150 At002 - en P

Application Techniques
SMC Flex Solid-State Smart Motor Controller

Bulletin 150
Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Automation Publication 150-AT002C-EN-P - March 2013
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 1 Overview
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SMC Flex Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Standard: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pump Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Braking Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Soft Start with Selectable Kickstart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Current Limit Start with Selectable Kickstart . . . . . . . . . . . . . . . . . . . 10 Dual Ramp Start with Selectable Kickstart. . . . . . . . . . . . . . . . . . . . . . 13 Full Voltage Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Preset Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Linear Speed Acceleration with Selectable Kickstart . . . . . . . . . . . . . 22 Soft Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pump Control Option with Selectable Kickstart . . . . . . . . . . . . . . . . 27 Braking Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SMB Smart Motor Braking Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Accu-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Slow Speed with Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SCR Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Standard or Wye-Delta Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Parameter Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electronic Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Stall Protection and Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Ground Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Thermistor Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Metering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Parameter Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Communication Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Auxiliary Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Modular Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Control Terminal Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table of Contents
Chapter 3 Special Application Considerations

SMC-Flex Controllers in Drive Applications . . . . . . . . . . . . . . . . . . . . . . . Use of Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall Protection and Jam Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Built-in Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Factor Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-motor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wye-Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Winding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wound Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synchronous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Altitude De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolation Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SMC-Flex Controller with Bypass Contactor (BC). . . . . . . . . . . . . . . . . . SMC-Flex Controller with Reversing Contactor . . . . . . . . . . . . . . . . . . . . SMC-Flex Controller as a Bypass to an AC Drive . . . . . . . . . . . . . . . . . . . SMC-Flex Controller with a Bulletin 1410 Motor Winding Heater . . Motor Torque Capabilities with SMC Flex Controller Options . . . . . . SMB Smart Motor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preset Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accu-Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 57 58 58 58 59 60 61 61 62 62 62 62 63 63 64 65 66 66 66 66 67
Chapter 4 Product Line Applications Matrix

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mining and Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Food Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulp and Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Petrochemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transportation and Machine Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM Specialty Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lumber and Wood Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water/Wastewater Treatment and Municipalities . . . . . . . . . . . . . . . . . . 69 69 70 70 71 71 72 72 72
Chapter 5 Design Philosophy

Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Voltage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current and Thermal Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Shock and Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise and RF Immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 73 73 73 74 74 74 74
Table of Contents
Chapter 6 Reduced Voltage Starting

Introduction to Reduced Voltage Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Reduced Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 SMC Flex Solid-State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Chapter 7 Solid-State Starters Using SCRs Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Chapter 8

Motor Output Speed/Torque/ Horsepower. . . . . . . . . . . . . . . . . . . . . . . . Torque and Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-load Torque (FLT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locked-Rotor Torque (LRT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pull-Up Torque (PUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breakdown Torque (BT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-load Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locked-rotor Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Output for NEMA Design Designations Polyphase 1500 Hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating Torque (Acceleration Torque Required for Rotating Motion) . . . . . . . . . . . . . . . Inertia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Motor Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Characteristics on Common Applications . . . . . . . . . . . . . . . . . . Electrical Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ohms Law: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power in DC Circuits: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating Accelerating Force for Linear Motion: . . . . . . . . . . . . . . 83 83 85 85 85 86 86 86 89 91 92 92 93 93 95 95 96 97 97
Table of Contents
Chapter
Overview
Introduction
The Allen-Bradley SMC Controller lines offer a broad range of products for starting or stopping AC induction motors from Hp to 6000 Hp. The innovative features, compact design, and available enclosed controllers meet world-wide industry requirements for controlling motors. Whether you need to control a single motor or an integrated automation system, our range of controllers meet your required needs. This document discusses the SMC Flex. Some of the key features are listed below.
SMC Flex Features

Soft Start with Selectable Kickstart Current Limit Start with Selectable Kickstart Dual Ramp with Selectable Kickstart Full Voltage Linear Speed Acceleration with Selectable Kickstart Preset Slow Speed Soft Stop Pump Control with Selectable Kickstart SMB Smart Motor Braking Accu-Stop Slow Speed with Braking Built in Bypass Inside the Delta Electronic Motor Overload Protection Stall and Jam Detection Ground Fault Protection Thermistor Input (PTC) Metering Fault Indication Parameter Programming Communication Capabilities
Chapter 1
Overview
Description
When the Smart Motor Controller (SMC) was first introduced in 1986, its modular design, digital setup, and microprocessor control set the standard for soft starters. Since its launch in 1996, the SMC Dialog Plus controller has been in a class by itself, providing unmatched performance with innovative starting and stopping options. Now, the SMC-Flex controller achieves a higher level of sophistication with greatly enhanced protection, expanded diagnostics, ability to log the motors operation (A, kW, and power factor), and flexibility to communicate with various network protocols. The SMC-Flex can also be wired in a standard wiring configuration, or inside-the-delta. This allows the product to operate wye-delta motors with a much smaller device than before.
Figure 1 - SMC Flex Controller
The SMC-Flex controller is a compact, modular, multi-functional solid-state controller used in both starting three-phase squirrel-cage induction motors or wye-delta motors and controlling resistive loads. The SMC-Flex contains, as standard, a built-in SCR bypass and a built-in overload. The SMC-Flex product line includes current ratings 5 to 480 A, 200 to 600V, 50/60Hz. This covers squirrel-cage induction motor applications up to 400 Hp (wye-delta motors up to 650 Hp). The SMC-Flex controller meets applicable standards and requirements. While the SMC-Flex controller incorporates many new features into its design, it remains easy to set up and operate. You can make use of as few or as many of the features as your application requires.
Overview
Chapter 1
Modes of Operation
The following modes of operation are standard within a single controller:
Standard:
Soft Start with Selectable Kickstart Current Limit with Selectable Kickstart Dual Ramp Start with Selectable Kickstart Full Voltage Start Preset Slow Speed Linear Speed Acceleration with Selectable Kickstart Soft Stop
Pump Option
Pump Control with Selectable Kickstart
Braking Option
Smart Motor Braking Accu-Stop Slow Speed with Braking
Standard
Soft Start with Selectable Kickstart

This method covers the most general applications. 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, which is user adjustable from 0 to 30 seconds. If, during the voltage ramp operation, the SMC-Flex controller senses that the motor has reached an up-to-speed condition, the output voltage will automatically switch to full voltage, and transition over the SCR Bypass contactors. The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started. It is intended to provide a current pulse, user adjustable 0-90% locked rotor torque for a selected period of time from 0.0 to 2.0 seconds.
Chapter 1
Overview
Figure 2 - Soft Start

Current Limit
00%
tial que
Ramp Time
Start
Run
Time in Seconds
Following are the parameters that are specifically used to provide and adjust the voltage ramp supplied to the motor.
Table 1 - Soft Start Parameters
Parameter SMC Option Starting Mode Ramp Time Initial Torque Kickstart Time Kickstart Level Option 2 Input Stop Mode Stop Time Adjustment Standard, Braking, Pump Soft Start 030 s 090% LRT 0.02.0 s 090% LRT Disable Disable 0s
Overview
Chapter 1
Figure 3 - Soft Start Sequence of Operation

Selectable Kickstart 100% Coast-to-rest Soft Stop
Percent Voltage
Start
Run Time (seconds)
Soft Stop
Push Buttons Start Closed Open Stop Closed Open Soft Stop Closed Open Auxiliary Contacts Normal Closed Open If Coast-to-rest Selected Up-to-speed Closed Open If Soft Stop Selected
Chapter 1
Overview
Figure 4 - Soft Start Wiring Diagram

Control Power
Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
SMC-Flex Control Terminals
Aux #1 Normal/Up-to-Speed/ Bypass
Internal Auxilary Contacts
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Customer supplied. Refer to the controller nameplate to verify the rating of the control power input rating.
Current Limit Start with Selectable Kickstart

This method provides a current limit start and is used when it is necessary to limit the maximum starting current. The starting current is user adjustable from 50 to 600% of full load amperes. The current limit ramp time is user adjustable from 0 to 30 seconds. The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started. It is intended to provide a current pulse, user adjustable 0-90% locked rotor torque for a selected period of time from 0.0 to 2.0 seconds.
10
Overview
Chapter 1
Figure 5 - Current Limit Start

600%
Percent Full Load Current
50%
Start Time (seconds)
To apply a current limit output to the motor, the following parameters are provided for user adjustment.
Table 2 - Current Limit Start Parameters
Parameter SMC Option Starting Mode Ramp Time Current Limit Level Kickstart Time Kickstart Level Option 2 Input Stop Mode Stop Time Adjustments Standard, Braking, Pump Current Limit 030 s 50600% FLC 0.02.0 s 090% LRT Disable Disable 0s
11
Chapter 1
Overview
Figure 6 - Current Limit Sequence of Operation

600%
Percent Full Load Current 100% Coast-to-rest 50%
Soft Stop
Start
Run Time (seconds)
Soft Stop
12
Overview
Chapter 1
Figure 7 - Current Limit Wiring Diagram

Control Power
Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Dual Ramp Start with Selectable Kickstart

This starting method is useful on applications with varying loads, starting torque, and start time requirements. Dual Ramp Start offers the user the ability to select between two separate Start profiles with separately adjustable ramp times and initial torque settings. The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started. It is intended to provide a current pulse, user adjustable 090% locked rotor torque for a selected period of time from 0.0 to 2.0 seconds.
13
Chapter 1
Overview
Figure 8 - Dual Ramp Start

