Typical Specification SMC Dialog Plus Controller

Bulletin 150

1. General (continued)
The controller shall offer the following optional features: Soft Stop Pump Control Preset Slow Speed SMB Smart Motor Braking Accu-Stop/Slow Speed with Braking The open-type device shall be modular, consisting of a logic component and a power structure. The logic component shall be a self-contained control module, compatible with the full range of power structures. The control module shall mount directly to the power structure without the use of wiring. The power structure shall consist of three power modules mounted on a heatsink for ratings up to and including 135 Amps. For ratings 180 Amps to 1000 Amps, the power structure shall consist of three power poles with integral heatsinks. The controller shall be designed to meet the applicable requirements of: EN IEC UL CSA NEMA IEEE VDE These standards shall include: Creep distances and clearances 600V (UL/CSA) and 500V (IEC) Power terminal markings per EN 50005 and EN 60947 Dielectric withstand per UL508 and IEC947 Noise and radio frequency (RF) immunity per NEMA ICS 1-109 Surge withstand per IEEE587 and IEC 801-5

2. Construction

2.1 2.2

3. Codes and Standards

4. Control Module Design Features
Mechanical 4.1.1 The control module shall consist of a power supply, logic control circuitry, silicon controlled rectifier (SCR) firing circuitry, I/O circuitry, a digital programming keypad, a backlit LCD display, and a serial communication port. 4.1.2 The control module shall be designed for integral mounting on the power structure and shall be compatible with the full range of current ratings 24 Amps to 1000 Amps. The control module shall be easily removed from the power structure, without the need to disassemble associated printed circuit board assemblies. Control terminals shall be easily accessible, and located on the front top of the device. The terminals shall be UL rated for 300 Volts, 10 Amps maximum and accept a maximum of two wires, 0.75-2.5mm2 (#18-#14 AWG). Digital parameter adjustment shall be provided through a built-in keypad. Analog potentiometer adjustments are not acceptable. A built-in alphanumeric, backlit LCD display shall be provided for controller set-up, diagnostics, status, and monitoring. The display shall be two-line, 16-characters minimum. A serial communication port shall be provided as standard. Optional communication protocol interface modules shall be available for connection to Remote I/O, DH485, DeviceNet, and RS 232/422/485. A minimum of three auxiliary contacts shall be provided for customer use. These shall be programmable as follows: Two form C SPDT: normal (instantaneous) or up-to-speed One SPST: normal or fault; N.O. or N.C.

Table A Ratings

Configuration Form C SPST N.O. N.C. N.O./N.C. NEMA Rating B300 C300 C300 Continuous 5A 2.5A 2.5A Sealed 360VA 180VA 180VA Inrush 3600VA 1800VA 1800VA Voltage 240 V AC max.
4. Control Module Design Features (continued)
Electrical 4.2.1 The control module shall provide digital microprocessor control and supervision of all controller operation, including SCR pulse firing control. The control modules power supply shall be self-tuning to accept control power input from 100 to 240 VAC, 50/60 Hz. The SCR firing circuitry shall incorporate an RC snubber network to prevent false SCR firing. The logic circuitry shall incorporate a latch circuit for three-wire control.

4.2.2 4.2.3 4.2.4 4.3

User Adjustments 4.3.1 4.3.2 4.3.3 4.3.4 The acceleration ramp time shall be adjustable from 0 to 30 seconds. The initial torque setting shall be adjustable from 0 to 90% of locked rotor torque. Current limit starting shall be adjustable from 50 to 600% of the motors full load current. A selectable kickstart feature shall be available to provide a current pulse at 550% of the motors full load current rating. The time period shall be adjustable from 0.0 to 2.0 seconds.

