Rockwell Automation Allen-Bradley SMC-PLUS Bulletin 150 Bedienungsanleitung

This manual describes the installation, setup,

operation and use of the SMC PLUS Controller. Basic

installation and troubleshooting instructions apply to

all of the SMC PLUS Controllers. The wiring and

set-up procedures are for the SMC PLUS Controllers

without options only. Wiring and set-up procedures fo

the SMC PLUS Controllers with options can be found

in the following publications:

• 150-805 Soft Stop Option

• 150-806 Pump Control Option

• 150-807 Preset Slow Speed

• 150-808 SMBTM Smart Motor Braking

• 150-809 Accu-StopTM Option

• 150-810 Slow Speed with Braking

Chapter Catalog Number

Identification

The following is an explanation of the catalog numbering system for the Bulletin 150 SMC

PLUSSmart Motor Controller.

Figure 1.1 – Open Type Controllers Figure 1.2 – Combination Controllers

8L4BD –A24 N150 – A

Bulletin Number

150 Solid–State Controller

Controller Rating

A24 24 amperes (standard duty)

1–15 hp @ 480V

21 amperes (heavy duty)

1–15 hp @ 480V

A35 35 amperes (standard duty)

1–25 hp @ 480V

30 amperes (heavy duty)

1–20 hp @ 480V

A54 54 amperes (standard duty)

1–40 hp @ 480V

45 amperes (heavy duty)

1–30 hp @ 480V

A97 97 amperes (standard duty)

5–75 hp @ 480V

79 amperes (heavy duty)

5–60 hp @ 480V

A135 135 amperes (standard duty)

5–100 hp @ 480V

105 amperes (heavy duty)

5–75 hp @ 480V

Type of Enclosure

N Open

A NEMA 1 B NEMA 1 Vent.

Input Line Voltage

BD 200–480 volts, 3–phase, 50 and 60 Hz

CD 200–600 volts, 3–phase, 50 and 60 Hz

Options

8L4 Max. 480 volt, line mounted Protective Module

8L6 Max. 600 volt, line mounted Protective Module

8M4 Max. 480 volt, load mounted Protective Module

8M6 Max. 600 volt, load mounted Protective Module

8B4 Max. 480 volt, line and load mounted Protective Module

8B6 Max. 600 volt, line and load mounted Protective Module

Options Functions

(Only one option may be added to standard unit)

A Soft Stop D SMBSmart Motor Braking

B Pump Control E Accu–Stop

C Preset Slow Speed F Slow Speed with Braking

Horsepower

Cat. HP Cat. HP Cat. HP

No. Rating No. Rating No. Rating

39 5 47 50 57 300

40 7.5 48 60 58 350

41 10 49 75 59 400

42 15 50 100 60 450

43 20 51 125 61 500

44 25 52 150 62 600

45 30 54 200 63 700

46 40 56 250

Type of Enclosure

A NEMA1 B NEMA 1 Vent.

J NEMA12

Options (only one option may be added to standard unit)

A Soft Stop

B Pump Control

C Preset Slow Speed

D SMBSmart Motor Braking

E Accu-Stop

F Slow Speed with Braking

Voltage Rating

H 200 volts, 50/60 Hz

A 240 volts, 50/60 Hz

B 480 volts, 50/60 Hz

C 600 volts, 50/60 Hz

Bulletin Number

152H Combination Controller

with fusible disconnect

and isolation contactor

152B Combination Controller

with fusible disconnect

153H Combination Controller

with circuit breaker

and isolation contactor

153B Combination Controller

with circuit breaker

39–B152H – W A A–

Protective Module –

•For 24A, 35A, and 54A controllers:

150-N84 Protective Module (max. 480V)

150-N86 Protective Module (max. 600V)

•For 97A–135A controller:

150-N84L Protective Module with wire leads (max. 480V)

150-N86L Protective Module with wire leads (max. 600V)

150-NT1 IEC line and load terminal cover

199-LF1 Terminal Lug Kit

Controller Rating

W Standard duty

Z Heavy duty

Accessories for Field Mounting

Catalog Number

Identification

Chapter Catalog Number Identification

1-2

Specifications

•Input Voltage – Power Module:

