SMC Dialog Plus Controller Bulletin 150 11 12 21 13 14 15 16 22 5 3 1 17 23 24 25 26 18 27 19 20 28 29 30 User Manual
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
toc–iv Table of Contents Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . 2-9 Fast Acting Current-limiting Fuses . . . . . . . . . . . . . . . . . . . . . . 2-10 Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Bypass . . . . . . . . . . . . . . . . . . . .
Table of Contents toc–v Example Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Undervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Overvoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Jam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
toc–vi Table of Contents Example #3 – PLC 5/20, 5/40, 5/60, and 5/80 . . . . . . . . . . . 8-18 1203-GD1 Communication Module Switch Settings . . . . . . . 8-19 I/O Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 Block Transfer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Block Transfer Datafiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Example #3 Ladder Logic Program . . . . . . . . . . . . . . . . . . . .
Table of Contents toc–vii 180–360 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 500–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Protective Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 650–1000 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 MOV Fuse Replacement . . . . . . . . . . . . . . . . .
toc–viii Table of Contents Figure 2.10 Current Transformer Connection to Converter Module . . . . . . . . . . . . . . . . . . . . . . 2-18 Figure 3.1 Wiring Terminal Locations (24 to 54 Amp) . . . . . . . 3-1 Figure 3.2 Wiring Terminal Locations (97 and 135 Amp) . . . . 3-1 Figure 3.3 Wiring Terminal Locations (180 to 360 Amp) . . . . . 3-2 Figure 3.4 Wiring Terminal Locations (500 Amp). . . . . . . . . . . 3-2 Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp) . . . . 3-3 FIgure 3.
Table of Contents 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.
toc–x 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 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
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.
1-3 Product Overview Selectable Kickstart① 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.
1-4 Product Overview Starting Modes (cont.) Dual Ramp Start① 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.
Product Overview Energy Saver 1-5 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.
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 motor’s 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.
1-7 Product Overview Figure 1.6 Class 15 Class 20 Class 30 10000.0 10000.0 100.0 1000.0 1000.0 1000.0 10.0 1.0 0.1 2 3 4 5 6 7 8 9 10 Multiples of FLC 10.0 1.0 1 2 3 4 100.0 10.0 100.0 10.0 1.0 1.0 5 6 7 8 9 10 1 Multiples of FLC 2 3 4 5 6 7 8 9 10 1 Multiples of FLC Approximate trip time for 3-phase balanced condition from cold start. 2 3 4 5 6 7 8 9 10 Multiples of FLC Approximate trip time for 3-phase balanced condition from cold start. Figure 1.
1-8 Product Overview Protection and Diagnostics (cont.) 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 motor’s FLC rating) and the delay time (up to 10.0 seconds) for application flexibility. Figure 1.
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.
1-10 Product Overview Protection and Diagnostics (cont.) 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.
1-11 Product Overview 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.
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.
1-13 Product Overview 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 0–30 seconds, and the stopping time is programmable from 0–120 seconds. Figure 1.
1-14 Product Overview Figure 1.14 Preset Slow Speed Option Forward 15% – High 7% – Low Time (seconds) Start Run 10% – Low 20% – High Reverse ! 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.
1-15 Product Overview Note: All braking current settings in the range of 1–100% 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.
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 Stop Time (seconds) 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 2 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.
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. ! ! ! Heat Dissipation 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.
2-3 Installation 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.
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 Ø .28 in. (7.14 mm) D 4 Mtg. Holes Ø .22 in.
2-5 Installation Figure 2.2 Dimensions: 97 and 135 Amp Controllers A E C Power Terminal H M10 Bolt 6 Places D G B F Ground Screw (M6) .281 in. (Ø 7.14 mm) 4 Mtg. Holes Fan Terminals Unit A Width B Height C Depth D E F G H Approx. Ship. Wt. 97A Controller mm 248 336 256.2 128 220 250 40.4 14 10.4 kg in. 9-49/64 13-15/64 10-3/32 5-3/64 8-21/32 9-27/32 1-39/64 9/16 23 lbs. 135A Controller mm 248 336 256.2 128 220 250 40.4 14 11.8 kg in.
2-6 Installation Mounting (cont.) Figure 2.3 Dimensions: 180 through 360 Amp Controllers A C D P Q N E .281 (7.1) Dia. 6 Mtg. Holes F .281 (7.1) Rad. 2 Key Holes G Terminal Detail J .136 (3.5) Dia. #8-32 UNC-2B B .413 (10.5) Dia. H 1.02 (25.9) .984 (25) K .531 (13.5) S R 1.161 (29.5) 2.250 (57) M Ground Nut (1/4-20) 180, 240, and 360 Amp Dbl. Lug Mtg. L 180A Cont. 240– 360A Cont. Unit A Width B Height C Depth D E F G H J K L M N P Q R S Approx. Ship. Wt.