Monitoring 4.4.1 The controller shall provide the following monitoring functions indicated through the built-in LCD display: Phase-to-phase supply voltage Three-phase line current Watts in kW kWH Elapsed time Power factor Motor thermal capacity usage
Protection and Diagnostics 4.5.1 The following protection shall be provided as standard with the controller: Power loss (with phase indication; pre-start) Line fault (with phase indication; pre-start) advising: Shorted SCR Missing load connection Line fault (running protection) advising: Power loss Shorted SCR Missing load connection Voltage unbalance Phase reversal Undervoltage Overvoltage Stall Jam Overload Underload Excessive starts/hour Open gate (with phase indication) Controller overtemperature
These protective features shall be defeatable.
Overload protection shall be as follows: Meets applicable standards as a motor thermal protective device. Three-phase current sensing shall be utilized; the use of two current transformers shall be unacceptable. Overload trip classes of 10, 15, 20, and 30 shall be provided and user-programmable. Electronic thermal memory shall be provided for enhanced motor protection. Overload protection shall be available through the controller, even in a bypass configuration. When fault conditions are detected, the controller shall inhibit starting or shut down SCR pulse firing.
Fault diagnostics shall be indicated in descriptive text on the built-in LCD display. The exclusive use of fault codes shall be unacceptable. An auxiliary contact that is programmable for fault indication shall be provided for customer use.

5. Control Options

Soft Stop 5.1.1 5.1.2 The Soft Stop option shall provide a voltage ramp-down for extended motor stopping times. Soft Stop shall be initiated by a dedicated Soft Stop input. A coast-to-rest stop shall still be possible with a separate stop input. The Soft Stop time shall be user adjustable from 0 to 60 seconds.

5.1.3 5.2

Pump Control 5.2.1 The Pump Control option shall be implemented to provide closed loop control of a motor to match the specific torque requirements of centrifugal pumps for both starting and stopping. This shall aid in eliminating the phenomena commonly referred to as water hammer. Methods utilizing Soft Start with Soft Stop shall not be acceptable. Closed loop control shall be achieved without using external sensors or feedback devices. Pump Stop shall be initiated by a dedicated Pump Stop input. A coast-to-rest stop shall still be possible with a separate stop input. The Pump Stop time shall be user adjustable from 0 to 120 seconds.

5.2.2 5.2.3

5.2.4 5.3
Preset Slow Speed 5.3.1 The Preset Slow Speed option shall provide two jog speeds in the forward direction: high (15% of base speed) and low (7% of base speed). Two jog speeds shall also be available in the reverse direction: high (20% of base speed) and low (10% of base speed). Reverse operation of the motor shall be achievable in the jog mode without the use of a reversing contactor.

5.3.2 5.3.3

The starting current for the slow speed operation shall be user adjustable from 0 to 450% of the motors full load current rating. The running current for the slow speed operation shall be user adjustable from 0 to 450% of the motors full load current rating.
SMB Smart Motor Braking 5.4.1 The SMB Smart Motor Braking option shall provide braking torque to the motor to shorten the time period for the motor to come to rest. Braking shall be achieved without using additional equipment such as resistors or contactors. The controller shall bring the motor to rest and automatically shut it down when zero speed is sensed. Additional equipment, such as tachometers, encoders, or speed switches, shall not be required for sensing a zero-speed condition. Braking shall be initiated by a dedicated brake input. A coast-to-rest stop shall still be possible with a separate stop input. The strength of the braking torque shall be user adjustable from 0 to 400% of the motors full load current rating.

5.4.2 5.4.3 5.4.4

5.4.6 5.5
Accu-Stop/Slow Speed with Braking 5.5.1 The Accu-Stop/Slow Speed with Braking option shall provide general positioning control by providing jogging and braking control. Two jog speeds in the forward direction shall be provided for both the starting and end-of-cycle periods: high (15% of base speed) and low (7% of base speed). The starting current for the slow speed operation shall be user adjustable from 0 to 450% of the motors full load current rating. The running current for the slow speed operation shall be user adjustable from 0 to 450% of the motors full load current rating. Braking shall provide braking torque to the motor to shorten the time period for the motor to reach the preset slow speed or brake to zero speed.
5. Control Options (continued)

5.5.6 5.5.7

Braking shall be achieved without the use of additional equipment such as resistors or contactors. The strength of the braking torque shall be user adjustable from 0 to 400% of the motors full load current rating.
Note: Only one option may be selected when ordering. Note: Soft Stop, Pump Control, SMB Smart Motor Braking and Accu-Stop are not intended to be used as emergency stopping means. Refer to the applicable standards for emergency stop requirements. Note: Dual Ramp Starting is not available when a control option is specified.