– 200 – 480 VAC, 3–phase, +10%, –15%

– 200 – 600 VAC, 3–phase, +10%, –15%

•Control Voltage – Control Module:

100 – 240 VAC, 1 phase, +10%, –15%

•Input Frequency – Control and Power:

50 and 60 Hz

•Repetitive Peak Inverse Voltage Rating:

– 1400V (Line voltage 200–480V)

– 1600V (Line voltage 200–600V)

•Operating Temperature:

0°C to +50°C

•Storage Temperature:

–40°C to +85°C

•Relative Humidity:

5 – 95% (non–condensing)

•Shock:

30 G shock peak acceleration for 11 ms

•Vibration:

2.5 G vibration for 60 minutes

•Altitude:

2000 meters without derating

•Noise and RF Immunity:

Surge transient 3KV peak, 1500 V

showering arc

•Auxiliary Contact Rating:

– N.O.– 470 VA sealed, 4700 VA inrush,

240V max., 24V min.

– N.C.– 275 VA sealed, 2750 VA inrush,

240V max., 24V min.

•Diagnostics:

– Start Fault

– Stalled Motor

– Temperature Fault

– Line Fault

•DV/DT Protection:

RC Snubber Network

•Transient Protection (optional):

Metal Oxide Varistors, 220 joules

Standard Adjustments

•Soft Start:

– 2 to 30 seconds

•Initial Torque:

– 5 to 90% locked rotor torque

•Kickstart:

– 500% current for 0.4 to 2 seconds

•Current Limit:

– 50 to 500% full load amperes

Options

•Soft Stop:

– 2 to 60 seconds

•Preset Slow Speed:

– Forward: 7% (LOW) or 15% (HIGH) speed

– Reverse: 10% (LOW) or 20% (HIGH) speed

– Slow Speed Current adjustment (50 to 450%

of full load current)

•Pump Control:

– Starting: 2 to 30 seconds

– Stopping: 2 to 120 seconds

•SMB Smart Motor Brake:

– Braking Current 150 to 400% full load

amperes

•Accu-Stop

– Slow Speed:7% (LOW) and 15% (HIGH)

– Slow Speed Current adjustment

(50 to 450% of full load current)

– Braking Current (150 to 400% full load current)

•Slow Speed with Braking

– Slow Speed: 7% (LOW) and 15% (HIGH)

– Slow Speed Current adjustment

(50 to 450% of full load current)

– Braking Current (150 to 400% full load

current)

–Slow Speed Acceleration Current Adjustment

(50 to 400% of full load current)

Chapter Installation and

Wiring

Before installing the controller, make a complete visual check of the controller for

damage in shipment or handling. Claims for damaged or missing parts must be

made to the carrier as soon as possible after receipt of shipment.

The open-style controller can be installed in an enclosure. The internal

temperature of the enclosure must be kept within the range of 0°C to 50°C.

For NEMA Type 1 enclosures, the following guidelines are recommended in order

to limit the maximum controller ambient temperature.

There should be a clearance of at least six inches above and below the controller.

This area allows air to flow through the heatsink. Ventilation openings are required

above and below this air space.

An outlet should be placed at least six inches above the controller. The inlet should

be placed near the bottom of the enclosure. It should be capable of accepting a fan

rated 110 CFM or greater. A filter is required to prevent contaminants from

entering the enclosure.

The minimum vent area should be ten square inches. For the 97 and 135 amp

controller, the minimum vent area should be 36 square inches. Deductions must be

made for the grill work or ventilation pattern.

CAUTION: When thermal overload relays are installed in the same

enclosure, a barrier should be provided around the relay. However, this

should not inhibit air flow on forced air cooled units (97 and 135A).

The following table shows the maximum heat dissipation at rated current for the

controllers. For currents lower than rated value, heat dissipation will be lower.

Figure 2.1 - Maximum Heat Dissipation

SMC PLUS Controller Current

Size 24A 35A 54A 97A 135A

Maximum Watts 110 150 200 285 410

For NEMA Type 12 or non-ventilated enclosures, it is recommended that a by-pass

contactor be used. This will allow the controller to start the motor. Once up to full

voltage, the controller would be by-passed. Note that the energy saver and

protective features of the controller would no longer be available. See Page 2-5,

Figure 2.10 for this configuration.