Current Limit 2 Current Limit 1 100% Ramp #2
Initial que #2 Ramp #1 Initial que #1
Start #1 Start #2 Time in Seconds
Run #1 Run #2
To obtain Dual Ramp Start control, the following parameters are available when you select Dual Ramp in the Option 2 Input parameter.
Table 3 - Dual Ramp Start Parameters
Parameter SMC Option Starting Mode Ramp Time Initial Torque Current Limit Level Torque Limit Kickstart Time Kickstart Level Option 2 Input Starting Mode 2 Start Time 2 Initial Torque 2 Current Limit Level 2 Torque Limit 2 Kickstart Time 2 Kickstart Level 2 Stop Mode Stop Time Adjustments Standard Full Voltage, Current Limit, Soft Start, Linear Speed 030 s 090% LRT 50600% FLC 0100% LRT 0.02.0 s 090% LRT Dual Ramp Full Voltage, Current Limit, Soft Start, Linear Speed 030 s 090% LRT 50600% FLC 0100% LRT 0.02.0 s 090% LRT Disable 0s
14
Overview
Chapter 1
Figure 9 - Dual Ramp Start Sequence of Operation

Ramp #2 100% Coast-to-rest Soft Stop Percent Voltage Ramp #1
Start #1 Start #2 2
Run n #1 Run #2 Time (seconds)
Soft Stop
15
Chapter 1
Overview
Figure 10 - Dual Ramp Start Wiring Diagram

Control Power
Stop
Ramp 1 Ramp 2
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Full Voltage Start

This method is used in applications requiring across-the-line starting. The SMC-Flex controller performs like a solid-state contactor. Full inrush current and locked rotor torque are realized. The SMC-Flex may be programmed to provide full voltage start in which the output voltage to the motor reaches full voltage in second.
16
Overview
Chapter 1
Figure 11 - Full Voltage Start

100%
Percent Voltage
Time in Seconds
The basic parameter setup for Full Voltage Start follows:

Table 4 - Full Voltage Start Parameters
Parameter SMC Option Starting Mode Stop Mode Stop Time Adjustments Standard, Braking, Pump Full Voltage Disable 0s
17
Chapter 1
Overview
Figure 12 - Full Voltage Start Sequence of Operation
100% Coast-to-rest
Percent Voltage
Soft Stop
Start
Run Time (seconds)
Soft Stop
18
Overview
Chapter 1
Figure 13 - Full Voltage Start Wiring Diagram

Control Power
Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Preset Slow Speed

This method can be used on applications that require a slow speed for positioning material. The Preset Slow Speed can be set for either Low, 7% of base speed, or High, 15% of base speed. Reversing is also possible through programming. Speeds provided during reverse operation are Low, 10% of base speed, or High, 20% of base speed.
19
Chapter 1
Overview
Figure 14 - Preset Slow Speed
100%
Motor Speed Forward 15% - High 7% - Low Time (seconds) 10% - Low 20% - High Reverse
Start
Run
The basic parameter setup for Soft Start selection with Preset Slow Speed Option follows:
Table 5 - Preset Slow Speed Parameters
Parameter SMC Option Starting Mode Ramp Time Initial Torque Current Limit Level Torque Limit Kickstart Time Kickstart Level Option 2 Input Stop Mode Stop Time Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur Adjustments Standard, Braking Full Voltage, Current Limit, Soft Start, Linear Speed 030 s 090% LRT 50600% FLC 0100% LRT 0.02.0 s 090% LRT Preset SS Disable 0s SS Low, SS High SS Forward, SS Reverse 0450% FLC 0450% FLC
20
Overview
Chapter 1
Figure 15 - Preset Slow Speed Sequence of Operation
100% Coast-to-rest Motor Speed Soft Stop 7 or 15%
Slow Speed
Start
Run Time (seconds)
Coast
Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Auxiliary Contacts Normal Closed Open
Up-to-speed
Closed Open
21
Chapter 1
Overview
Figure 16 - Preset Slow Speed Wiring Diagram

Control Power
Stop
Slow Speed
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Linear Speed Acceleration with Selectable Kickstart

This method starts the motor following a linear speed ramp. The ramp time defines the time the motor will ramp from zero speed to full speed. This ramp time is user adjustable from 030 seconds. Linear Speed requires a tachometer input (05V DC, 4.5 V = 100% speed). The current limit is active during the starting ramp. The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started. It is intended to provide a current pulse, user adjustable 090% locked rotor torque for a selected period of time, 0.02.0 seconds. Note that speed ramp begins once the kickstart is completed.
22
Overview
Chapter 1
Figure 17 - Linear Speed Acceleration
100%
Start
Run Time (seconds)
Stop
The basic parameter set for Linear Speed follows:

Table 6 - Linear Speed Acceleration Parameters
Parameter SMC Option Starting Mode Ramp Time Current Limit Level Kickstart Time Kickstart Level Option 2 Stop Mode Stop time Adjustments Standard Linear Speed 0.030.0 s 0600% FLC (Full Load Current) 0.02.0 s 090% LRT Disable Linear Speed 0.0120.0 s
23
Chapter 1
Overview
Figure 18 - Linear Speed Acceleration Sequence of Operation
100% Coast-to-rest Soft Stop or Linear Speed Motor Speed
Start
Run Time (seconds)
Soft Stop
Push Buttons Start Closed Open Stop Closed Open Soft Stop or Linear Speed Closed Open Auxiliary Contacts Normal Closed Open If Coast-to-rest Selected Up-to-speed Closed Open If Soft Stop Selected
24
Overview
Chapter 1
Figure 19 - Linear Speed Acceleration Wiring Diagram

Control Power
Stop
Linear Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Soft Stop
The Soft Stop option can be used in applications requiring an extended coast-to-rest. The voltage ramp down time is user adjustable from 0120 seconds. The Soft Stop time is adjusted independently from the start time. The load will stop when the voltage drops to a point where the load torque is greater than the motor torque.
25
Chapter 1
Overview
Figure 20 - Soft Stop
Selectable Kickstart
Coast-to-rest Soft Stop
Start
Run Time (seconds)
Soft Stop
The basic parameter setup for Soft Stop follows:

Table 7 - Soft Stop Parameters
Parameter SMC Option Stop Mode Stop Time Adjustments Standard, Braking, Pump Soft Stop 0120 seconds
Figure 21 - Soft Stop Sequence of Operation
100% Coast-to-rest Soft Stop Motor Speed
Start
Run Time (seconds)
Soft Stop
26
Overview
Chapter 1
Figure 22 - Soft Stop Wiring Diagram

Control Power
Stop
Soft Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Pump Control
Pump Control Option with Selectable Kickstart

The SMC-Flex controllers unique interactive Pump Control is designed to reduce fluid surges in pumping systems. It provides closed loop acceleration and deceleration control of centrifugal pump motors without the need for feedback devices. The kickstart feature provides a boost at startup to break away loads that may require a pulse of high torque to get started. It is intended to provide a current pulse with user adjustable locked rotor torque from 0-90% and kickstart time from 0.0 to 2.0 seconds.
27
Chapter 1
Overview
Figure 23 - Pump Control Option with Selectable Kickstart
100%
Motor Speed
Pump Start Ramp Time
Run Time in Seconds
Pump Stop Stop Time
The basic parameter setup for Pump Control follows:

Table 8 - Pump Control Option Parameters
Parameter SMC Option Starting Mode Start Time Initial Torque Kickstart Time Kickstart Level Stop Time Anti-Backspin Timer Adjustments Pump Pump Start 030 s 090% LRT 0.02.0 s 090% LRT 0120 s 0999 s
28
Overview
Chapter 1
Figure 24 - Pump Control Option Sequence of Operation

Motor Speed
100%
Coast-to-Rest
Pump Start
Run
Pump Stop
Time in Seconds Push Buttons

Start Closed Open Stop Closed Pump Stop 1 (Stop Option) Open Closed Open
Auxillary Contacts
Normal Closed Open Up-to-Speed Closed Open
If the Pump Stop is Selected
If the Coast-to-Rest is Selected
29
Chapter 1
Overview
Figure 25 - Pump Control Option Wiring Diagram

Control Power
Stop
Pump Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Braking Control
SMB Smart Motor Braking Option

The SMB Smart Motor Braking option provides motor braking for applications, which require the motor to stop quickly. It is a microprocessor based braking system, which applies braking current to a motor. The strength of the braking current is adjustable from 0400% of full load current.
30
Overview
Chapter 1
Figure 26 - Smart Motor Braking
100%
Smart Motor Braking Coast-to-Rest Automatic Zero Speed Shut-Off Stop Time Start Run Time in Seconds Brake
The basic parameter setup for Smart Motor Braking follows:

Table 9 - Smart Motor Braking Parameters
Parameter SMC Option Stop Mode Braking Current Adjustments Braking SMB 0400% FLC
Motor Speed
31
Chapter 1
Overview
Figure 27 - Smart Motor Braking Sequence of Operation

Motor Speed
100%
Smart Motor Braking Coast-to-Rest
Automatic Zero Speed Shut-Off Start Run Brake
Time in Seconds Push Buttons