6. Power Structure Design Features
Mechanical: 24 Amps to 135 Amps 6.1.1 6.1.2 The power structure shall consist of three plug-in modules for controllers rated 24 Amps to 135 Amps. The three power modules rated 24 Amps to 135 Amps shall be mounted on a single heatsink. The heatsink shall be isolated from the power modules and shall have a grounding provision. Power modules rated 24 Amps to 135 Amps shall be encapsulated and shall include two power-switching semiconductors and control module interface pins. Integral lugs for power wiring terminations shall be provided for controllers rated 24 Amps to 54 Amps.
Mechanical: 180 Amps to 1000 Amps 6.1.4 The power structure for controllers rated 180 Amps to 1000 Amps shall consist of three power poles with a clamped pair of hockey puck style power switching semiconductors. The individual power poles for controllers rated 180 Amps to 1000 Amps shall have integral, power-conducting heatsinks that mount to the controller-mounting flange. The controller-mounting flange shall have a grounding provision. For controllers rated 180 Amps to 1000 Amps, a printed circuit board shall be provided to interface the control module with the power structure. Interface pins shall be located on the printed circuit board for direct mounting of the control module.
Electrical 6.2.1 Back-to-back SCR pairs shall be the only power-switching semiconductor means acceptable. Diode-SCR combinations shall not be acceptable. There shall be separate power sections to operate from 200V to 480V and 200V to 600V, 50/60 Hz. SCRs shall have the following minimum repetitive peak inverse voltage ratings: 200 to 480V: 1400V 200 to 600V: 1600V The power section shall have a minimum thermal capacity rating of 600% of the controllers current rating for 10 seconds.

6.2.2 6.2.3

Transient Protection: 24 Amps to 360 Amps 6.3.1 For controllers rated 24 Amps to 360 Amps, transient protection with separately mounted protective modules shall be available as an option. Protective modules shall consist of metal oxide varistors (MOVs) in combination with capacitors to protect the power components from electrical transients and/or electrical noise. The capacitors shall be provided to shunt noise energy away from the controllers electronics. The MOVs and capacitors shall be encapsulated in a clear material for easy inspection. The protective modules shall be mounted so that they will not cause damage to the power components upon absorbing an electrical transient. The MOVs shall be rated for a minimum of 220 joules.

6.3.3 6.3.4

Transient Protection: 500 Amps to 1000 Amps 6.3.6 6.3.7 For controllers rated 500 Amps to 1000 Amps, transient protection shall be provided as standard. The MOVs shall be rated for a minimum of 220 joules for 200-480V rated controllers and 300 joules for 200-600V rated controllers. Integral fusing shall be provided for additional protection.

7. Energy Saver

The Energy Saver feature shall operate to automatically cause the output voltage from the controller to be reduced when a motor is unloaded or lightly loaded. Customer adjustments shall not be required. The Energy Saver feature shall be defeatable. Additional mounting space or wiring shall not be required. When the Phase Rebalance feature is enabled, the controller shall regulate the individual phase output voltages from the controller to maintain equal three-phase currents to the motor. Customer adjustments shall not be required. The Phase Rebalance feature shall be defeatable. Additional mounting space or wiring shall not be required. Temperature Ratings 9.1.1 9.1.2 The open-type device shall deliver its rated current in ambient temperatures ranging from 0C to +50C. The ambient storage temperature shall range from 20C to +75C.

7.2 7.3 7.4

8. Phase Rebalance

8.2 8.3 8.4

9. Environmental Ratings
Humidity Range 9.2.1 The controller shall be operable in relative humidity of 5 to 95%, non-condensing.
Shock and Vibration 9.3.1 9.3.2 The controller shall withstand a 30G shock for 11 ms in any plane without malfunction. The controller shall withstand 2.5G vibration for one hour in any plane without malfunction.
Altitude Rating 9.4.1 The controller shall be suitable for operation up to altitudes of 2,000 meters without derating.
Noise and RF Immunity 9.5.1 The controller shall perform without malfunction from showering arc tests of 500V to 1500V (NEMA ICS 2-230).
The controller shall perform without malfunction when subjected to 3000V surges at a rate of 100 bursts per second for 10 seconds (IEEE STD 472).
Dielectric Withstand 9.6.1 The controller shall be tested to withstand 1000V + 2x (voltage rating) at a rate of 200V per second (held for 60 seconds, then gradually reduced) between live parts and ground. The controller shall be subjected to an additional test at the previous voltage level plus 20% for one second (UL 508) (CSA Std. C22.2).
Publication 1502.5 June 1995
Copyright 1995 Allen-Bradley Company, Inc., a Rockwell International company. Printed in USA

