 44 45 46 47 % FLC % FLC 1 1 Low, High Reverse, Forward 0 0 450 450 High Forward 0 0 28 42 Seconds 1 Soft Start, Current Limit, and Pump Start 0 120 Soft Start 42 Seconds 1 0 60 0
SMB Smart Motor Braking Braking Current Accu-Stop Slow Speed Select Slow Accel Current Slow Running Current Braking Current Stopping Current 44 46 47 48 51 % FLC % FLC % FLC % FLC 1 1 1 1 0 0 0 0 Low, High 450 450 400 400 High 0 0 0 0 48 % FLC 1 0 400 0
B-3

Group Parameter Description Parameter Number Display Units Scale Factor Minimum Maximum Default Setting User Setting
Slow Speed with Braking Slow Speed Select Basic Setup (cont.) Slow Accel Current Slow Running Current Braking Current Dual Ramp Ramp Time #2 Initial Torque #2 Undervolt Level Undervolt Delay Overvolt Level Overvolt Delay Jam Level Jam Delay Advanced Setup Unbalance Level Unbalance Delay Rebalance Underload Level Underload Delay Phase Reversal Starts per Hour Restart Attempts Restart Delay ETM Reset Parameter Management 44 46 % FLC 1 0 Low, High 450 High 0
47
% FLC
450
48 29 32 33 52 53 54 55 56 57 58 86 59 60 61 62 63 64 65 15 17
% FLC Seconds % LRT % Line Voltage Seconds % Line Voltage Seconds % FLC Seconds % Seconds % FLC Seconds Seconds
1 1 1 1 1 1 1 1 10 1 1 1 1 1 1 1
0 No, Yes 0 0 0 0 0 0 0 0.0 0 0 Off, On 0 0 Off, On 0 0 0 Off, On
400
0 No
30 90 99 99 199 99 999 10.0 25 99
10 70 0 (Off) 0 0 (Off) 0 0 (Off) 0 0 (Off) 0 Off
99 99
0 (Off) 0 Off
99 5 60
0 (Off) 2 0 Off Ready
Ready, Default Init. Recll Frm EE,Store In EE
B-4

Group Parameter Description Overload Class Overload Reset Motor HP Rating Motor kW Rating Line Voltage Motor FLC Service Factor Motor Code Letter LRC Ratio Converter Rating CT Ratio Calibration Enter Calib. Amps Current Phase A x Parameter Mgmt.
x y Read-only capability. The scale factor is 100 when Motor FLC, parameter 70, has a programmed value of up to 10.0 Amps; above 10.0 Amps, the scale factor is 10.
Parameter Number 36 88 79 80 69 70 84 72 81 74
Display Units HP kW Volts Amps
Scale Factor 10 10 1 10 100 10
Minimum
Maximum
Default Setting Off Manual 0.0 0.0 480 1.0 1.15 G 0.0 None
User Setting
Off, 10, 15, 20, and 30 Manual-Auto 0.0 0.0 0 1.0 0.01 6,553.5 6,553.5 9999 999.9 1.99
Calibrate
A, B, C, D, E, F, G, H, J, K, L, M, N, P, R, S, T, U, and V 0.0 19.9
None, 20, 180, 630 5, 50, 75, 100, 150, 200, 250, 300, 400, 500, 600, 750, 800, 1000, 1200 :5 Off, Activate 0.01 999.9
75 76 77
Amps
5:5 Off 0.0
Amps
10
17
Ready, Default Init. Recll Frm EE,Store In EE
Ready
B-5
Table B.2
Parameter Text/Display Unit Cross Reference

Description Setting Text Standard Soft Stop Pump Control 14 SMC Option Preset Slow Speed Smart Motor Braking Accu-Stop Slow Speed with Braking 15 ETM Reset Off On Ready 17 Parameter Mgmt. Default Init Recall From EE Store In EE 18 Clear Fault No Yes Current Limit 28 Starting Mode Soft Start Pump Start x 29 Dual Ramp y No Yes Off 10 36 Overload Class 15 20 30 38 39 40 41 44 45 59 62 Energy Saver Aux Contacts 1&2 Aux Contact 3 Contact 3 Config Slow Speed Select
z
Parameter Number
Display Unit 0 1 2 3 4 5 6 0 1 0 1 2 3 0 1 0 1 2 0 1 0 1 2 3 4 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
Off On Normal Up-to-speed Normal Fault N.O N.C. Low High Reverse Forward Off On Off On
Slow Speed Direction { Rebalance Phase Reversal
x y z {
Pump Start is only available with the Pump Control option. Dual Ramp is only available with the standard controller. Slow Speed Select is only available with the Preset Slow Speed and Accu-Stop options. Slow Speed Direction is only available with the Preset Slow Speed option.
B-6
Table B.2 (cont.) Parameter Text/Display Unit Cross Reference