2-7 Installation Figure 2.4 Dimensions: 500 Amp Controller M .531 in. (13.5 mm) for 1/2 Bolts Typ. E N P F J K L A G .312 in. (7.9 mm) 6 Mtg. Holes Q Q H D Ground Nut (1/4-20) B C Unit A Height B Width C Depth D E F G H J K L M N P Q Approx. Ship. Wt. mm 588.4 508 310.7 183 51.4 50.8 469.9 489 19 196.9 393.7 38.9 18.6 17.5 136 40.8 kg in.
2-8 Installation Mounting (cont.) Figure 2.5 Dimensions: 650-1000 Amp Controllers A D .56 Dia. (Ø 14.2) 2 – Lifting Holes C G E L F H .5 Dia. (Ø 12.7) 6 – Holes M R R P N Q .105 Steel Sheet (2.67) T .75 Dia. (Ø 19.1) 2 – Holes 2.0 (50.8) B 4.0 (101.6) .688 (17.5) .515 (13.1) Dia. Typ. 1.312 (33.3) 1.312 (33.3) J K 650–720 Amp 2.5 (63.5) 5.0 (127) .688 (17.5) .64 (16.3) Typ. .64 (16.3) .67 (17) .64 (16.
2-9 Installation 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.
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.
Installation 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.
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.
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.
2-14 Installation Human Interface Module (cont.) Series A Human Interface Modules Action — — 1. Press any key to access the Choose Mode function. 2. Scroll with the Up/Down keys until the Program option appears. 3. Press the Enter key to access the Program option. 4. Scroll with the Up/Down keys to the Linear List option. 5. Press the Enter key to access the Linear List programming group. 6. Scroll with the Up/Down keys to parameter number 85 – Logic Mask. 7. 8. 9.
2-15 Installation Series B Human Interface Modules Description Action — — 1. Press any key to access the Choose Mode function. 2. Scroll with the Up/Down keys until the Control Logic option is presented. Display STOPPED 0.0 AMPS CHOOSE MODE _____ or CHOOSE MODE CONTROL STATUS 3. Press the Enter key to access Control Logic options. CONTROL LOGIC DISABLE 4. Press the Select key to access the settings available. CONTROL LOGIC DISABLE 5. Use the Up/Down keys to obtain the Enable option. 6.
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.
2-17 Installation Figure 2.9 shows the connection between the controller and the module. Figure 2.9 Converter Module Connection Interface L1 L2 L3 Converter Module ➀ T1 T2 T3 Cable (provided as standard with the converter module) ➁ 150-NFS Fanning Strip 21 22 23 24 25 26 27 28 29 30 ① The converter module rating must be programmed in the calibration group for proper current measurement scaling. ② Cable length is three meters.
2-18 Installation Converter Modules (cont.) For applications in which the motor’s 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.
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).
2-20 Installation
Chapter 3 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 24–135A, a grounding screw is provided to ground the heatsink per applicable codes. For controllers rated 180A–1000A, a grounding lug is provided on the mounting plate.
3-2 Wiring Terminal Locations (cont.) Input Power Connections Figure 3.3 Wiring Terminal Locations (180 to 360 Amp) Control Wiring Access Door Fan Power Connections TB3 Control Circuit Connections 1 2 3 4 5 Output Power Connections Figure 3.
3-3 Wiring Figure 3.5 Wiring Terminal Locations (650 to 1000 Amp) Input and Output Power Connections Control Circuit Connections Fan Power Connections Power Wiring 24–54A The power modules for controllers rated 24A–54A 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 AWG 2.5–25 mm2 #14–#4 Table 3.B Tightening Torque Tightening Torque Wire Size 2.
3-4 Wiring Terminal Locations (cont.) Control Power Table 3.C Lug Wire Capacity and Tightening Torque SMC Rating Lug Kit Cat. No. Conductor Range 97– 135A 199-LF1 180– 360A Max. No.
3-5 Wiring Fan Power Controllers rated 97A–1000A 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 650A–1000A controllers.
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.
3-7 Wiring Standard Controller Wiring Diagrams Figure 3.11 through Figure 3.22 show typical wiring for the SMC Dialog Plus controller. Figure 3.
3-8 Wiring Standard Controller Wiring Diagrams (cont.) Figure 3.12 Typical Wiring Diagram for Two-Wire Control or Programmable Control Interfacing L1/1 T1/2 L2/3 T2/4 L3/5 T3/6 3-Phase M➀ Input Power Fast-acting SCR Fuses (optional) ➀ ➀ Branch Protection ➀ ➀ SMC Dialog Plus Controller ➀ Two-wire Device ➀ ➁ 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 ① Customer supplied.