Allen-Bradley Bulletin 150 SMC Dialog Plus ControllerGetting Started
Allen-Bradley SMC Dialog Plus

Introduction

This guide provides you with the basic information required to start up your SMC Dialog Plus controller. Factory default settings and information regarding installing, programming, and calibrating the controller are described here. For detailed information on specific product features or configurations, refer to the SMC Dialog Plus User Manual, Publication 150-5.3. This guide is intended for qualified service personnel responsible for setting up and servicing these devices. You must have previous experience with and a basic understanding of electrical terminology, configuration procedures, required equipment, and safety precautions.
SMC Dialog Plus is a trademark of Rockwell Automation.

Installation

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 C (32122 F). The controller is convection cooled. It is important to mount the controller in a position that allows air to flow vertically through the power structure. Allow for a minimum of six inches (15 cm) of free space around all sides of the controller.

Wiring

Power Wiring
Refer to the product nameplate for power lug termination information including: Lug wire capacity Tightening torque requirements Lug kit catalog numbers (971000 A)

Control Wiring

Refer to the product nameplate for control terminal wire capacity and tightening torque requirements. Each control terminal will accept a maximum of two wires. The SMC Dialog Plus controller accepts control power input of either 100240V AC, (+10/15%) single-phase, 50/60 Hz or 24V AC/DC. Refer to the product nameplate prior to applying control power. 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 971000 A, control power is also required for the heatsink fans as defined in Table A. Depending on the specific application, additional control circuit transformer VA capacity may be required.
Table A Heatsink Fan Power Requirements
SMC Rating 97360 A 500 A 6501000 A Heatsink Fan VA 320

Control Terminals

Figure 1 SMC Dialog Plus Controller Control Terminals
Table B Control Terminal Designation
Terminal Number Description Control Power Input Control Power Common Controller Enable Input Logic Ground Dual Ramp/Option Input Start Input Stop Input Auxiliary Relay Common N.O. Auxiliary Contact #1 N.C. Auxiliary Contact #2
Not Used Not Used Not Used Not Used Converter Module Fanning Strip Connection Converter Module Fanning Strip Connection Converter Module Fanning Strip Connection Converter Module Fanning Strip Connection Auxiliary Contact #3 Auxiliary Contact #3
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.
Figure 2 Typical Wiring Diagram
L1/1 3-Phase L2/3 Input Power L3/5
Branch Protection Fast-acting SCR Fuses (optional)

T1/2 T2/4 T3/6

SMC Dialog Plus Controller
Fan Power Terminals (971000 A)

Start

SMC Dialog Plus Control Terminals
Internal Auxiliary Contacts

Customer supplied.

Figure 3 Heatsink Fan Wiring
97 A and 135 A Factory Set 110/120 VAC 6 To Supply Jumpers 180500 A Factory Set 110/120 VAC To Supply Jumpers 6501000 A Factory Set 110/120 VAC To Supply
Refer to Chapter 3 of the SMC Dialog Plus Controller User Manual (Publication 150-5.3) for optional 220/240V AC fan power connections and other sample wiring diagrams. Chapter 7 of Publication 150-5.3 also provides typical wiring diagrams for the control options (for example, Pump Control).

Programming

The SMC Dialog Plus controller can be programmed with the built-in keypad and LCD display or with the optional Bulletin 1201 human interface modules. Parameters are organized in a four-level menu structure and divided into programming groups.

Keypad Description

Escape Pressing the Escape key causes the programming system to move up one level in the menu structure.
Select 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. Up/ Down Arrows These keys are used to increment and decrement a parameter value or to scroll through the different modes, groups, and parameters.
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 the display will automatically become active, allowing the user to scroll to the next parameter.

Programming (Cont.)