Parameter Number Description Setting Text A B C D E F G H J 72 Motor Code Letter K L M N P R S T U V None 74 Converter Rating 20 180 630 5:5 50:5 75:5 100:5 150:5 200:5 250:5 75 CT Ratio 300:5 400:5 500:5 600:5 700:5 800:5 1000:5 1200:5 88 Overload Reset Manual Auto Display Unit 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 1 2 3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 1
Appendix
Renewal Parts
Description Standard Soft Stop Pump Control Preset Slow Speed SMC Rating All All All All 2454A 97135A SMB 180360A 500650A 7201000A 2454A 97135A Accu-Stop 180360A 500650A 7201000A 2454A 97135A Slow Speed with Braking 180360A 500650A Control Modules 7201000A Standard Soft Stop Pump Control Preset Slow Speed All All All All 2454A 97135A SMB 180360A 500650A 7201000A 2454A 97135A Accu-Stop 180360A 500650A 7201000A 2454A 97135A Slow Speed with Braking 180360A 500650A 7201000A
x One piece provided per part number.
Input Control Voltage
Part Number x 40888-490-01-S1FX 40888-490-01-A1FX 40888-490-01-B1FX 40888-490-01-C1FX 40888-490-01-D1AX 40888-490-01-D1BX 40888-490-01-D1CX 40888-490-01-D1DX 40888-490-01-D1EX
120240V AC
40888-490-01-E1AX 40888-490-01-E1BX 40888-490-01-E1CX 40888-490-01-E1DX 40888-490-01-E1EX 40888-490-01-F1AX 40888-490-01-F1BX 40888-490-01-F1CX 40888-490-01-F1DX 40888-490-01-F1EX 40888-490-01-S2FX 40888-490-01-A2FX 40888-490-01-B2FX 40888-490-01-C2FX 40888-490-01-D2AX 40888-490-01-D2BX 40888-490-01-D2CX 40888-490-01-D2DX 40888-490-01-D2EX
24V AC/DC
40888-490-01-E2AX 40888-490-01-E2BX 40888-490-01-E2CX 40888-490-01-E2DX 40888-490-01-E2EX 40888-490-01-F2AX 40888-490-01-F2BX 40888-490-01-F2CX 40888-490-01-F2DX 40888-490-01-F2EX
C-2
Renewal Parts
Description
SMC Rating 24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A
Line Voltage 200480V 200480V3 200480V 200480V 200480V 200480V 200480V 200480V 200480V 200480V 200480V 200480V 200480V 200600V 200600V 200600V 200600V 200600V 200600V 200600V 200600V 200600V 200600V 200600V 200600V 200600V
Part Number x 40382-899-02 40382-899-03 40382-899-03 40382-806-01 40382-806-03 40382-809-03 40382-809-05 40382-809-07 40382-810-01 40382-818-01 40382-818-03 40382-819-01 40382-819-03 40382-899-04 40382-899-04 40382-899-04 40382-806-02 40382-806-04 40382-809-04 40382-809-06 40382-809-08 40382-810-02 40382-818-02 40382-818-04 40382-819-02 40382-819-04
Power Modules 24A 35A 54A 97A 135A 180A 240A 360A 500A 650A 720A 850A 1000A
x One piece provided per part number.
Renewal Parts
C-3
Description
SMC Rating 24500A 650A 720A 850A 1000A
Line Voltage 200480V 200480V 200480V 200480V 200480V 200600V 200600V 200600V 200600V 200600V All All All All All All All All All All All 200480V 200480V 200600V 200600V
Part Number x N/A 40382-811-01 40382-811-03 40382-812-03 40382-812-01 N/A 40382-811-02 40382-811-04 40382-812-04 40382-812-02 N/A 40382-805-01 40382-814-01 40382-814-02 N/A 40382-807-01 40382-804-01 40382-813-01 40382-815-01 N/A 40382-816-01
y
Individual SCRs 24500A 650A 720A 850A 1000A 24135A 180360A Interface Board 500A 6501000A 2454A 97135A Heatsink Fans 180360A 500A 6501000A 24360A MOV Fuse 5001000A 24360A 5001000A MOV 24360A 5001000A
x y One piece provided per part number. Protective modules are available as a fieldinstalled accessory. See Appendix D. y
40382-817-01
40382-817-02
C-4
Renewal Parts
Appendix
Accessories
Description Description/Used With 2454A, 480V 2454A, 600V Protective Modules 97360A, 480V 97360A, 600V 97360A Terminal Lugs 500720A 8501000A 97135A IEC Terminal Covers 180360A IP30 (Type 1) Door Mount Bezel Kit IP30 (Type 1) Programmer Only Human Interface Module IP65 (Type 4/12) Programmer Only IP30 (Type 1) Analog Control Panel IP30 (Type 1) Digital Control Panel IP65 (Type 4/12) Digital Control Panel Remote I/O DH 485 or RS 232/422/485 (DF-1) Communication Modules DeviceNet Flex I/O SLC Communication Module 1/3 meter, Male-Male Communication Cables 1 meter, Male-Male 3 meter, Male-Male 9 meter, Male-Male 112.5A 9100A Converter Modules 64360A Fanning Strip 825-MCM630 150-NFS 150-NT2 1201-DMA 1201-HAP 1201-HJP 1201-HA1 1201-HA2 1201-HJ2 1203-GD1 1203-GD2 1203-GK5 1203-FB1 1203-FM1 1201-SM1 1202-C03 1202-C10 1202-C30 1202-C90 825-MCM120 825-MCM180 150-N84L 150-N86L 199-LF1 199-LG1 199-LJ1 150-NT1 Cat. No. 150-N84 150-N86
Glossary