3-9 Wiring Figure 3.13 Typical Wiring Diagram for Dual Ramp Applications L1/1 T1/2 L2/3 T2/4 L3/5 T3/6 3-Phase M➀ Input Power Fast-acting SCR Fuses (optional) ➀ ➀ Branch Protection ➀ ➀ SMC Dialog Plus Controller ➀ Stop ➀ Ramp 1 ➀ Ramp 2 Start ➀ ➁ 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 ① Customer supplied.
3-10 Wiring Standard Controller Wiring Diagrams (cont.) 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 controller’s SCANport.
3-11 Wiring Figure 3.15 Typical Wiring Diagram for Retrofit Applications 3-Phase L1/1 T1/2 L2/3 T2/4 L3/5 T3/6 M➀ Input Power Branch Protection ➀ Existing Motor Starter ➀ ➀ ➀ Fast-acting SCR Fuses SMC Dialog Plus Controller (optional) ➀ ➀ OL ➀➁ M ➀ Start ➀ Stop ➀ M➀ ➂ 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 Internal Auxiliary Contacts 26 27 28 29 30 ① Customer supplied.
3-12 Wiring Standard Controller Wiring Diagrams (cont.) Figure 3.
3-13 Wiring Figure 3.
3-14 Wiring Standard Controller Wiring Diagrams (cont.) Figure 3.
3-15 Wiring Figure 3.19 Typical Wiring Diagram for Shunt Trip Applications Shunt Trip Circuit Breaker L1/1 T1/2 L2/3 T2/4 L3/5 T3/6 3-Phase M➀ Input Power Fast-acting SCR Fuses SMC Dialog Plus (optional) ➀ Controller ➀ Branch Protection ➀ ➀ ➀ Stop ➀ Start ➀ ➁ 11 12 13 14 15 16 17 18 19 20 26 27 28 29 30 SMC Dialog Plus Control Terminals ST 21 22 ➀ 23 24 25 Auxiliary contact set for Fault and N.O. ① Customer supplied.
3-16 Wiring Standard Controller Wiring Diagrams (cont.) Figure 3.
3-17 Wiring Figure 3.21 Typical Wiring Diagram for Two-speed Applications L L1/1 T1/2 3-Phase H L2/3 T2/4 Input Power H L3/5 T3/6 SMC Dialog Plus Controller Branch Protection ➀ ➀ ➀ ➁ ➁ M➀ H Fast-acting SCR Fuses (optional) ➀ ➀ Two-speed Motor Starter ➀ LOL ➀ Stop ➀ High Low ➀ ➀ HOL ➀ H ➀ L L ➀ ➀ L ➀ H H ➀ ➀ L 1 sec. H ➀ 1 sec.
3-18 Wiring Standard Controller Wiring Diagrams (cont.) Figure 3.22 Typical Wiring Diagram for Hand-Off-Auto (SCANport) Control L1/1 T1/2 L2/3 T2/4 3-Phase M➀ Input Power L3/5 T3/6 Fast-acting SCR Fuses SMC Dialog Plus (optional) ➀ Controller ➀ Branch Protection ➀ ➀ ➀ H ➀ A ➁ 11 12 13 14 15 16 17 18 19 20 SMC Dialog Plus Control Terminals 21 22 23 24 25 Internal Auxiliary Contacts 26 27 28 29 30 ① Customer supplied.
Chapter 4 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. Keypad Description 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.
4-2 Programming Programming Menu (cont.) Figure 4.
4-3 Programming Figure 4.1 (Cont.) Menu Structure Hierarchy or Metering See Chapter 6 Linear List Basic Setup Advanced Setup Faults Calibrate See Chapter 5 Language ➀ ➁ GROUP LEVEL ➀ Volts Phase A–B Volts Phase B–C Volts Phase C–A 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.
4-4 Programming Programming Menu (cont.) Table 4.A Parameter Linear List Parameter No. Description Parameter No. Description 1 Volts Phase A–B 45 Slow Speed Dir. 2 Volts Phase B–C 46 Slow Accel Cur. 3 Volts Phase C–A 47 Slow Running Cur.
4-5 Programming 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. 1. 2. 3. Description Action — — 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.
4-6 Programming Parameter Management Before you begin programming, it’s 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.
4-7 Programming Using Parameter Management Description Action Display 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. PARAMETER MGMT STORE IN EE 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.
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 Action — — 1. Press any key to go from the status display to the Choose Mode menu. 2. Scroll with the Up/Down keys until the Program option appears. 3. Press the Enter key to access the Program menu. 4.
4-9 Programming 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. Soft Start, Current Limit Ramp Time #1 ① This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed.
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.
4-11 Programming 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.
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 controller’s 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.