The controller is convection cooled except for the 97A and 135A fan cooled unit. It

is important to locate the controller in a position which allows free air flow

vertically through the power module. The controller must be mounted with

heatsink fins in a vertical plane and have a minimum of 6 inches free

space above and below the controller. See Figure 2.2.

Inspection

Enclosures

Ventilated Enclosures

Non-ventilated

Enclosures

Mounting

Chapter Installation and Wiring

2-2

Figure 2.2 - Dimension Drawings

24, 35, and 54 Amp Controller 97 and 135 Amp Controller

BFG

.281DIA.

(04.14)

4 Mtg. Holes

.219DIA.

(05.56)

4 Mtg. Holes

.281DIA.

(04.14)

4 Mtg. Holes

Unit A

Width B

Height C

Depth D E F G H J Approx.

Ship. Wt.

24A Millimeter 154 180 159 50 140 160 140 10 20 4.5 kg

24A

Controller Inch 6-1/16 7-3/32 6-17/64 1-31/32 5-33/64 6-5/16 5-33/64 13/32 51/64 10 lbs

35A Millimeter 214 240 169 60 200 200 180 20 30 6.8 kg

35A

Controller Inch 8-7/16 9-29/64 6-21/32 2-23/64 7-7/8 7-7/8 7-3/32 51/64 1-3/16 15 lbs

54A Millimeter 244 290 199 90 230 240 200 25 45 11.3 kg

54A

Controller Inch 9-39/64 11-27/64 7-27/32 3-35/64 9-1/64 9-29/64 7-7/8 63/64 1-25/32 25 lbs

97A

and Millimeter 248 336 230 128 220 250 40 10.4 kg (97A)

11.8 kg (135A)

and

35A

Controllers Inch 9-49/64 13-15/64 9-1/16 5-3/64 8-21/32 9-27/32 1-39/64 23 lbs (97A)

26 lbs (135A)

All dimensions are approximate and are not to be used for construction purposes. Refer to nearest Sales Office or the Sales Department at

Milwaukee, Wisconsin, for complete dimension drawings.

Figure 2.3 - Wiring Terminal Locations

The controller wiring terminal locations

are shown in Figure 2.3. Make wiring

connections as indicated in the typical

connection diagrams shown in Figures

2.7, 2.8, 2.9, 2.10, and 2.11. Connect

the line to terminals L1/1, L2/3, and

L3/5. Connect the load to terminals

T1/2, T2/4, and T3/6. A provision is

available for grounding the isolated

heatsink per applicable codes.

Wiring

Input

Connections

Control

Circuit

Connections

Output

Connections

Chapter Installation & Wiring

2-3

Figure 2.4 - Power Wiring and Power Lug Connections

Controller

Wire Size

er Metric AWG

24 A-54 A 2.5 - 25 mm2#14 – #4

97 A-135 A 16 - 120 mm26 – 4/0

Tightening Torque

Wiring Size

2.5-6 mm210 mm216-25 mm216-120 mm2

ze 14–10 AWG 8 AWG 6–4 AWG 6 – 4/0

Torque

2.80 N-m 3.4 N-m 3.95 N-m 31 N-m

orque 25 LB-IN 30 LB-IN 35 LB-IN 275 LB-IN

Control voltage: 100–240 VAC, (+10/–15%), 1 phase, 50/60 Hz. Connect control

power to the controller at terminals 10 and 60. The control power requirement is 30

VA. In addition, 45 VA capacity is required to operate the heatsink fan on the 97

and 135 Amp controller. Additional control circuit transformer VA capacity may be

required depending on the specific application.

Use the following figure as a guide for control wiring:

Figure 2.5 - Control Wiring and Tightening Torque

Wire Size Torque

Metric 1.5 - 4 mm23.95 N-m

AWG #14 – #12 35 LB-IN

The wiring of the control circuit depends on the specific application. Typical

connections for a number of typical applications are shown in Figures 2.7 through

2.12.

The 97 and 135 Amp controllers have a heatsink fan which requires an additional

45VA capacity. To gain access to the fan connection, see Figure 2.6.

CAUTION: The fan jumpers have been factory installed for 110/120

VAC input. Refer to Figure 2.6 for optional 220/240 VAC fan wiring.