AC AC Contactor Alternating current. An alternating current (AC) contactor is designed for the specific purpose of establishing or interrupting an AC power circuit. Ambient temperature is the temperature of air, water, or a surrounding medium where equipment is operated or stored. A standard system used for designing the size of electrical conductors. Gauge numbers have an inverse relationship to size; larger numbers have a smaller cross sectional area. However, a single-strand conductor has a larger cross-sectional area than a multi-strand conductor of the same gauge so that they have the same current-carrying specification. Block Transfer is the method used by a PLC to transfer data that does not require continuous updates. To perform this function, the module provides a status word to the PLC during normal discrete transfer scan. This status word occupies the first module group in the PLC I/O image table for the designated rack. The status word is then used by the PLC program to control the BTW and BTR functions of the PLC. A PLC Block Transfer Read instruction. A PLC Block Transfer Write instruction. 1. In software terms, a register or group of registers used for temporary storage of data to compensate for transmission rate differences between the transmitter and receiving device. 2. In hardware terms, an isolating circuit used to avoid the reaction of one circuit with another. Contactor, Reversing A method of reversing motor rotation by the use of two separate contactors, one of which produces rotation in one direction and the other produces rotation in the opposite direction. The contactors are electrically (and mechanically) interlocked so that both cannot be energized at the same time. This instruction copies data from one location into another. It uses no status bits. If you need an enable bit, program a parallel output using a storage address. The intensified or blinking element in a video display. A means for indication where data entry or editing occurs. 1. A sequence of operations that is repeated regularly. 2. The time it takes for one sequence of operations to occur.
Ambient Temperature
American Wire Gauge (AWG)
Block Transfer
BTR BTW Buffer
COP
Cursor
Cycle
Glossary-2
DH-485 Link
Data Highway 485 link. An Allen-Bradley token-passing baseband link for a local area network based on the RS-485 standard. To inhibit logic from being activated. The relationship between the operating and rest times or repeatable operation at different loads. To allow an action or acceptance of data by applying an appropriate signal to the appropriate input. Any malfunction that interferes with normal system operation. G File configuration is based on the devices that you have on the RIO link. G File configuration consists of setting logical device starting addresses and the logical device image size of each physical device/adapter with which the scanner communicates. The control element of an SCR (silicon controlled rectifier) commonly referred to as a thyristor. When a small positive voltage is applied to the gate momentarily, the SCR will conduct current (when the anode is positive with respect to the cathode of the SCR). Current conduction will continue even after the gate signal is removed. Jogging is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element. A short conductor with which you connect two points. Liquid crystal display, which is a reflective visual readout device commonly used in digital watches and laptop computers. The minimum torque that a motor will develop at rest for all angular positions of the rotor (with rated voltage applied at rated frequency). A selected method of operation. Example: run, test, or program. A set of contacts on a relay or switch that are closed when the relay is de-energized or the switch is de-activated. They are open when the relay is energized or the switch is activated. A set of contacts on a relay or switch that are open when the relay is de-energized or the switch is de-activated. They are closed when the relay is energized or the switch is activated. 1. An Allen-Bradley programmable controller. 2. An Allen-Bradley programmable controller with a name that includes the letters PLC. See Programmable Controller.
Disable Duty Cycle
Enable
Fault G File
Gate
Jogging
Jumper LCD
Locked Rotor Torque
Mode Normally Closed Contacts
Normally Open Contacts
PLC Controller
Glossary-3
Port