4-13 Programming Parameter Example Settings Option Phase Reversal This parameter allows the user to enable phase reversal protection. Off, On Starts Per Hour Allows the user to limit the number of starts during a one hour period. 0–99 (0 is the Off setting) Restart Attempts ① Determines the number of attempts the controller will make to automatically restart the motor after a fault. 0 to 5 Restart Delay ① Provides a delay period prior to a restart attempt.
4-14 Programming
Chapter 5 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. ! Motor Data Entry ATTENTION: For overload protection, it is critical that the data be entered as it appears on the motor nameplate.
5-2 Calibration Motor Data Entry (cont.) Parameter Option Display Motor Code Letter ① Enter the value from the motor’s nameplate. If the motor nameplate does not provide this, consult the motor manufacturer. See Table 5.A for code letter definitions. A–V MOTOR CODE LETTER # LRC Ratio ① IEC motors do not provide a motor code letter. Consult the motor manufacturer for the motor’s locked rotor current/full load current ratio. 0.0–19.9 LRC RATIO ##.
5-3 Calibration 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.
5-4 Calibration Calibration Procedure (cont.) Description 7. 8. 9. Action Display You can scroll to the next parameter to view the current measurement in phase A. CURRENT PHASE A ###.# AMPS Scroll to the next parameter to save the Calibrate group settings. PARAMETER MGMT READY 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.
Chapter 6 Metering Overview While the SMC Dialog Plus controller operates your motor, it also monitors several different parameters, providing a full function metering① package. Viewing Metering Data To access the metering information, follow the procedure below. Description Action — — 1. Press any button to access the Choose Mode menu. 2. Scroll with the Up/Down keys until the Display option is shown. 3. Press the Enter key to select the Display option. 4.
6-2 Metering Viewing Metering Data (cont.) Description 6. Scroll through the Metering parameters with the Up/Down keys to access the desired information. Action Display or VOLTS PHASE A–B ### VOLTS . VOLTS PHASE B–C ### VOLTS VOLTS PHASE C–A ### 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.
Chapter 7 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. Human Interface Module The control buttons available with the Bulletin 1201 human interface modules are compatible with the SMC Dialog Plus controller’s control options.
7-2 Options Option Action Preset Slow Speed 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 Smart Motor Braking 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.
7-3 Options 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 Parameter Soft Stop SMC Option This parameter identifies the type of control present and is not user programmable.
7-4 Options Programming Parameters (cont.) SMB Smart Motor Braking Accu-Stop Slow Speed with Braking ① SMC Option This parameter identifies the type of control present and is not user programmable. Braking Current ① 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.
7-5 Options Control Wiring for SCANport Control Refer to Figure 3.14 on page 3-10 for the applicable wiring diagram to achieve start-stop control via the SCANport. Soft Stop, Pump Control, and SMB Smart Motor Braking Options 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.
7-6 Options Figure 7.2 Typical Retrofit Wiring Diagram Control Power ➂ OL ➀ ➁ M➀ Stop ➀ Option Stop ➀ ➃ Start ➀ 11 12 13 14 15 16 17 18 19 20 Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30 ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller. ③ Refer to the controller nameplate to verify the rating of the control power input voltage.
7-7 Options Figure 7.3 Typical Wiring Diagram for Applications Requiring an Isolation Contactor Control Power ➁ IC ➀ Stop ➀ Option Stop ➀ ➂ Start ➀ 11 12 13 14 15 16 17 18 19 20 Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30 ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage. ③ Soft Stop, Pump Stop, or Brake.
7-8 Options Figure 7.4 Typical Wiring Diagram for Applications Requiring a Bypass Contactor Control Power ➁ BC ➀ Stop ➀ Option Stop ➀ ➂ Start ➀ 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 Fanning Strip ➀ 23 24 25 26 27 Internal Auxiliary Contacts 28 29 30 ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.
7-9 Options Figure 7.5 Typical Wiring Diagram for Two-wire Control or Programmable Controller Interfacing Control Power ➁ Two-wire device ➀ 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 ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage. Notes: (1) (2) Refer to Chapter 3 for typical power circuits.
7-10 Options Soft Stop, Pump Control, and SMB Smart Motor Braking Options (cont.) Figure 7.
7-11 Options Soft Stop Option Figure 7.7 Soft Stop Option Sequence of Operation 100% Coast-to-rest Motor Speed Start Soft Stop Run Time (seconds) Push Buttons Start Closed Open Stop Closed Open Soft Stop Closed Open Auxiliary Contacts 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 Coast-to-rest 100% Motor Speed Start Soft Stop Run Time (seconds) Push Buttons Start Closed Open Stop Closed Open Pump Stop Soft Stop Closed Open Auxiliary Contacts Pump 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.
7-13 Options SMB Smart Motor Braking Option Figure 7.