After control wiring is complete, replace control terminal strip cover.

NOTE:

Jumpers have been factory installed for 110/120 VAC input.

Figure 2.6 - Location of Fan Wiring and Jumpers for 97A and 135A Controller

Factory Set

110/120 VAC Fan Power Optional

220/240 VAC Fan Power

14 To Supply

Jumpers To Supply

Jumpers

NOTE: Customer is to wire fan to control voltage supply.

Jumpers are factory arranged for 110/120 VAC fan power.

Control Power

Fan Power

Chapter Installation and Wiring

2-4

Figure 2.7 shows a typical connection for standard control module. See page 3-2

for a description of the start sequence.

Figure 2.7 - Typical Connection Diagram for Standard Unit

10 20 30 40 50 60 70 80 90

Stop Start

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

SMC PLUS

Controller

Overload

Relay ➀

Fast-Acting

SCR fuses

(optional) ➀

SMC PLUS Control Terminals

11 12 13 14 Fan Power

(97A and

135A Only) ➁

O.L.

Auxiliary

Contacts

11 12 13 14

Optional

220/240 VAC Fan Power

Jumper

Branch

Protection

➀

Jumper

To Supply

Power Input

3-Phase

➀

➀➀

➀

➀➀

➀Customer Supplied

➁Customer wires fan to control voltage supply.

Jumpers are arranged for 110/120 VAC fan power.

NOTE: For two wire control, remove stop/start

push buttons and connect two wire device

between terminals 10 and 40.

Figure 2.8 shows a typical connection of standard unit for use with an isolation

contactor. Starting and stopping of the motor is controlled by the controller. The

controller also controls the electromechanical contactor. The contactor provides

isolation between the motor and the power lines when the controller is “OFF.”

WARNING: When not using an isolation contactor, hazardous voltages are present at the load terminals

of the controller when the controller is turned off. Warning labels must be attached to the motor

terminal box, the controller enclosure, and the control station. Additional circuitry must be included to

provide automatic isolation.

Figure 2.8 - Typical Connection Diagram of Standard Unit with Isolation Contactor

10 20 30 40 50 60 70 80 90

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14

C.I.

Stop Start

SMC PLUS

Controller

Fast-Acting

SCR fuses

(optional) ➀

SMC PLUS Control Terminals

Fan Power

(97A and

135A Only) ➁

O.L.

Auxiliary

Contacts

➂

Optional

220/240 VAC Fan Power

Jumper

Branch

Protection

➀

Jumper

To Supply

Power Input

3-Phase ➀

➀

➀➀

➀

➀➀

➀Customer Supplied

➁Customer wires fan to control voltage supply.

Jumpers are arranged for 110/120 VAC fan power.

➂Set auxiliary contact for normal setting.

NOTE: For two wire control, remove stop/start

push buttons and connect two wire device

between terminals 10 and 40.

Typical Connection

with Isolation

Contactor

Chapter Installation & Wiring

2-5

Figure 2.9 shows a typical connection diagram for use in a retrofit application. In

this scheme, the controller provides control of the load when the electromechanical

starter is energized. This method of controlling the load can be used in applications

where the existing control scheme is to remain intact.

Starting and stopping of the motor is controlled by the controller. The controller

also controls the electromechanical contactor. The contactor provides isolation

between the motor and the power lines when the controller is “OFF.”

If a fault occurs, the N.O. auxiliary contact opens and drops out the “M” contactor,

thus providing isolation from line potential. In this scheme the auxiliary contact

selection DIP switch must be set for normal auxiliary contact operations.

Figure 2.9 - Typical Connection Diagram for Retrofit Applications of

Standard Unit

➀

Stop Start

SMC PLUS

Controller

Fast-Acting

SCR fuses

(optional) ➀

SMC PLUS Control Terminals

Fan Power

(97A and

135A Only) ➁

O.L.

Auxiliary

Contacts

➂

Optional

220/240 VAC Fan Power

Jumper

Branch

Protection

➀

Jumper

To Supply

Power Input

3-Phase

➀

➀➀

➀

10 20 30 40 50 60 70 80 90

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14

Existing Motor

Starter ➀

11 12 13 14 ➀

➀Customer Supplied

➁Customer wires fan to control voltage supply.