On a communication link, the logic circuitry or software at a station that determines its communication parameters for a particular communication channel. A measurement of the time phase difference between the voltage and current in an AC circuit. It is represented by the cosine of the angle of this phase difference. Power factor is the ratio of Real Power (kW) to total kVA or the ratio of actual power (W) to apparent power (volt-amperes). Preset speed refers to one or more fixed speeds at which the drive will operate. A solid-state system that has a user-programmable memory for storage of instructions to implement specific functions such as I/O control, logic, timing, counting, report generation, communication, arithmetic, and data file manipulation. A controller consists of a central processor, input/output interface, and memory. A controller is designed as an industrial control system. A set of conventions governing the format and timing of data between communication devices. I/O connected to a processor across a serial link. With a serial link, remote I/O can be located long distances from the processor. An EIA standard that specifies electrical, mechanical, and functional characteristics for serial binary communication circuits in a point-to-point link. An EIA standard that specifies electrical characteristics of balanced-voltage digital interface circuits in a point-to-point link. An EIA standard that specifies electrical characteristics of balanced-voltage digital interface circuits in a multi-point link. The vertical movement of data on a display screen caused by the dropping of one line of displayed data for each new line added at the opposite end. Pertaining to time-sequential transmission of, storage of, or logic operations on data, using the same facilities for successive parts. When used on a motor nameplate, a number which indicates how much above the nameplate rating a motor can be loaded without causing serious degradation (i.e., a motor with 1.15 S-F can produce 15% greater torque than one with 1.0 S-F) to adjust measured loads in an attempt to compensate for conditions which are difficult to measure or define. A solid-state switch, sometimes referred to as a thyristor. The SCR has an anode, (SCR) cathode and control element called the gate. The device provides controlled rectification since it can be turned on at will. The SCR can rapidly switch large currents at high voltages. They are small in size and low in weight. An Allen-Bradley programmable controller with a name that includes the letters SLC. See Programmable Controller.
Power Factor
Preset Speed Programmable Controller
Protocol
Remote I/O
RS-232-C
RS-422
RS-485
Scrolling
Serial
Service Factor (S-F)
Silicon Controlled Rectifier
SLC Controller
Glossary-4
Status
The condition at a particular time of any numerous entities within a system. These conditions may be represented by values in a status line. The process of absorbing and clipping voltage transients on an incoming AC line or control circuit. MOVs (Metal Oxide Varistors) and specially designed R-C networks are usually used to accomplish this. To switch alternately between two possible selections. A momentary deviation in an electrical or mechanical system. Underwriters Laboratories (an approval agency).
Surge Protection
Toggle Transient UL
Index
A accessories, D-1 Accu-Stop option, wiring diagrams, 7-14, 7-15, 7-16, 7-17 Accu-Stop, description of, 1-15 Accu-Stop option programming parameters for, 7-4 sequence of operation, 7-20 B Bulletin 825 converter module description, 2-16, 2-17, 2-18 for metering, 1-10 in a bypass configuration, 2-11 part numbers of, D-1 rating of, 5-2 with fanning strip connection, 3-6, D-1 with overload protection, 1-5 with phase rebalance, 1-5 C calibration, 5-1 procedure, 5-3 clear fault, 9-1 communication, 1-11, 8-1 communication (comm) fault, 9-5 communication modules, 2-16, 8-4 control enable, 8-2 control module removal, 10-6, 10-7, 10-8, 10-9 180-360 amp, 10-7, 10-8 24-135 amp, 10-6 500-1000 amp, 10-9 control module replacement, 10-10 control options, 1-12, 1-13, 1-14, 1-15
control power, 3-4 control voltage, 3-4 control wiring, 3-4 control terminals, 3-6 controller overview, 1-1 controller setup, 4-11 advanced setup, 4-12 controller temperature (temp), 9-5 current limit start description of, 1-3 programming parameters, 4-9 D datalinks, 8-4 diagnostics, 1-5, 1-7, 9-1 dimension drawings 180A360A controllers, 2-6 24A, 35A, and 54A controllers, 2-4 500A controllers, 2-7 650A1000A controllers, 2-8 97A and 135A controllers, 2-5 dual ramp start description of, 1-4 programming parameters for, 4-10 wiring diagram of, 3-9 E EMC, 2-18, 2-19 enclosures, 2-2, 2-3 energy saver, 1-5 ESD, effects of, 2-2 excess starts per hour, 1-10