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 ➁ Stop ➀ Option Command ➀ ➂ Start ➀ 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 ① Customer supplied.
7-15 Options Figure 7.11 Typical Retrofit Wiring Diagram Control Power ➂ OL ➀ ➁ M➀ Stop ➀ Option Command ➀ ➃ Start ➀ 11 12 13 14 15 16 17 18 19 20 Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30 ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller. ③ Refer to the controller nameplate to verify the rating of the control power input voltage.
7-16 Options Figure 7.12 Typical Wiring Diagram for Applications Requiring an Isolation Contactor Control Power ➁ IC ➀ Stop ➀ Option Command ➀ ➂ Start ➀ 11 12 13 14 15 16 17 18 19 20 Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30 ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage. ④ Slow Speed or Accu-Stop.
7-17 Options Figure 7.13 Typical Wiring Diagram for Applications Requiring a Bypass Contactor Control Power ➁ BC ➀ Stop ➀ Option Command ➀ ➂ Start ➀ 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 Fanning Strip ➀ 23 24 25 26 27 Internal Auxiliary Contacts 28 29 30 ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.
7-18 Options Preset Slow Speed and Accu-Stop Options (cont.) Figure 7.
7-19 Options Preset Slow Speed Option Figure 7.
7-20 Options Accu-Stop Option Figure 7.16 Accu-Stop Option Sequence of Operation Braking 100% Motor Speed Slow Speed Braking/Coast Slow Speed Slow Speed Run Start Accu-Stop Time (seconds) Push Buttons Start Closed Open Stop Closed Open Accu-Stop Closed Open ➀ Auxiliary Contacts Normal If Stopping Current is set to 0%. Up-to-speed ① When Accu-Stop push button is closed, start/stop function is disabled.
7-21 Options 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 ➁ Stop ➀ Brake ➀ Slow Speed ➀ Start ➀ 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 ① Customer supplied.
7-22 Options Figure 7.18 Typical Retrofit Wiring Diagram for the Slow Speed with Braking Option Control Power ➂ OL ➀ ➁ Stop ➀ M➀ Brake ➀ Slow Speed ➀ Start ➀ 11 12 13 14 15 16 17 18 19 20 Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30 ① Customer supplied. ② Overload protection should be disabled in the SMC Dialog Plus controller.
7-23 Options Figure 7.19 Typical Wiring Diagram for the Slow Speed with Braking Option with an Isolation Contactor Control Power ➁ Stop ➀ IC ➀ Brake ➀ Slow Speed ➀ Start ➀ 11 12 13 14 15 16 17 18 19 20 Auxiliary contacts set for Normal SMC Dialog Plus Control Terminals Internal Auxiliary Contacts 21 22 23 24 25 26 27 28 29 30 ① Customer supplied. ② Refer to the controller nameplate to verify the rating of the control power input voltage.
7-24 Options Figure 7.20 Typical Wiring Diagram for the Slow Speed with Braking Option with a Bypass Contactor Control Power ➁ BC ➀ Stop ➀ Brake ➀ Slow Speed ➀ Start ➀ 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 Fanning Strip ➀ 23 24 25 26 27 Internal Auxiliary Contacts 28 29 30 ① Customer supplied.
7-25 Options Figure 7.21 Slow Speed with Braking Option Sequence of Operation 100% Braking Motor Speed Slow Speed Push Buttons Start Run Brake Time (seconds) Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Normal 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.
Chapter 8 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.
8-2 Serial Communications 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. Description Action — — Display STOPPED 0.0 AMPS 1. Press any key to access the Choose Mode function. 2. Scroll with the Up/Down keys until the Program option appears. 3.
8-3 Serial Communications SMC Status Data The information in Table 8.B provides the SMC Dialog Plus controller status information that can be sent to the logic controller’s input image table. Table 8.
8-4 Serial Communications 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.
Serial Communications Remote I/O Examples 8-5 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.
8-6 Serial Communications 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.
8-7 Serial Communications 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 scanner’s I/O image file of the SMC Dialog Plus controller applies.
8-8 Serial Communications Remote I/O Examples (cont.) SMC Dialog Plus Controller Logic Control Addresses① I or O Slot② Word③ Bit④ Address Stop O 1 16 00 O:1.16/00 Start O 1 16 01 O:1.16/01 Option Command O 1 16 02 O:1.16/02 Clear Fault O 1 16 03 O:1.16/03 Bit Description SMC Dialog Plus Controller Status Addresses ① I or O Slot ② Word③ Bit ⑤ Address Enabled I 1 16 00 I:1.16/00 Running I 1 16 01 I:1.16/01 Starting I 1 16 04 I:1.
8-9 Serial Communications 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.