Start Closed Open Stop Closed Open Smart Motor Braking (Stop Option 1 ) Closed Open
Auxillary Contacts
Normal Closed Open Up-to-Speed Closed Open If Coast-to-Rest Selected If Brake Selected
32
Overview
Chapter 1
Figure 28 - Smart Motor Braking Wiring Diagram

Control Power
Stop
Brake
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Accu-Stop
The Accu-Stop option provides rapid braking to a slow speed, and then braking to stop, facilitating cost-effective general positioning control.
33
Chapter 1
Overview
Figure 29 - Accu-Stop
The basic parameter setup for Accu-Stop follows:

Table 10 - Accu-Stop Parameters
Parameter SMC Option Stop Mode Slow Speed Sel Slow Accel Cur Slow Running Cur Braking Current Stopping Current Adjustments Braking Accu Stop SS Low, SS High 0450% FLC 0450% FLC 0400% FLC 0400% FLC
34
Overview
Chapter 1
Figure 30 - Accu-Stop Sequence of Operation
100 %
Motor Speed
Braking Slow Speed Braking Coast-to-rest Slow Speed Slow Speed Start Run Time (seconds) Accu-Stop
Push Buttons Start Closed Open Stop Closed Open Accu-Stop Closed Open Auxiliary Contacts Normal Closed Open Up-to-speed If Coast-to-rest Selected Slow Speed Braking
Closed Open
35
Chapter 1
Overview
Figure 31 - Accu-Stop Wiring Diagram

Control Power
Stop
Accu-Stop
Start
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Slow Speed with Braking

The Slow Speed with Braking option combines the benefits of the SMB Smart Motor Braking and Preset Slow Speed options for applications that require slow setup speeds and braking to a stop.
36
Overview
Chapter 1
Figure 32 - Slow Speed with Braking
The basic parameter setup for Slow Speed with Braking follows:
Figure 33 - Slow Speed with Braking Parameters
Parameter SMC Option Option 2 Input Slow Speed Sel Slow Speed Dir Slow Accel Cur Slow Running Cur Stop Mode Braking Current Adjustments Braking Preset SS SS Low, SS High SS Forward, SS Reverse 0450% FLC 0450% FLC SMB 0400% FLC
37
Chapter 1
Overview
Figure 34 - Slow Speed with Braking Sequence of Operation
100% Coast-to-Stop Motor Speed
Braking
Slow Speed
Start
Run Time (seconds)
Brake
Push Buttons Start Closed Open Stop Closed Open Slow Speed Closed Open Brake Closed Open Auxiliary Contacts Normal Closed Open Up-to-speed Closed Open If Coast-to-rest selected e Brake
38
Overview
Chapter 1
Figure 35 - Slow Speed with Braking Wiring Diagram

Control Power
Stop
Brake
Start
Slow Speed
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PTC Input
TACH Input
Ground Fault
Fault Contact
Alarm Contact
Aux #2 Normal
Features
SCR Bypass
The SMC-Flex has a built-in bypass contactor that is automatically pulled in when the motor reaches full speed. An external bypass contactor may be used. When an external bypass contactor is enabled (by setting the parameter Aux1 Config to Bypass) the internal bypass contactor will not be used, and a separate overload is required.
Standard or Wye-Delta Wiring

The SMC-Flex can operate either a standard squirrel-cage induction motor or a wye-delta motor. The user must program the selected configuration into the unit using the Motor Connection parameter. The wye-delta motor is connected in an inside-the-delta wiring configuration, and the Motor Connection is det to Delta.
39
Chapter 1
Overview
LCD Display
A graphical backlit LCD display provides parameter definition with straightforward text so that controller setup may be accomplished without a reference manual. Parameters are arranged in an organized three-level menu structure for ease of programming and fast access to parameters. The displayed language can also be changed to meet global customer needs.
Parameter Programming
Programming of parameters is accomplished through a five-button keypad on the front of the SMC-Flex controller. The five buttons include up and down arrows, an Enter button, a Select button, and an Escape button. The user needs only to enter the correct sequence of keystrokes for programming the SMC-Flex controller.
Figure 36 - LCD Display with Keypad
LCD Display
Keypad
Electronic Overload
The SMC-Flex controller meets applicable requirements as a motor overload protective device. Overload protection is accomplished electronically through current sensors and an I2t algorithm. The overload trip class is selectable for OFF, 10, 15, 20, or 30 protection. The trip current is set by entering the motors full load current rating and the service factor.
40
Overview
Chapter 1
Thermal memory is included to model motor operating and cooling temperatures. Ambient insensitivity is inherent in the electronic design of the overload.
Stall Protection and Jam Detection

Motors can experience locked rotor currents and develop maximum torque in the event of a stall (during start) or a jam (after full speed is reached). These conditions can result in winding insulation breakdown or mechanical damage to the connected load. The SMC-Flex controller provides both stall and jam detection for enhanced motor and system protection. Stall protection allows the user to program a maximum stall time of up to 10 seconds. Jam detection allows the user to determine the jam level as a percentage of the motors full load current rating, and a trip delay time of up to 99 seconds. The stall trip delay time is in addition to the programmed start time.
Figure 37 - Stall Protection Sequence of Operation
600% Percent Full Load Current
Programmed Start Time Time (seconds)
Stall
Figure 38 - Jam Detection Sequence of Operation

Percent Full Load Current
User Programmed Trip Level
100%
Running Time (seconds)
Jam
41
Chapter 1
Overview
Ground Fault Protection

The SMC-Flex Controller can sense ground faults before they become short circuits. Ground faults generally start at low levels (amps), but can rapidly increase to hundreds or thousands of amperes. This feature is not intended as a ground fault circuit-interrupter for personnel protection. The Ground Fault protection settings are user-adjustable. A separate Cat. No. 825-CBCT core balance current transformer is required for setup of this feature.
Thermistor Input
The SMC-Flex controller offers enhanced motor protection with additional circuitry to monitor motor stator-embedded positive temperature coefficient (PTC) thermistors. The PTC acts as a thermally sensitive resistor. It exhibits a large sudden increase in resistance at its activation temperature rating. Excessive motor heating can still occur without the motor being overloaded. Such over-heating can result from blocked motor ventilation or high ambient temperatures, and the PTC will help identify this. The thermistor input settings are user adjustable. See the User Manual for more details.
Metering
The SMC-Flex controller contains several power monitoring parameters as standard. These parameters include: Three-phase current Three-phase voltage Power in kW Power usage in kWH Power factor Elapsed time Motor thermal capacity usage
Fault Indication
The SMC-Flex controller monitors both the pre-start and running modes. If the controller senses a fault, the SMC-Flex controller shuts down the motor and displays the appropriate fault condition in the LCD display. The controller monitors the following conditions: Line Loss Shorted SCR Open SCR Gate Thermistor (PTC)
42
Overview
Chapter 1
Overtemperature (Power Pole, SCR, Motor) Bypass Failure No Load Overvoltage Undervoltage Overload Underload Jam Stall Phase Reversal Phase Unbalance Current Unbalance Voltage Unbalance Loss of Communication Power Loss Excessive Starts/Hour Ground Fault Motor Lead Loss Line Fault Communication Fault
Any fault condition will cause the auxiliary contacts to change state and the hold-in circuit to release.
Parameter Programming
Communication Capabilities
A serial interface port is furnished as standard with the SMC-Flex controller. This communication port allows connection to a Bulletin 20 Human Interface Module, and a variety of 20-COMM modules. These include Allen-Bradley Remote I/O, DeviceNet, ControlNet, Ethernet, ProfiBUS, Interbus, and RS485.
Auxiliary Contacts
Four hard contacts are provided as standard with the SMC-Flex controller. The first contact is programmable for Normal/Up-to-speed/Bypass. The second, third and fourth contact are configured to N.O/N.C.
43
Chapter 1
Overview
Modular Design
The SMC-Flex controller packaging is designed for industrial environments. The modularity of control and power modules feature plug-in functionality. There are no gate wires to remove and no soldering is required. Common control modules reduce inventory requirements.
Figure 39 - Exploded View
Control Terminal Description

The SMC-Flex controller contains 24 control terminals on the front of the controller. These control terminals are described below. See Figure 40
44
Overview
Chapter 1
Table 11 - Control Terminal Designation.