I2
Index
F fan power, 3-5 fan terminations, 3-5 180A500A, 3-5 650A1000A, 3-5 97A and 135A, 3-5 fault auxiliary contact, 9-2 buffer, 9-2 codes, 9-2 definitions comm fault, 9-5 controller temp, 9-5 excess starts/hour, 9-5 jam detection, 9-4 line fault, 9-3 open gate, 9-5 overload protection, 9-4 overvoltage and undervoltage protection, 9-3 phase reversal, 9-3 power loss, 9-3 stall protection, 9-4 underload, 9-4 voltage unbalance, 9-4 display, 9-1 full voltage start description of, 1-4 programming parameters, 4-10 fuses, recommended, 2-10 G grounding provision, 3-6 H heat dissipation, 2-2 human interface module, 7-1 human interface module (HIM), 2-12 connecting the HIM to the controller, 2-13 control enable, 2-13 series A human interface modules, 2-14 series B human interface modules, 2-15
I inspection, 2-1 installation, 2-1 interfacing, 8-4 J jam detection, 9-4 K keypad description, 1-11, 4-1 L ladder logic program, 8-9, 8-15 line fault, 1-9, 9-3 logic control data, 8-1 M metering, 1-10, 6-1 motor data entry, 5-1 motor codes, 5-2 motor overload protection, 2-11 bypass configuration, 2-11 multi-motor protection, 2-11 series A human interface modules, 2-14 series B human interface modules, 2-15 two-speed motor connection, 2-11 mounting, 2-4 dimensions, 2-4, 2-5, 2-6, 2-7, 2-8 MOV fuse replacement, 10-11 O open gate, 1-9 options, 7-1 overload protection, 1-5 overvoltage protection, 9-3
Index
I3
P parameter electrically erasable programmable readonly memory (EEPROM), 4-6 listing of, 4-4, 8-3, B-1 management of, 4-6 modifying of, 4-8 random access memory (RAM), 4-6 read only memory (ROM), 4-6 using parameter management, 4-7 phase rebalance, 1-5 phase reversal, 1-9, 9-3 power factor correction capacitors, 2-9 power loss, 9-3 power module (and interface board) resistance check, 10-11, 10-12, 10-13, 10-14 feedback resistance, 10-12, 10-13 gate lead resistance, 10-12, 10-13 preparation, 10-11 shorted SCR test, 10-12, 10-13 thermistor resistance, 10-12, 10-14 precautions, 2-2 preset slow speed option description of, 1-13 programming parameters for, 7-3 sequence of operation, 7-19 wiring diagrams, 7-14, 7-15, 7-16, 7-17 programming advanced, 4-12, 4-13 basic, 4-11 example settings, 4-13 password, 4-5 programming menu, 4-1 programming parameters, 7-3 keypad, 1-11 protection and diagnostics, 1-5 excessive starts/hour, 1-10, 9-5 line faults, 1-9, 9-3 open gate, 1-9, 9-5 overload, 1-5 overtemperature, 1-10 stall and jam, 1-8
underload, 1-9, 9-4 protective cover removal, 10-10 protective modules, 2-11 pump control option description of, 1-13 programming parameters for, 7-3 sequence of operation, 7-12 wiring diagrams, 7-5, 7-6, 7-7, 7-8, 7-9, 7-10 R receiving the controller, 2-1 renewal parts, C-1 S scale factor conversion, 8-3 SCANport, 8-1 location, 1-11 search, 4-5 selectable kickstart, 1-3 serial communication, 8-1 Slow Speed with Braking option, description of, 1-15 Slow-speed with Braking option programming parameters for, 7-4 sequence of operation, 7-25 wiring diagrams, 7-21, 7-22, 7-23, 7-24 SMB Smart Motor Braking option description of, 1-14 programming parameters for, 7-4 sequence of operation, 7-13 SMB Smart Motor Braking option, wiring diagrams, 7-5, 7-6, 7-7, 7-8, 7-9, 7-10 SMC status data, 8-3 soft start option description of, 1-2 programming parameters, 4-9 soft stop option description, 1-12
I4
Index
programming parameters for, 7-3 sequence of operation, 7-11 wiring diagrams, 7-5, 7-6, 7-7, 7-8, 7-9, 7-10 soft stop/pump control/SMB smart motor braking options, wiring diagrams, 7-5, 7-6, 7-7, 7-8, 7-9 specifications, A-1 stall protection, 9-4 stall protection and jam detection, 1-8 standard controller wiring diagrams, 3-7, 3-9, 3-10, 3-11, 3-12, 3-13, 3-14, 3-15, 3-16, 3-17, 3-18, 7-10, 7-18 starting modes, 1-2 status indication, 1-11 storing the controller, 2-1 T terminal locations, 3-1 180360A, 3-2 2454A, 3-1 500A, 3-2 6501000A, 3-3 97 and 135A, 3-1 power wiring, 3-3 2454A, 3-3 971000A, 3-3
trip curves, 1-7 troubleshooting, 10-1 fault display explanation, 10-3 flowchart, 10-2 troubleshooting tables, 10-4, 10-5 U underload, 1-9, 9-4 undervoltage, 1-9 undervoltage protection, 9-3 unpacking, 2-1 V viewing metering data, 6-1 voltage unbalance, 1-9, 9-4 W wiring, 3-1
Publication 0150-5.3 - October 1998