8-10 Serial Communications Remote I/O Examples (cont.) Example #2 - SLC 500 Controller with Block Transfer This example demonstrates a block transfer of the SMC Dialog Plus controller’s metering group (parameters 1–11) 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.
8-11 Serial Communications SLC Image Table Map SLC Word Output Image Input Image Rack Size Start at Group 0 Block Transfer Block Transfer 1/4 0① 1 Logic Command Logic Status ① Set SW2, Switches 1 and 2 to “On.
8-12 Serial Communications Remote I/O Examples (cont.) 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.
8-13 Serial Communications 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.
8-14 Serial Communications Remote I/O Examples (cont.) 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.
8-15 Serial Communications 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 0 N10:0 128 Dest Rung 2:1 Copy the BT Status Bits from the 1747-SN into the Virtual BT Status Buffer. MOV MOVE Source M1:1.100 * N10:100 0 Dest Rung 2:2 This rung sets up the BT buffer for a BTW. User Logic BTR_Avail BTW_Avail I:1.0 B3:0 I:1.
8-16 Serial Communications Remote I/O Examples (cont.) 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 B3:0 Virtual BTW = 0 BTR = 1 N10:0 I:1.0 L 1 7 10 Virtual BT_Enable Bit N10:0 L 15 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 N10:0 I:1.
8-17 Serial Communications 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 Parameter Number Display Value Parameter Number Display Value Voltage Phase A–B 1 470 Wattmeter 7① 90.0 Voltage Phase A–B 2 474 Kilowatt Hours 8 82 Voltage Phase A–B 3 469 Elapsed Time 9 72 Current Phase A 4① 120.0 Power Factor 10 ① .
8-18 Serial Communications Remote I/O Examples (cont.) 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 controller’s Parameter 19, Fault Buffer #1.
8-19 Serial Communications 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.
8-20 Serial Communications Remote I/O Examples (cont.
Serial Communications 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.
8-22 Serial Communications Remote I/O Examples (cont.) Block Transfer Datafiles The tables below provide the necessary data file configuration for a parameter value read of the SMC Dialog Plus controller’s Fault Buffer #1. BTW Datafile: Message Length PLC Decimal Value Parameter Number Address 0 1 2 N10:10 3 769① 19 ① 3 4 5 6 7 8 9 7 8 9 This is a fixed value, associated with the Parameter Value Read function.
8-23 Serial Communications 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.
8-24 Serial Communications 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.
8-25 Serial Communications Example Information Description Switch Setting Node Address: 13 SW2, Switches 1, 3 & 4 (On) Switches 2, 5 & 6 (Off) Data Rate: 125k SW2, Switches 7 & 8 (Off) Datalinks: No ① SW1, Switches 1 - 4 (Off) Zero data to logic command on fault: Yes SW1, Switch 6 (Off) Fault on comm loss: Yes SW1, Switch 7 (Off) Fault on PLC/SLC program/idle modes: Yes SW1, Switch 8 (Off) ① The SMC Dialog Plus controller does not support Datalinks.
8-26 Serial Communications 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.
Serial Communications 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.
8-28 Serial Communications This indicates that the SMC Dialog Plus controller’s 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-500’s output data associated with the SMC Dialog Plus controller is mapped to words 7 and 8.
8-29 Serial Communications SMC Dialog Plus Controller Status Addresses② ② Bit Description Address Enabled I:1.7/00 Running I:1.7/01 Starting I:1.7/04 Stopping I:1.7/05 Fault I:1.7/07 At Speed 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.
8-30 Serial Communications Explicit Message Response (Get Attribute Multiple) 15 0 TXID STATUS PORT SIZE SERVICE MAC ID word 0 PARAMETER DATA “ 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.
8-31 Serial Communications 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 Service ① Class ① Instance ① Attribute ① Single Parameter Read 0E 0F Par. # ② 1 Single Parameter Write 10 0F Par.
8-32 Serial Communications 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 controller’s 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.
8-33 Serial Communications 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 it’s in the “run mode.” This is accomplished by setting bit 0 of the 1747-SDN’s command word (word 0).
8-34 Serial Communications 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 controller’s 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 controller’s status word indicates that it has received the comand and has responded appropriately.
Chapter 9 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.
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%.
Diagnostics Fault Definitions 9-3 Power Loss Power loss indicates that an input power phase is not present. The controller’s 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 ① Line fault with the affected phase displayed identifies three possible pre-start conditions.
9-4 Diagnostics Fault Definitions (cont.) Voltage Unbalance ① 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.
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.
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.
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 See Table 10.A on page 10-3 Motor rotates but does not accelerate to full speed See Table 10.B on page 10-4 Motor stops while running See Table 10.C on page 10-4 See Table 10.D on page 10-4 Miscellaneous situations See Table 10.