Terminal Number
11 12 13 14 15 16 17 18 19 20
Description Control Power Input Control Power Common Controller Enable Input Ground Option Input #2 Option Input #1 Start Input Stop Input N.O. Aux. Contact #1 (Normal/Up-to-Speed/External Bypass) N.O. Aux. Contact #1 (Normal/Up-to-Speed/External Bypass)
21 22
Not Used Not Used PTC Input PTC Input Tach Input Tach Input Ground Fault Transformer Input Ground Fault Transformer Input Fault Contact (N.O./N.C.) Fault Contact (N.O./N.C.) Alarm Contact (N.O./N.C.) Alarm Contact (N.O./N.C.) Aux Contact #2 Normal (N.O./N.C.) Aux Contact #2 Normal (N.O./N.C.)
23 24 25 26 27 28 29 30 31 32 33 34
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.
External Bypass operates an external contactor and overload once the meter reaches full speed. The
SMC-Flex overload functionality is disabled when the external bypass is activated. Proper sizing of the contactor and overload is required.
45
Chapter 1
Overview
Figure 40 - SMC-Flex Controller Control Terminals
11
12
13
14
15
16 Opt Input #1
17
18 Stop Input
19
20
21
22
Opt Input #2
Start Input
Aux #1

23 24 25 26 27 28 29 30 31 32 33 34
PTC Input
TACH Input
Ground Fault
Aux #2
Aux #3
Aux #4
46
Chapter
Application Profiles for the SMC Flex Controller

Overview
In this chapter, a few of the many possible applications for the SMC Flex controller are described. The basis for selecting a particular control method is also detailed. Illustrations are included to help identify the application. Motor ratings are specified, but the ratings may vary in other typical applications. For example, a tumbler drum is described as requiring the Soft Start feature. The application is examined further to determine how the SMC Flex controller options can be used to improve the tumbler drum performance and productivity.
Figure 41 - Compressor with Soft Start
InletValve AirFilter TurnValve Ports 208...480 Volts 50...250Hp 50/60 Hz
Problem: A compressor OEM shipped its equipment into overseas markets, where wye-delta motors are common. There were many different voltage and frequency requirements to meet because of the compressors final destination. Due to power company requirements and mechanical stress on the compressor, a reduced voltage starter was required. This made ordering and stocking spare parts difficult. Solution: The SMC Flex controller was installed and wired to a wye-delta motor. The unit was set for an 18-second Soft Start, which reduced the voltage to the motor during starting and met the power company requirements. By reducing the voltage, the starting torque was also reduced, minimizing the shock to the compressor. Panel space was saved because the SMC Flex controller has a built-in overload and SCR bypass feature.
47
Chapter 2
Figure 42 - Tumbler with Soft Start and Accu-Stop

480 Volts 150 Hp Loading Door
Tumbler Drum
Drive Chain
Motor
Problem: A tumbler drum used in the de-burring process was breaking the drive chain because of the uncontrolled acceleration from the across-the-line starter. To increase production on the drum, the coasting time on stop had to be reduced. Previous solutions were a separate soft start package plus a motor brake, which required additional panel space and power wiring. A small enclosure size and simplified power wiring were needed to reduce the cost of the controls. Because a PLC was controlling several other processes in the facility, communication capabilities were desired. Solution: The SMC Flex controller with the braking option configured as Accu-Stop was installed on the process. The Soft Start provided a smooth acceleration of the drive chain, which reduced downtime. The controlled acceleration made positioning for loading/unloading easier. The drum was positioned for loading using the Preset Slow Speed. For unloading, the drum was rotated at Preset Slow Speed and then accurately stopped. This increased the productivity of the loading/unloading cycle. Further, the Accu-Stop option did not require additional panel space or wiring. The SMC Flex controllers built-in overload eliminated the need to mount an external overload relay in the enclosure. The built-in SCR Bypass eliminated the need for an external bypass contact in the enclosure. Both features saved further panel space. The communication feature of the SMC Flex controller allowed remote starting and stopping of the process from a PLC.
48
Chapter 2
Figure 43 - Pump with Soft Start

480V 150 Hp
Ground Level
Check Valve
Pump Motor
Problem: A municipal water company was experiencing problems with pump impellers being damaged. The damage occurred during frequent motor starting while the load below the check valve was draining from the system. A timing relay was installed to prevent restart underload, but need to be adjusted frequently.The pumping station motor was over 100 feet below ground, making repair costly. For maintenance scheduling purposes, an elapsed time meter measuring motor running time had to be installed in the enclosure. Solution: The SMC Flex controller with Pump control was installed, providing a controlled acceleration of the motor. By decreasing the torque during start up, the shock to the impeller was reduced. The SMC Flex Anti-backspin timer feature was implemented to prevent the motor from starting while turning in a reverse direction. Panel space was saved by employing the built-in elapsed time meter. The SMC Flex controllers line diagnostics detected the pre-start and running single-phase condition and shut off the motor, protecting against motor damage.
49
Chapter 2
Figure 44 - Bandsaw with Soft Start and Slow Speed with Braking
480 Volts 300 Hp
Saw Blade
Log Carriage
Motor
High Inertia
Problem: Because of the remote location of the facility and power distribution limitations, a reduced voltage starter was needed on a bandsaw application. When the saw blade became dull, the current drawn by the motor increased. Therefore, an ammeter was required. The saw was turned off only during shift changes or routinely to change the saw blade. This application required 25 minutes to coast to stop, and braking devices were unacceptable due to their high complexity and panel space requirements. After a blade was replaced, it was dangerous to bring the saw up to full speed because of alignment problems. Metering the application for jam conditions was a necessity. In addition, single phasing of the motor was a problem because of distribution limitations. Solution: The SMC Flex controller was installed to provide a reduced voltage start. This minimized the starting torque shock to the system. With the braking option configured as Slow Speed with Braking, it provided a preset slow speed, allowing the saw blade tracking to be inspected before the motor was brought to full speed. The current monitoring and jam detection features of the SMC Flex controller were implemented, saving valuable panel space and the cost of purchasing dedicated monitoring devices. The controllers built-in programmable overload protection was used. The SMC Flex controllers diagnostic capabilities would detect single phasing and shut the motor off accordingly. Starting and stopping control was furnished in a single modular unit, providing ease of installation.
50
Chapter 2
Figure 45 - Rock Crusher with Soft Start

250 HP 480 Volts Starts: Unloaded
Gearbox Motor Discharge
Problem: Because of the remote location of a rock quarry, the power company required a reduced voltage start on all motors over 150 Hp. The starting current on these large motors strained the capacity of the power system, causing severe voltage dips. When the rock crusher became overloaded, the current draw by the Wye-Delta motor increased. Therefore, current monitoring capabilities within the soft starter were required. Because the conveyor feeding the rock crusher was controlled by a PLC, communications between the soft starter and a PLC was necessary. When the rock crusher ran, occasionally a stall or jam would occur. Solution: The SMC Flex controller was installed, meeting the power company requirements. The motor was wired inside-the-delta, which saves valuable panel space. The metering capabilities of the SMC Flex controller allowed the current drawn by the motor to be monitored. With the built-in communications capabilities, the motor current was communicated to the PLC. When the motor current reached a specified limit, the conveyor feeding the rock crusher could be slowed. By slowing the conveyor, a jam condition in the rock crusher was avoided. The stall and jam detection capabilities of the SMC Flex controller would shut off the motor when a stall or jam condition occurred.
51
Chapter 2
Figure 46 - Hammermill with Current Limit Start and SMB Smart Motor Braking
480 Volts 350 Hp
Belts
Hammer
Feed Motor
Problem: A hammermill required a reduced voltage start because of power company restrictions. A stopping time less than the present 5 minute coast-to-rest was desired. To save panel space, the customer wanted to incorporate both starting and stopping control in the same device. Solution: The SMC Flex controller with the braking option configured as SMB Smart Motor Braking was installed. A 23-second, 450% current limit acceleration was programmed, meeting the power company requirements and reducing the mechanical stress on the belts during start-up. The braking function was accomplished without additional power wiring, panel space, or contactors. Zero speed was detected without additional sensors or timers. The current limit start, braking, and overload protection were accomplished within the same modular package.
52
Chapter 2
Figure 47 - Centrifuge with Current Limit Start and SMB Smart Motor Braking
480 Volts 400 Hp
Centrifuge
Motor
Gearbox
Problem: A centrifuge required a reduced voltage start because of power company restrictions. The high torque during starting was causing damage to the gearbox. A shorter stopping time than the present 15 minute coast-to rest was desired. The long stop time caused delays in the production process. A Wye-Delta starter with a mechanical brake was currently in use. A zero-speed switch was used to release the brake. The mechanical brake required frequent maintenance and replacement, which was costly and time consuming. Both the mechanical brake and zero-speed switches were worn out and required replacement. Solution: The SMC Flex controller with the braking option configured as SMB Smart Motor Braking was installed and wired inside-the-delta to the wye-delta motor. The controller was set for a 28-second, 340% current limit start, meeting the power company requirements and reducing the starting torque stress to the gearbox. SMB Smart Motor Braking allowed the centrifuge to stop in approximately 1 minute. The SMC Flex controller with SMB Smart Motor Braking did not require additional mounting space or panel wiring. The controller was mounted in a panel that was considerably smaller than the previous controller. Additionally, the controller did not require frequent maintenance and could sense zero speed without a feedback device.
53
Chapter 2
Figure 48 - Wire Draw Steel Mill Machine with Soft Start

575 Volts 35 Hp Unwind Spool Die Take-Up Spool
Chain Wire
Motor
Problem: An across-the-line starter was used on a wire draw machine to pull wire. This rapid cycling application caused mechanical wear on both the chain and the electromechanical starter. Other soft starts had been experimented with, but not enough torque was developed to pull the wire through the die. Solution: The SMC Flex controller was installed to accelerate the motor smoothly. The kickstart feature was adjusted to provide enough torque to pull the wire through the die. After the initial kickstart, the controller went back to the soft start acceleration mode, reducing the amount of starting torque on the chain and helping to lower maintenance inspection and repair time. The controller was set for a 9-second ramp time.
54
Chapter 2
Figure 49 - Overload conveyor with Linear Speed and Tack Feedback