Supersedes Publication 0150-5.3 - September 1996
40055-145-01(C)
1998 Rockwell International. All Rights Reserved. Printed in USA

Manual SMC Dialog Plus Controller. Allen Bradley

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Manual SMC Dialog Plus Controller. Allen Bradley

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SMC Dialog Plus Controller

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Chapter 1 Product Overview 1-1

Chapter 6 Metering Chapter 7 Options

Chapter 8 Serial Communications

Start Time (seconds)

Start Time (seconds)

Current Limit Starty

Start Time (seconds)

Starting Modes (cont.)

Dual Ramp Startx

Full Voltage Start

Full Voltage Start

Dual Ramp Start is available only with the standard controller.

Protection and Diagnostics

Protection and Diagnostics (cont.)

Overload Trip Curves

Approximate Trip Time (seconds)

Approximate Trip Time (seconds)

Approximate Trip Time (seconds)

Approximate Trip Time (seconds)

Figure 1.7 Restart Trip Curves after Auto Reset

Class 10 Class 15 Class 20 Class 30

Percent Full Load Current Setting

Protection and Diagnostics (cont.)

Stall Protection and Jam Detection

Figure 1.8 Stall Protection

600% Percent Full Load Current

Programmed Start Time Time (seconds)

Figure 1.9 Jam Detectionx

Percent Full Load Current

User Programmed Trip Level

Running Time (seconds)

Jam detection is disabled during slow speed and braking operation.

Protection and Diagnostics (cont.)

Soft Stop Option

Coast-to-rest Soft Stop

Run Time (seconds)

Pump Control Option

Run Time (seconds)

Preset Slow Speed Option

Figure 1.14 Preset Slow Speed Option

15% High 7% Low

Time (seconds) 10% Low 20% High Reverse

SMB Smart Motor Braking Option

100% Smart Motor Braking Motor Speed

Run Time (seconds)

Brake Automatic Zero Speed Shut-off

Braking Slow Speed

Slow Speed Braking/Coast

Run Time (seconds)

Slow Speed with Braking Option

100% Coast-to-rest Motor Speed 7% or 15% Braking

Run Time (seconds)

SMC Rating Max. Watts

(10 in2) 233 cm2 (36 in2)

13 76 (5 30) 13 76 (5 30) 13 76 (5 30) 13 76 (5 30)

.22 in. (5.56 mm)

Unit mm in. mm in. mm in.

A Width 154 6-1/16 214 8-7/16 244 9-39/64

B Height 180 7-3/32 240 9-39/64 290 11-22/64

C Depth 185 7-19/64 195 7-11/16 225 8-7/8

D 50 1-31/32 60 2-23/64 90 3-35/64

E 140 5-33/64 200 7-7/8 230 9-1/64