Troubleshooting 10-3 Table 10.A SMC Fault Display Explanation Display Fault Code Power Loss ① (with phase indication) F1, F2, F3, F30, F31, & F32 Line Fault ① (with phase indication) F11, F12, F13, F26, F27, & F28 Line Fault ② (no phase indication) F15 and F29 Voltage Unbalance F10 Phase Reversal F16 Possible Causes • • Missing supply phase (as indicated) Converter module and/or cable failure • • Check for open line (i.e.
10-4 Troubleshooting Table 10.B Motor Will Not Start — No Output Voltage to the Motor Display Possible Cause Possible Solutions • See fault description • See Table 10.
10-5 Troubleshooting Table 10.
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.
Troubleshooting 10-7 180–360 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 Figure 10.
Troubleshooting 10-9 500–1000 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. Figure 10.
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 650–1000 Amp Figure 10.
Troubleshooting MOV Fuse Replacement 10-11 500–1000 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.
10-12 Troubleshooting Power Module and Interface Board Resistance Check (cont.) 24–135 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.
10-13 Troubleshooting 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.
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 100Ω. If any of the resistances measure greater than 100Ω, 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.
Appendix A Specifications Electrical Ratings UL/CSA/NEMA IEC Power Circuit Method of Connection Motor in delta or star, SCRs between windings and supply Number of Poles Equipment designed for three phase loads only Rated Operation Voltage (Ue) 200–480 VAC (–15%, +10%) 200–600 VAC (–15%, +10%) 200–415VY (–15%, +10%) 200–500VY (–15%, +10%) Rated Insulation Voltage (Ui) N/A 500V~ Rated Impulse Voltage (Uimp) N/A 4000V 2200 VAC 2500V~ 200–480 VAC: 1400V 200–600 VAC: 1600V 200–415~: 1400V 20
A-2 Specifications Electrical Ratings UL/CSA/NEMA IEC 100–240 VAC (–15%, +10%) 24 VAC (–15%, +10%) 24 VDC (–20%, +10%) 100–240 V~ (–15%, +10%) 24 V~ (–15%, +10%) 24 VDC (–20%, +10%) Rated Insulation Voltage N/A 240 V~ Rated Impulse Voltage N/A 3000 V Dielectric Withstand 1600 VAC 2000 Y~ Operating Frequency 50/60 Hz 50/60 Hz N/A IP20 Control Circuit Rated Operation Voltage ① Protection Against Electrical Shock Power Requirements Control Module 40VA Heatsink Fan(s) 24A — 35A — 54A
A-3 Specifications Electrical Ratings UL/CSA/NEMA IEC 100–240 VAC (–15%, +10%) 24 VAC (–15%, +10%) 24 VDC (–20%, +10%) 100–240 V~ (–15%, +10%) 24 V~ (–15%, +10%) 24 VDC (–20%, +10%) Rated Insulation Voltage N/A 240 V~ Rated Impulse Voltage N/A 3000 V Dielectric Withstand 1600 VAC 2000 Y~ Operating Frequency 50/60 Hz 50/60 Hz N/A IP20 Control Circuit Rated Operation Voltage ① Protection Against Electrical Shock Power Requirements Control Module 40VA Heatsink Fan(s) 24A — 35A — 54A
A-4 Specifications Other Ratings UL/CSA/NEMA IEC EMC Emission Levels Conducted Radio Frequency Emissions Class A Radiated Emissions Class A EMC Immunity Levels Electrostatic Discharge 8kV Air Discharge Radio Frequency Electromagnetic Field Per IEC 947-4-2 Fast Transient Per IEC 947-4-2 Surge Transient Per IEC 947-4-2 Overload Characteristics: Type Solid-state thermal overload with phase loss Current Range 1.0–999.
A-5 Specifications Environmental Ratings Operating Temperature Range Storage and Transportation Temperature Range UL/CSA/NEMA IEC 0°C–50°C (open) 0°C–40°C (enclosed) –20°C–+75°C Altitude 2000 meters Humidity 5%–95% (nonñcondensing) Pollution Degree 2
A-6 Specifications
Appendix B Parameter Information Table B.
B-2 Parameter Information Table B.1 (cont.) Parameter List Group Parameter Description Parameter Number Display Units Scale Factor Minimum Maximum Default Setting Stall Delay 37 Seconds 10 0.0 10.0 0 (Off) Energy Saver 38 — — Off, On Off Aux. Contacts 1 and 2 39 — — Normal, Up-to-speed Normal Aux. Contact 3 40 — — Normal, Fault Normal Contact 3 Config 41 — — N.O., N.C. N.O. Parameter Mgmt. 17 — — Ready, Default Init.
B-3 Parameter Information Table B.1 (cont.) Parameter List Group Parameter Description Parameter Number Display Units Scale Factor Minimum Maximum Default Setting Slow Speed with Braking Basic Setup (cont.