240 Vol 1.5 Hp Chain Conveyor
Motor
Motor
Motor
Problem: A overload gravel conveyor had three motors to drive the conveying system. Across-the-line starts caused damage to the conveyor and spilled gravel on the conveyor. Occasionally, the conveyor would stop fully loaded. An across-the-line start would then be needed to provide enough torque to accelerate the load. Solution: The conveyor OEM installed a single SMC Flex controller with linear speed and tach feedback to provide a smooth acceleration to all three motors, reducing the starting torque of the motors and the mechanical shock to the conveyor and load. In addition, the controller could be configured to simulate a full voltage start, allowing the conveyor to accelerate when fully loaded. The OEM liked the SMC Flex controller because of its ability to control three motors as if they were a single motor, eliminating the need for multiple soft starters.
Figure 50 - Ball Mill with Current Limit Start
Loading Port 480 Volts 150 Hp
Drum Gearbox Substance Motor
Ball Shot
55
Chapter 2
Problem: An across-the-line starter was used to start the motor in a ball mill application. The uncontrolled start was causing damage to the gearbox, resulting in maintenance downtime, as well as the potential for the loss of the product (paint) being mixed. Line failures were a frequent problem. The application required prestart and running protection, as well as an elapsed time meter to monitor the process time. Communication capability was desired, and panel space was limited. Solution: The SMC Flex controller was installed. It was programmed for a 26-second current limit start, thereby reducing the starting torque and the damage to the gearbox. The metering feature of the SMC Flex controller contained an elapsed time meter, which could monitor the process time of the ball mill. The communications capabilities of the controller allowed the process time to be communicated to the PLC, which could remotely stop the ball mill. The line diagnostics required in the application are standard in the SMC Flex controller, and the built-in overload protection and SCR Bypass saved panel space.
56
Chapter
Special Application Considerations
SMC-Flex Controllers in Drive Applications
The SMC-Flex controller can be installed in starting and stopping control applications. A variable frequency drive must be installed when speed variation is required during run.
Use of Protective Modules

A protective module (see Figure 51) containing metal oxide varistors (MOVs) can be installed to protect the power components from electrical transients and/or electrical noise. The protective modules clip transients generated on the lines and prevent such surges from damaging the SCRs.
Figure 51 - Protective Module
PRO TEC TIV EM ODU LE

MAX . LIN E V MADE OLT IN AGE U.S.A
There are two general situations that may occur which would indicate the need for using the protective modules. 1. Transient spikes may occur on the lines feeding the SMC-Flex controller (or feeding the load from the SMC-Flex controller). Spikes are created on the line when devices are attached with current-carrying inductances that are open-circuited. The energy stored in the magnetic field is released when the contacts open the circuit. Examples of these are lightly loaded motors, transformers, solenoids, and electromechanical brakes. Lightning can also cause spikes. 2. The second situation arises when the SMC-Flex controller is installed on a system that has fast-rising wavefronts present, although not necessarily high peak voltages. Lightning strikes can cause this type of response. Additionally, if the SMC-Flex controller is on the same bus as other SCR devices, (AC/DC drives, induction heating equipment, or welding equipment) the firing of the SCRs in those devices can cause noise.
57
Chapter 3
Motor Overload Protection
When coordinated with the proper short-circuit protection, overload protection is intended to protect the motor, motor controller, and power wiring against overheating caused by excessive overcurrent. The SMC Flex controller meets applicable requirements as motor overload protective device. The SMC Flex controller incorporates, as standard, electronic motor overload protection. This overload protection is accomplished electronically with circuits and an I2t algorithm. The controllers overload protection is programmable, providing the user with flexibility. The overload trip class can be selected for class OFF, 10, 15, 20, or 30 protection. The trip current can be programmed to the motor full load current rating. Thermal memory is included to model motor operating and cooling temperatures. Ambient insensitivity is inherent in the electronic design of the overload.
Stall Protection and Jam Detection
Motors can experience locked rotor currents and develop high torque levels in the event of a stall or a jam. These conditions can result in winding insulation breakdown or mechanical damage to the connected load. The SMC Flex controller provides both stall and jam detection for enhanced motor and system protection. Stall protection allows the user to program a maximum stall protection delay time from 0 to 10 seconds. The stall protection delay time is in addition to the programmed start time and begins only after the start time has timed out. Jam detection allows the user to determine the motor jam detection level as a percentage of the motors full load current rating. To prevent nuisance tripping, a jam detection delay time, from 099 seconds, can be programmed. This allows the user to select the time delay required before the SMC Flex controller will trip on a motor jam condition. The motor current must remain above the jam detection level during the delay time. Jam detection is active only after the motor has reached full speed.
Built-in Communication
A serial interface port is furnished as standard on the SMC-Flex controller. The connections allows a Bulletin 20-COMM to be installed. Using the built-in communication capabilities, the user can remotely access parameter settings, fault diagnostics, and metering. Remote start-stop control can also be performed. When used with the Bulletin 20-COMM communication modules, the SMC-Flex controller offers true networking capabilities with several network protocols, including Allen-Bradley Remote I/O, DeviceNet network, RS 485, ControlNet, EtherNet, ProfiBUS, and Interbus.
58
Chapter 3
Power Factor Capacitors
The controller may be installed on a system with power factor correction capacitors. These capacitors must be installed on the line side to prevent damage to the SCRs in the SMC-Flex controller (See Figure 52).
Figure 52 - Power Factor Capacitors
L1/1
3-Phase
T1/2 T2/4 T3/6 M
L2/3
Input Power
L3/5
Branch Protection
SMC-Flex Controller
Customer Supplied
Power Factor Correction Capacitors
Overload protection is included as a standard feature of the SMC-Flex controller.
High values of inrush current and oscillating voltages are common when capacitors are switched. Therefore, additional impedance should be connected in series with the capacitor bank to limit the inrush current and dampen oscillations. The preferred practice is to insert air-core inductors as shown in Figure 53. The inductors can be simply constructed: for volts greater than or equal to 460V: use a six-inch diameter coil with eight loops for volts less than 460V: use a six-inch diameter coil with six loops The wire should be sized to carry the steady-state current that will flow through the capacitor bank during normal operations. The coils should be mounted on insulated supports away from metal parts. This will minimize the possibility of producing heating effects. Do not mount the coils to be stacked directly on top of each other. This will increase the chances of cancelling the effectiveness of the inductors. If an isolation contactor is used, it is preferable that the power factor capacitors be installed ahead of the isolation contactor if at all possible (see Figure 53). In some installations, this may not be physically possible and the capacitor bank will have to be connected to the downstream terminals of the contactor. In this case, the installer must exercise caution and ensure that the air-core inductance is sufficient to prevent oscillating voltages from interfering with the proper performance of the SMC Flex controller. It may be necessary to add more loops to the coil.
59
Chapter 3
Figure 53 - Power Factor Capacitors with Isolation Contactor
L1/1
3-Phase
T1/2 T2/4 T3/6 M
L2/3
Input Power
L3/5
Branch Protection Isolation Contactor (IC)
SMC-Flex Controller
Customer Supplied
Power Factor Correction Capacitors
Multi-motor Applications
The SMC-Flex controller will operate with more than one motor connected to it. To size the controller, add the total nameplate amperes of all of the connected loads. The stall and jam features should be turned off. Separate overloads are still required to meet the National Electric Code (NEC) requirements.
Note: The SMC-Flex controllers built-in overload protection cannot be used in multi-motor applications. Figure 54 - Multi-Motor Application
L1/1 T1/2 T2/4 T3/6
Overload Relay (O.L.)
3-Phase
L2/3
Input Power
Motor No. 1
L3/5
Branch Protection
Customer Supplied
SMC-Flex Controller
Motor No. 2
Overload Relay (O.L)
60
Chapter 3
Special Motors
The SMC Flex controller may be applied or retrofitted to special motors (wye-delta, part winding, synchronous, and wound rotor) as described below.
Wye-Delta
Wye-Delta is a traditional electro-mechanical method of reduced voltage starting. It requires a delta-wound motor with all its leads brought out to facilitate a wye connection. At the start command, approximately 58% of full line voltage is applied, generating about 33% of the motors full voltage starting torque capability. After an adjustable time interval, the motor is automatically connected in delta. To apply an SMC Flex controller to a wye-delta motor, the power wiring from the SMC Flex controller is simply wired in an inside-the-delta configuration to the motor. This connects all six motor connections back to the SMC-Flex. Because the SMC Flex controller applies a reduced voltage start electronically, the transition connection is no longer necessary. Additionally, the starting torque can be adjusted with parameter programming.
Note: Increased Hp ratings are achieved with the SMC-Flex being connected to wye-delta motors. Figure 55 - Inside-the-Delta Wiring.
1/L 3/L2 5/L3
12/T6
2/T1
8/T4
4/T2
10/T5
6/T3
M
3~
61
Chapter 3
Part Winding
Part winding motors incorporate two separate, parallel windings in their design. With the traditional part winding starter, one set of windings is given full line voltage, and the motor draws about 400% of the motors full load current rating. Additionally, about 45% of locked rotor torque is generated. After a preset interval, the second winding is brought online in parallel with the first and the motor develops normal torque. The part winding motor may be wired to an SMC-Flex controller by connecting both windings in parallel. Again, the starting torque can be adjusted to match the load with parameter programming.
Wound Rotor
Wound rotor motors require careful consideration when implementing SMC-Flex controllers. A wound rotor motor depends on external resistors to develop high starting torque. It may be possible to develop enough starting torque using the SMC-Flex controller and a single step of resistors. The resistors are placed in the rotor circuit until the motor reaches approximately 70% of synchronous speed. At this point, the resistors are removed from the secondary by a shorting contactor. Resistor sizing will depend on the characteristics of the motor used. Please note that it is not recommended to short the rotor slip rings during start-up, as starting torque will be greatly reduced, even with full voltage applied to the motor. The starting torque will be even further reduced with the SMC-Flex controller since the output voltage to the motor is reduced on startup.
Synchronous
Synchronous, brush-type motors differ from standard squirrel-cage motors in the construction of the rotor. The rotor of a synchronous motor is comprised of two separate windings, a starting winding and a DC magnetic field winding. The starting winding is used to accelerate the motor to about 95% of synchronous speed. Once there, the DC magnetic field winding is energized to pull the motor up to synchronous speed. The SMC Flex controller can be retrofitted to a synchronous controller by replacing the stator contactor with the SMC Flex controller and maintaining the DC field application package.
Altitude De-rating
62
Because of the decreased efficiency of fans and heatsinks, it is necessary to de-rate the SMC-Flex controller above 6,500 feet (approximately 2,000 meters). When
Chapter 3
using the controller above 6,500 feet, use the next size device to guard against potential overtemperature trips.
Note: The motor FLA Rating must remain in the range of the SMC Flex Amp rating.
Isolation Contactor
When installed with branch circuit protection and an overcurrent device, SMC Flex controllers are compatible with the National Electrical Code (NEC). When an isolation contactor is not used, hazardous voltages are present at the load terminals of the power module even when the controller is turned off. Warning labels must be attached to the motor terminal box, the controller enclosure, and the control station to indicate this hazard. The isolation contactor is used to provide automatic electrical isolation of the controller and motor circuit when the controller is shut down. Shut down can occur in either of two ways: either manually, by pressing the stop button, or automatically, by the presence of abnormal conditions (such as a motor overload relay trip). Under normal conditions the isolation contactor carries only the load current. During start, the isolation contactor is energized before the SCRs are gated on. While stopping, the SCRs are gated off before the isolation contactor is de-energized. The isolation contactor is not making or breaking the load current.
Figure 56 - Typical Connection Diagram with Isolation Contactor
L1/1
3-Phase
T1/2 T2/4 T3/6 M
L2/3
Input Power
L3/5
Branch Protection Isolation Contactor (IC)
SMC-Flex Controller
Customer Supplied
SMC-Flex Controller with Bypass Contactor (BC)
Controlled start and stop are provided by wiring the controller as shown in Figure 57. When the motor is up to speed, the external bypass contactor is pulled in for run. The bypass mode must have a separate overload as the SMC-Flex overload is not active in this configuration.
63
Chapter 3
Figure 57 - Typical Application Diagram of a Bypass Contactor
L1/1
3-Phase
T1/2 T2/4 T3/6 M
L2/3
Input Power
L3/5
Branch Protection
SMC-Flex Controller
External BC
Customer Supplied Overload protection is included as a standard feature of the SMC-Flex controller.
note: Aux Contact #1 must be set to Bypass.
SMC-Flex Controller with Reversing Contactor
By using the controller as shown in Figure 58, the motor accelerates under a controlled start mode in either forward or reverse.
Note: Minimum transition time for reversing is second. Phase Reversal must be OFF. Figure 58 - Typical Application with a Single-Speed Reversing Starter
L1/1
3-Phase
T1/2 T2/4 T3/6 M
L2/3
Input Power
L3/5
Branch Protection
SMC-Flex Controller
Customer Supplied
Reversing Contactors
64
Chapter 3
SMC-Flex Controller as a Bypass to an AC Drive
By using the controller as shown in Figure 59, a soft start characteristic can be provided in the event that an AC drive is non-operational.
Note: A controlled acceleration can be achieved with this scheme, but speed control is not available in the bypass mode. Figure 59 - Typical Application Diagram of a Bypass Contactor for an AC Drive
AF AF O.L.
3-Phase
VFD
Input Power
VFD Branch Protection
L1/1 L2/3 L3/5