Figure 4 Menu Structure Hierarchy Power-Up and Status Display

OPERATION LEVEL

Choose Mode

MODE LEVEL

Control Status

Display read only

Program read/write

Password

Search read only
Control Logic Fault Queue

Linear List

Metering

Basic Setup

Advanced Setup

Faults

Calibrate

Language

GROUP LEVEL
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.

Figure 4 (cont.) Menu Structure Hierarchy
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. Limit Level Kickstart Time Stall Delay Energy Saver Aux Contacts 1&2 Aux Contact #3 Contact 3 Config (Option Settings) 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 Settings) Undervolt Level Overvolt Level Overvolt Delay Jam Level Jam Delay Unbalance Level Unbalance Delay Rebalance Underload Level 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 Ratio Converter Rating CT Rating Calibration Enter Calib. Amps Current Phase A Parameter Mgmt.

PARAMETER LEVEL

Steps back one level. English is currently the only available language For further information on parameters, see Appendix B of the SMC Dialog Plus User Manual, Publication 150-5.3. For further information on parameter management, see page 8.

Factory Default Settings

The SMC Dialog Plus controller is pre-programmed with the settings listed in the table below.
Parameter Starting Mode Ramp Time Initial Torque Kickstart Energy Saver Stall Phase Rebalance Auxiliary Contacts Service Factor Overload Class Line Voltage Motor FLC Motor HP Rating Motor Code Letter Soft Start 10 seconds 70% of locked rotor torque Off Off Off Off Normal 1.15 Off 480 volts 1.0 amps 0.0 HP G Setting
ATTENTION: Overload protection in the SMC Dialog Plus controller is disabled from the factory. The user must program the desired overload trip class and motor full load current rating to achieve proper protection
Saving Programmed Values to Memory
After you have programmed the controller settings you must save them to the controllers memory. To do this, follow the steps below: 1. Scroll to Parameter Mgmt. This is the last parameter provided in the Basic Setup, Advanced Setup, and Calibrate programming groups. 2. Select the Store In EE option. 3. Press Enter. Important: If control power is removed from the SMC Dialog Plus controller before you store the programmed values to memory, all programmed values will be lost.

Calibration

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. 2. Using the clamp-on ammeter, measure the three-phase motor currents. Place the ammeter around the phase with the largest current draw. 3. In the Calibrate group, scroll to the Calibration parameter. 4. 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. 5. Access the next parameter using the Up key. 6. 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

CALIBRATION OFF

CALIBRATION ACTIVATE

ENTER CALIB. AMPS 0.0 AMPS
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.
Description 7. You can scroll to the next parameter to view the current measurement in phase A. 8. Scroll to the next parameter to save the Calibrate group settings. 9. 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

PARAMETER MGMT READY

PARAMETER MGMT STORE IN EE

Communication

ATTENTION: After calibration is completed, program the desired overload class and save the setting to the controllers EEPROM.
ATTENTION: The method of current measurement is not applicable to the multi-motor installations or resistive heating loads. Utilization of the Bulletin 825 converter module is required for these applications if current measurement is required.
A serial interface port (called SCANport) is provided as standard, and allows connection to a Bulletin 1201 human interface module or a variety of Bulletin 1203 communication modules.
Figure 5 SCANport Location

SCANport

ATTENTION: Only one peripheral device can be connected to the SCANport. The maximum output current is 100 mA.

Human Interface Modules

The Bulletin 1201 human interface modules with control panels can start and stop the SMC Dialog Plus controller. However, the factory default settings disable control commands other than Stop through the serial communication port.
To enable motor control from a connected human interface module, you must take the following programming steps: Series A 1. Enter into the Program mode. 2. Select the Linear List programming group. 3. Scroll to the Logic Mask parameter (number 85). 4. Program the Logic Mask parameter for a value of 4. 5. Press Enter. Series B 1. Enter the Control Status mode. 2. Select the Enable option of Control Logic. 3. Press Enter. Important: Control Logic must be disabled or the Logic Mask set to 0 prior to disconnecting a human interface module from the SMC Dialog Plus controller.
Publication 150-UM002A-US-P March 2000
Supersedes Publication 150-5.4 February 1998

40055-146-01(C)

2000 Rockwell International. All Rights Reserved. Printed in USA