B-4 Parameter Information Table B.1 (cont.) Parameter List Group Calibrate Default Setting Parameter Description Parameter Number Display Units Scale Factor Overload Class 36 — — Off, 10, 15, 20, and 30 Off Overload Reset 88 — — Manual-Auto Manual Motor HP Rating 79 HP 10 0.0 6,553.5 0.0 Motor kW Rating 80 kW 10 0.0 6,553.5 0.0 Line Voltage 69 Volts 1 0 9999 480 Motor FLC 70 Amps 10 1.0 999.9 1.0 Service Factor 84 — 100 0.01 1.99 1.
B-5 Parameter Information Table B.2 Parameter Text/Display Unit Cross Reference Parameter Number 14 15 17 18 28 29 36 38 Description SMC Option Setting Text Display Unit 0 1 Pump Control 2 Preset Slow Speed 3 Smart Motor Braking 4 Accu-Stop 5 Slow Speed with Braking 6 Off 0 On 1 ETM Reset Parameter Mgmt.
B-6 Parameter Information Table B.2 (cont.
Appendix C Renewal Parts Description SMC Rating Input Control Voltage Standard All 40888-490-01-S1FX Soft Stop All 40888-490-01-A1FX Pump Control All 40888-490-01-B1FX Preset Slow Speed All 40888-490-01-C1FX 24–54A 40888-490-01-D1AX SMB 97–135A 40888-490-01-D1BX 180–360A 40888-490-01-D1CX 500–650A 40888-490-01-D1DX 720–1000A 24–54A Accu-Stop Slow Speed with Braking 40888-490-01-D1EX 120–240V AC 40888-490-01-E1AX 97–135A 40888-490-01-E1BX 180–360A 40888-490-01-E1CX 500–650A
C-2 Renewal Parts Description SMC Rating Line Voltage Part Number ① 24A 200–480V 40382-899-02 35A 200–480V3 40382-899-03 54A 200–480V 40382-899-03 97A 200–480V 40382-806-01 135A 200–480V 40382-806-03 180A 200–480V 40382-809-03 240A 200–480V 40382-809-05 360A 200–480V 40382-809-07 500A 200–480V 40382-810-01 650A 200–480V 40382-818-01 720A 200–480V 40382-818-03 850A 200–480V 40382-819-01 1000A 200–480V 40382-819-03 24A 200–600V 40382-899-04 35A 200–600V 40382-
C-3 Renewal Parts Description SMC Rating Line Voltage Part Number ① 24–500A 200–480V N/A 650A 200–480V 40382-811-01 720A 200–480V 40382-811-03 850A 200–480V 40382-812-03 1000A 200–480V 40382-812-01 24–500A 200–600V N/A 650A 200–600V 40382-811-02 720A 200–600V 40382-811-04 850A 200–600V 40382-812-04 1000A 200–600V 40382-812-02 24–135A All N/A 180–360A All 40382-805-01 500A All 40382-814-01 650–1000A All 40382-814-02 24–54A All N/A 97–135A All 40382-807-01
C-4 Renewal Parts
Appendix Accessories Description Description/Used With Cat. No.
Glossary AC Alternating current. AC Contactor An alternating current (AC) contactor is designed for the specific purpose of establishing or interrupting an AC power circuit. Ambient Temperature Ambient temperature is the temperature of air, water, or a surrounding medium where equipment is operated or stored. American Wire Gauge (AWG) A standard system used for designing the size of electrical conductors.
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. Disable To inhibit logic from being activated. Duty Cycle The relationship between the operating and rest times or repeatable operation at different loads. Enable To allow an action or acceptance of data by applying an appropriate signal to the appropriate input. Fault Any malfunction that interferes with normal system operation.
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. Power Factor 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).
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. Surge Protection 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. Toggle To switch alternately between two possible selections.
Index A accessories, D-1 Accu-Stop option, wiring diagrams, 7-14, 7-15, 7-16, 7-17 control power, 3-4 control voltage, 3-4 control wiring, 3-4 control terminals, 3-6 Accu-Stop, description of, 1-15 controller overview, 1-1 Accu-Stop option programming parameters for, 7-4 sequence of operation, 7-20 controller setup, 4-11 advanced setup, 4-12 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
I–2 Index F fan power, 3-5 fan terminations, 3-5 180A–500A, 3-5 650A–1000A, 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 paramet
Index 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 sho
I–4 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 trip curves, 1-7 troubleshooting, 10-1 fault display explanation, 10-3 flowchart,
Publication 0150-5.3 - October 1998 Supersedes Publication 0150-5.3 - September 1996 40055-145-01(C) 1998 Rockwell International. All Rights Reserved.