IC
T1/2 T2/4 T3/6

IC
SMC-Flex Mechanical interlock required Controller Customer supplied Many VF drives are rated 150% FLA. Because the SMC-Flex controller can be used for 600% FLA starting, separate branch circuit protection may be required. Overload protection is included as a standard feature of the SMC-Flex controller.
65
Chapter 3
SMC-Flex Controller with a Bulletin 1410 Motor Winding Heater

3-Phase
Figure 60 - Typical Application Diagram of SMC-Flex Controller with a Bulletin 1410 Motor Winding Heater
IC
O.L.
L1/1 L2/3
Input Power
T1/2 T2/4 T3/6 M
L3/5
SMC-Flex Controller
HC
Bulletin 1410 MWH

Customer supplied. Overload protection is included as a standard feature of the SMC-Flex controller.
Motor Torque Capabilities with SMC Flex Controller Options
SMB Smart Motor Braking

The stopping torque output of the SMC Flex controller will vary depending on the braking current setting and motor characteristics. Typically the maximum stopping torque will be between 80100% of the full load torque of the motor when set at 400% braking current.
Preset Slow Speed

Two torque characteristics of the Preset Slow Speed option must be considered. The first is the starting torque. The second is the available running torque at low speed (see Figure 61). These torque characteristics will also vary, depending on the speed selected. Refer to Table 12 for the approximate maximum available starting and running full load torque at maximum current settings. On adjustment (Slow Speed Current) will control the starting and running torque values.
66
Chapter 3
Figure 61 - Starting and Running Torque

100% Motor Speed 7-or-15% Time-(seconds)
-Starting-torque -Running-torque
Table 12 - Maximum Torque at Maximum Current Settings

Present Slow Speed
7% 15%
Maximum Starting Torque as a Percentage of Full Load Torque

90100% 50%
Maximum Running Torque as a Percentage of Full Load Torque

110120% 100%
Accu-Stop
Two levels of braking torque are applied with the Accu-Stop option. There is the braking portion that brakes to slow speed, and the slow speed braking/coast (see Figure 3.12). The level of these braking currents are adjusted using one rotary digital switch. The maximum braking torque available from braking to slow speed and from slow speed to stop is approximately 80100% of full load torque of the motor. Using the slow speed starting portion of the Accu-Stop option will result in the same starting and running torque characteristics as described in the Preset Slow Speed option.
Figure 62 - Accu-Stop Option
100% Motor Speed Braking (A) Slow-Speed
Slow-Speed Braking/Coast (B)
Time-(seconds)
67
Chapter 3
68
Chapter
Product Line Applications Matrix
Description
Use this chapter to identify possible SMC Flex controller applications. This chapter contains an application matrix which will identify starting characteristics, as well as typical stopping features that may be used in various applications.
Mining and Metals

SMC Flex = X Applications Soft Start Current Limit X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Kickstart Soft Stop Pump Control Accu-St op Smart Motor Brake X X Preset Slow Speed Slow Speed with Brake X X Linear Speed Acceleration
Roller Mills Hammermills Roller Conveyors Centrifugal Pumps Fans Tumbler Rock Crusher Dust Collector Chillers Compressor Wire Draw Machine Belt Conveyors Shredder Grinder Slicer Overload Conveyor
69
Chapter 4
Food Processing
SMC Flex = X Applications Soft Start X X X X X X X X X X X X X X X X X X X X X X X X X X X X Current Limit X X X Kickstart Soft Stop Pump Control X Accu-St op Smart Motor Brake Preset Slow Speed Slow Speed with Brake Linear Speed Acceleration
Centrifugal Pumps Pallitizers Mixers Agitators Centrifuges Conveyors Fans Bottle Washers Compressors Hammermill Separators Dryers Slicers
Pulp and Paper

SMC Flex = X Applications Soft Start Current Limit X X X X X X X X X X X X X X X X X X X X X X X X X X X X Kickstart Soft Stop Pump Control Accu-St op Smart Motor Brake Preset Slow Speed Slow Speed with Brake Linear Speed Acceleration
Compressors Conveyors Trolleys Dryers Agitators Centrifugal Pumps Mixers Fans Re-Pulper Shredder
70
Chapter 4
Petrochemical
SMC Flex = X Applications Soft Start Current Limit X X X X X X X X X X X X X X X X X X X X X X X X X Kickstart Soft Stop Pump Control X Accu-St op Smart Motor Brake Preset Slow Speed Slow Speed with Brake Linear Speed Acceleration
Centrifugal Pumps Extruders Screw Conveyors Mixers Agitators Compressors Fans Ball Mills Centrifuge
Transportation and Machine Tool

SMC Flex = X Applications Soft Start Current Limit X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Kickstart Soft Stop Pump Control Accu-Sto Smart Motor p Brake X X X X Preset Slow Speed X X X X Slow Speed with Brake Linear Speed Acceleration
Material Handling Conveyors Ball Mills Grinders Centrifugal Pumps Trolleys Presses Fans Palletizers Compressors Roller Mill Die Charger Rotary Table
71
Chapter 4
OEM Specialty Machine

SMC Flex = X Applications Soft Start Current Limit X X X X X X X X X X X X X X X Kickstart Soft Stop Pump Control X X X X X X X X X Accu-St op Smart Motor Brake Preset Slow Speed Slow Speed with Brake Linear Speed Acceleration
Centrifugal Pumps Washers Conveyors Power Walks Fans Twisting/ Spinning Machine
Lumber and Wood Products