Jumpers are arranged for 110/120 VAC fan power.

➂Set auxiliary contact for normal setting.

NOTE: For two wire control, remove stop/start

push buttons and connect two wire device

between terminals 10 and 40.

By using the controller as shown in Figure 2.10 below, a soft start characteristic can

be provided. Once the motor has reached full speed, the auxiliary contact on the

SMC energizes the bypass contactor.

NOTE:

The controller is by-passed in this circuit. Controller features are not

available once the by-pass contactor is energized. Also, auxiliary contacts

must be set for up to speed operation.

Figure 2.10 - Typical Application Diagram of a By-Pass Contactor with Standard Unit

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14

10 20 30 40 50 60 70 80 90

11 12 13 14

Stop ➀

Start ➀

SMC PLUS

Controller

Fast-Acting

SCR fuses

(optional) ➀

SMC PLUS Control Terminals

Fan Power

(97A and

135A Only) ➁

Auxiliary

Contacts

➂

Optional

220/240 VAC Fan Power

Branch

Protection

➀

Jumper

To Supply

Power Input

3-Phase

➀

BC➀

O.L.

➀

Bypass

Contactor

➀Customer Supplied

➁Customer wires fan to control voltage supply.

Jumpers are arranged for 110/120 VAC fan power.

➂Set auxiliary contacts for up-to-speed setting.

NOTE: For two wire control, remove stop/start

push buttons and connect two wire device

between terminals 10 and 40.

L.B.

Typical Connection

for Retrofit

Application

By-Pass Mode

Chapter Installation and Wiring

2-6

Figure 2.11 shows a typical connection diagram for use with a shunt trip circuit

breaker. In this scheme, the electromechanical contactor is eliminated. The shunt

trip circuit breaker provides automatic isolation from the main power lines during

abnormal conditions and can also be used to provide a manual isolation from the

main power lines.

Figure 2.11 - Typical Connection Diagram with Shunt Trip Circuit Breaker

10 20 30 40 50 60 70 80 90

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14

TR ➀ST

N.O.T.C

.N.O.T.C.

11 12 13 14

SMC PLUS Control Terminals

Optional

220/240 VAC Fan Power

Jumper

To Supply

Stop ➀Start ➀

SMC PLUS

Controller

Overload

Relay

O.L. ➀Fast-Acting SCR

fuses (optional) ➀

Fan Power

(97A and

135A Only) ➁O.L.

Auxiliary

Contacts

➃

Jumpers

Branch

Protection

➀

Power Input

3-Phase

➀

CR ➀➀

Shunt Trip

Circuit

Breaker ➀

CR ➀

TR ➀

Shunt

Trip Coil ➀

➀Customer Supplied

➁Customer wires fan to control voltage supply.

Jumpers are arranged for 110/120 VAC fan

power.

➂For two wire control, remove stop/start push

buttons and connect two wire device between

points A and B.

➃Set auxiliary contact for normal setting.

When using solid-state devices to operate the SMC PLUS controller the voltage

and frequency range will be 100–240V, 50/60 Hz. The OFF state leakage current

from the solid-state device must be less than 6 mA. The nominal input current is

25mA at 120 VAC and 50 mA at 240 VAC.

Figure 2.12 - Typical Connection with 2-Wire Control Scheme

10 20 30 40 50 60 70 80 90

11 12 13 14

L1/1

L2/3

L3/5

T1/2

T2/4

T3/6

11 12 13 14

SMC PLUS Control Terminals

Optional

220/240 VAC Fan Power

Jumper

To Supply

SMC PLUS

Controller

Overload

Relay

O.L. ➀Fast-Acting SCR

fuses

(optional) ➀

Fan Power

(97A and

135A Only) ➁

Auxiliary

Contacts

Jumpers

Branch

Protection

➀

Power Input

3-Phase

➀

O.L. ➀

➀

Two-wire device ➀

➀Customer Supplied

➁Customer wires fan to control voltage

supply. Jumpers are arranged for

110/120 VAC fan power.

Typical Connection

with Shunt Trip

Circuit Breaker

Programmable

Controller and

Sensor Interface

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