SMC Flex = X Applications Soft Start Current Limit X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Kickstart Soft Stop Pump Control Accu-St op Smart Motor Brake X X X X Preset Slow Speed Slow Speed with Brake X X X Linear Speed Acceleration
Chipper Circular Saw Bandsaw Edger Conveyors Centrifugal Pumps Compressors Fans Planers Sander Debarker
Water/Wastewater Treatment and Municipalities

SMC Flex = X Applications Soft Start Current Limit X X X X X X X X Kickstart Soft Stop Pump Control X X X Accu-St op Smart Motor Brake Preset Slow Speed Slow Speed with Brake Linear Speed Acceleration
Centrifugal Pumps Centrifuge Fans Compressors
72
Chapter
Design Philosophy
Philosophy
Allen-Bradley SMC controllers are designed to operate in todays industrial environments. Our controllers are manufactured to provide consistent and reliable operation. Rockwell Automation has more than just an adequate solution to meet your needs; we have the right solution. With a broad offering of power device products and application services, Rockwell Automation can effectively address the productivity issues most important to you.
Line Voltage Conditions
Voltage transients, disturbances, harmonics and noise exist in any industrial supply. A solid-state controller must be able to withstand these noises and should not be an unnecessary source of generating noise back into the line. Ease of selection for the required line voltage is achieved with a design that provides operation over a wide voltage range, at 50/60 Hz, within a given controller rating. The controller can withstand 3000V surges at a rate of 100 bursts per second for 10 seconds (IEEE Std. 472). Further, the controller can withstand the showering arc test of 3501500V (NEMA Std. ICS2-230) for higher resistance to malfunction in a noisy environment. An optional MOV module is available to protect SCRs from voltage transients.
Current and Thermal Ratings
Solid-state controller ratings must ensure reliability under the wide range of current levels and starting times needed in various applications. SCR packaging keeps junction temperatures below 125C (257F) when running at full-rated current to reduce thermal stress and provide longer, more reliable operation. The thermal capacity of the SMC Flex controllers meet NEMA standards MG-1 and IEC34 (S1).
Mechanical Shock and Vibration
Solid-state controllers must withstand the shock and vibration generated by the machinery that they control.
73
Chapter 5
Design Philosophy
SMC Flex controllers meet the same shock and vibration specifications as electromechanical starters. They can withstand a 5 G shock for 11 ms in any plane and one hour of vibration of 1.0 G without malfunction.
Noise and RF Immunity Altitude
This product meets Class A requirements for EMC emission levels.
Altitudes up to 2000 meters (6560 ft) are permitted without de-rating. The products allowable ambient temperature must be de-rated for altitudes in excess of 2000 meters (6560 ft). The allowable ambient temperature must be de-rated by 3C (27F) per 1000 meters (3280 ft), up to a maximum of 7000 meters (23000 ft). Current ratings of the devices do not change for altitudes that require a lower maximum ambient temperature.
Pollution Setup
This product is intended for a Pollution Degree 2 environment.
Simple, easily understood settings provide identifiable, consistent results. For ease of installation, the controllers include compact design and feed-through wiring. SMC Flex controllers are global products rated at 50/60 Hz. All parameter adjustments are programmed into the controller through the built-in keypad. A full line of enclosures is available.
74
Chapter
Reduced Voltage Starting
Introduction to Reduced Voltage Starting
There are two primary reasons for using reduced voltage when starting a motor: Limit line disturbances Reduce excessive torque to the driven equipment The reasons for avoiding these problems will not be described. However, different methods of reduced voltage starting of motors will be explored. When starting a motor at full voltage, the current drawn from the power line is typically 600% of normal full load current. This high current flows until the motor is almost up to speed and then decreases, as shown in Figure 63. This could cause line voltage dips and brown-outs.
Figure 63 - Full-Load Current vs. Speed
600 500 % Full Load Current 400 300 200 100
% Speed
100
In addition to high starting currents, the motor also produces starting torques that are higher than full-load torque. The magnitude of the starting torque depends on the motor design. NEMA publishes standards for torques and currents for motor manufacturers to follow. Typically, a NEMA Design B motor will have a locked rotor or starting torque in the area of 180% of full-load torque. In many applications, this starting torque can cause excessive mechanical damage such as belt, chain, or coupling breakage.
75
Chapter 6
Reduced Voltage
Figure 64 - Bulletin 570 Autotransformer
The most widely used method of electromechanical reduced voltage starting is the autotransformer. Wye-Delta (Y-D), also referred to as Star-Delta, is the next most popular method. All forms of reduced voltage starting affect the motor current and torque characteristics. When a reduced voltage is applied to a motor at rest, the current drawn by the motor is reduced. In addition, the torque produced by the motor is a factor of approximately the square of the percentage of voltage applied. For example, if 50% voltage is applied to the motor, a starting torque of approximately 25% of the normal starting torque would be produced. In the previous full voltage example, the NEMA Design B motor had a starting torque of 180% of full load torque. With only 50% voltage applied, this would equate to approximately 45% of full load torque. Table 13 shows the typical relationship of voltage, current, and torque for a NEMA Design B motor.
Table 13 - Typical Voltage, Current and Torque Characteristics for NEMA Design B Motors
Starting Method Full Voltage Autotrans. 80% tap 65% tap 50% tap Part Winding Wye-Delta Solid-state % Voltage at Motor Terminals
100 80 65 50 100 100 0100
Motor Starting Current as a % of: Locked Rotor Full Load Current Current
100 80 65 50 65 33 0100 600 480 390 300 390 198 0100
Line Current as a % of: Locked Rotor Current

100 64 42 25 65 33 0100
Motor Starting Torque as a % of: Locked Rotor Torque

100 64 42 25 50 33 0100
Full Load Current

600 384 252 150 390 198 0100
Full Load Torque

180 115 76 45 90 60 0100
With the wide range of torque characteristics for the various starting methods, selecting an electromechanical reduced voltage starter becomes more application dependent. In many instances, available torque becomes the factor in the selection processes.
76
Chapter 6
Limiting line current has been a prime reason in the past for using electromechanical reduced voltage starting. Utility current restrictions, as well as in-plant bus capacity, may require motors above a certain horsepower to be started with reduced voltage. Some countries require that any motor above 7 Hp be started with reduced voltage. Using reduced voltage motor starting also enables torque control. High inertia loads are a good example of an application in which electromechanical reduced voltage starting has been used to control the acceleration of the motor and load. Electromechanical reduced voltage starters must make a transition from reduced voltage to full voltage at some point in the starting cycle. At this point, there is normally a line current surge. The amount of surge depends upon the type of transition being used and the speed of the motor at the transition point. There are two methods of transition: Open Circuit Transition and Closed Circuit Transition. Open circuit transition means that the motor is actually disconnected from the line for a brief period of time when the transition takes place. With closed transition, the motor remains connected to the line during transition. Open circuit transition will produce a higher surge of current because the motor is momentarily disconnected from the line. Examples of open and closed circuit transition currents are shown in Figure 65 and Figure 66.
Figure 65 - Open Circuit Transition Figure 66 - Closed Circuit Transition
600
500 % Full Load Current 400 300 200 100
% Speed
100
% Speed
100
The motor speed can determine the amount of current surge that occurs at transition. Transfer from reduced voltage to full voltage should occur at as close to full speed as possible. This also minimizes the amount of surge on the line. Figure 67 and Figure 68 illustrate transition at low motor speed and near full speed. The transition at low speed shows the current surge as transition occurs at 550%, which is greater than the starting current of 400%. The transition near full speed shows that the current surge is 300%, which is below the starting current.
77
Chapter 6
Figure 67 - Transition at Low Speed
Figure 68 - Transition near Full Speed
% Speed
100
% Speed
100
SMC Flex Solid-State
The main function of solid-state controllers is their ability to provide a soft start or stepless reduced voltage start of AC motors. The same principles of current and torque apply to both electromechanical reduced voltage starters and solid-state controllers. Many solid-state controllers offer the choice of four starting modes: soft start, current limit start, dual ramp start, or full voltage start in the same device.
Figure 69 - SMC Flex Solid-State Controllers
585 A
108251 A
317480 A
In addition to selecting the starting modes, the solid-state controller allows adjustment of the time for the soft start ramp, or the current limit maximum value, which enables selection of the starting characteristic to meet the
78 Rockwell Automation Publication 150-AT002C-EN-P - March 2013
Chapter 6
application. The most widely used version is the soft start. This method provides a smooth start for most applications. The major advantages of solid-state controllers are the elimination of the current transition point and the capability of adjusting the time to reach full voltage. The result is no large current surge when the solid-state controller is set up and correctly matched to the load, as illustrated in Figure 70.
Figure 70 - Soft Start
Percent Voltage 100% Kickstart
Initial Torque
Start Time (seconds)
Run
Current limit starting can be used in situations in which power line limitations or restrictions require a specific current load. Figure 71 shows a 450% current limit curve. Other values may be selected, such as 200%, 300%, or 400%, depending on the particular application. Current limit starting is also used in applications where higher starting torque is required compared to a soft start, which typically starts at less than 300% current. Current limit starting is typically used on low inertia loads, such as compressors.
Figure 71 - Current Limit Start
600
450 % Full Load Current
100
% Speed
100
Other features available with solid-state controllers include additional protection to the motor and controller, and diagnostics to aid in setup and troubleshooting. Protection typically provided includes shorted SCR, phase loss, open load lead, SCR overtemperature, and stalled motor. Appropriate fault messages are
79
Chapter 6
displayed to aid in troubleshooting when one of these faults trip out the solid-state reduced voltage controller.
80
Chapter
Solid-State Starters Using SCRs
Overview
In solid-state starters, silicon controlled rectifiers (SCRs) (see Figure 72) are used to control the voltage output to the motor. An SCR allows current to flow in one direction only. The amount of conduction of an SCR is controlled by the pulses received at the gate of the SCR. When two SCRs are connected back to back (see Figure 73), the AC power to a load can be controlled by changing the firing angle of the line voltage (see Figure 74) during each half cycle. By changing the angle, it is possible to increase or decrease the voltage and current to the motor. The SMC-Flex controller incorporates a microprocessor to control the firing of the SCRs. Six SCRs are used in the power section to provide full cycle control of the voltage and current. The voltage and current can be slowly and steplessly increased to the motor.
Figure 72 - Silicon Controlled Rectifier (SCR)
SCR
Figure 73 - Typical Wiring Diagram for SCRs

Power-Input 3-Phase
L1
T1
L2
T2
Motor
L3
T3
SMC-Flex-Controller Power-Section
81
Chapter 7
Solid-State Starters Using SCRs
Figure 74 - Different Firing Angles (Single-Phase Simplification)
Supply Voltage
Firing for Approx. 50% RMS Voltage
Firing for 25% RMS Voltage
Firing for 100% RMS Voltage
82
Chapter
Reference
Certain mechanical parameters must be taken into consideration when applying motor controllers. The following section explains these parameters and how to calculate or measure them.
Motor Output Speed/Torque/ Horsepower
The speed at which an induction motor operates depends on the input power frequency and the number of poles for which the motor is wound. The higher the frequency, the faster the motor runs. The more poles the motor has, the slower it runs. To determine the synchronous speed of an induction motor, use the following equation:
Synchronous Speed = 60 x 2 x Frequency Number of Poles
Actual full-load speed (the speed at which the motor will operate at nameplate rated load) will be less than synchronous speed. This difference between synchronous speed and full-load speed is called slip. Percent slip is defined as follows:
Percent Slip = Synchronous Speed - Full Load Speed x 100 Synchronous Speed
Induction motors are built with slip ranging from less than 5% to as much as 20%. A motor with a slip of less than 5% is called a normal slip motor. Motors with a slip of 5% or more are used for applications requiring high starting torque.
Torque and Horsepower
Torque and horsepower, two important motor characteristics, determine the size of the motor required for a given application. The difference between the two can be explained using a simple illustration of a shaft and wrench.
83
Chapter 8
Figure 75 - Shaft and Wrench
One Pound
One Foot
Torque is merely a turning effort. In the previous illustration, it takes one pound at the end of the one-foot wrench to turn the shaft at a steady rate. Therefore, the torque required is one pound one foot, or one foot-lb. If the wrench were turned twice as fast, the torque required would remain the same, provided it is turned at a steady rate. Horsepower, on the other hand, takes into account how fast the shaft is turned. Turning the shaft rapidly requires more horsepower than turning it slowly. Thus, horsepower is a measure of the rate at which work is done. By definition, the relationship between torque and horsepower is as follows:
1 Horsepower = 33,000 ft.-lb./minute
In the above example, the one pound of force moves a distance of:
2 ft. x x 1 lb. = 6.28 ft.-lb.
To produce one horsepower, the shaft would have to be turned at rate of:
1 Hp x 33,000 ft-lb./minute 6.28 ft-lb./revolution = 5250 RPM
For this relationship, an equation can be derived for determining horsepower output from speed and torque.
Hp = RPM x Torque X 2 30,000
or
RPM x Torque 5250
For this relationship, full-load torque is:

Full-Load Torque in ft.-lb. = Hp x 5250 Full-Load RPM
84
Chapter 8
Figure 76 illustrates a typical speed-torque curve for a NEMA Design B induction motor. An understanding of several points on this curve will aid in properly applying motors.
Figure 76 - Speed-Torque Curve
Synchronous Speed Breakdown Torque - BT Locked Rotor Torque - LRT
% of Full Load Torque
Slip Pull Up Torque - PUT
Full Load Torque - FLT
Full Speed
Full-load Torque (FLT)

The full-load torque of a motor is the torque necessary to produce its rated horsepower at full-load speed. In foot-lbs, it is equal to the rated horsepower, multiplied by 5250, divided by the full-load speed in RPM.
Locked-Rotor Torque (LRT)

Locked-rotor torque is the torque which the motor will develop at rest for all angular positions of the rotor, with rated voltage at rated frequency applied. It is sometimes known as starting torque and is usually measured as a percentage of full-load torque.
Pull-Up Torque (PUT)

Pull-up torque of an induction motor is the minimum torque developed during the period of acceleration from locked rotor to the speed at which breakdown torque occurs. For motors that do not have definite breakdown torque (such as NEMA Design D), pull-up torque is the minimum torque developed, up to rated full-load speed, and is usually expressed as a percentage of full-load torque.
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Chapter 8
Breakdown Torque (BT)

The breakdown torque of an induction motor is the maximum torque the motor will develop with rated voltage applied, at rated frequency, without an abrupt drop in speed. Breakdown torque is usually expressed as a percentage of full-load torque. In addition to the relationship between speed and torque, the relationship of current draw to these two values is an important application consideration. The speed/torque curve is repeated below, with the current curve added, to demonstrate a typical relationship.
Figure 77 - Speed-Torque Curve with Current Curve
Locked Rotor Current Breakdown Torque - BT Synchronous Speed
Locked Rotor Torque - LRT % of Full Load Torque
Slip
Pull Up Torque - PUT
Full-load Torque - FLT
Full Speed Full-load Current
Two important points on this current curve require explanation.
Full-load Current
The full-load current of an induction motor is the steady-state current taken from the power line when the motor is operating at full-load torque with rated voltage and rated frequency applied.
Locked-rotor Current
Locked-rotor current is the steady state current of a motor with the rotor locked and with rated voltage applied at rated frequency. NEMA has designed a set of code letters to define locked-rotor: Kilovolt-amperes-per-horsepower (kVA/Hp). This code letter appears on the nameplate of all AC squirrel-cage induction motors.
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Chapter 8
kVA per Hp is calculated as follows: For three-phase motors:

kVA/Hp = 1.73 x Current (in Amperes) x Volts 1000 x Hp
For single phase motors:

kVA/Hp = Current (in Amperes) x Volts 1000 x Hp
Letter Designation
A B C D E F G H J K L M N P R S T U V
kVA per Hp
03.15 3.153.55 3.554.0 4.04.5 4.55.0 5.05.6 5.66.3 6.37.1 7.18.0 8.09.0 9.010.0 10.011.2 11.212.5 12.514.0 14.016.0 16.018.0 18.020.0 20.022.4 22.4 and up
By manipulating the preceding equation for kVA/Hp for three-phase motors, the following equation can be used for calculating locked-rotor current:
LRA = 1000 x Hp x KVA/Hp 1.73 x Volts
This equation can then be used to determine the approximate starting current of any particular motor. For instance, the approximate starting current for 7 Hp, 230V motor with a locked-rotor kVA code letter of G would be:
LRA = 1000 x 7.5 x 6.0 = 113 A 1.73 x 230
Operating a motor in a locked-rotor condition for an extended period of time will result in insulation failure because of the excessive heat generated in the stator. The following graph illustrates the maximum time a motor may be
Rockwell Automation Publication 150-AT002C-EN-P - March 2013 87
Chapter 8
operated at locked-rotor without incurring damage caused by heating. This graph assumes a NEMA Design B motor with Class B temperature rise.
Figure 78 - Motor Safe Time vs. Line Current Standard Induction Motors
From Operating Temperature 8
From Ambient
Motor Line Amps Per Unit
Motor Stalled 1.15 Serv. Factor Motor
2 Motor Running 1 0 1.0 Serv. Factor Motor 10 15 20 1000 Time in Seconds 2000 7000
Motor protection, either inherent or in the motor control, should be selected to limit the stall time of the motor.
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Chapter 8
Motor Output for NEMA Design Designations Polyphase 1500 Hp
NEMA has designated several specific types of motors, each having unique speed/torque relationships. These designs, along with some typical applications for each type, are described below. Following these descriptions are summaries of performance characteristics.
Figure 79 - Typical NEMA Design A Speed/Torque Curve

Torque
Starting Current: Starting Torque: Breakdown Torque: Full-load Slip:
High High High Low
Applications: Fans, blowers, pumps, machine tools, or other applications with high starting torque requirements and an essentially constant load.
Speed
Figure 80 - Typical NEMA Design B Speed/Torque Curve

Torque
Normal Normal Normal Normal
Applications: Fans, blowers, pumps, machine tools, or other applications with normal starting torque requirements and an essentially constant load.
Speed
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Chapter 8
Figure 81 - Typical NEMA Design C Speed/Torque Curve

Torque
Low High Low Low
Applications: The higher starting torque of NEMA Design C motors makes them advantageous for use on hard-to-start loads such as plunger pumps, conveyors, and compressors.
Speed
Figure 82 - Typical NEMA Design D Speed/Torque Curve

Torque
Normal High None High (513%)
Applications: The combination of high starting torque and high slip make NEMA Design D motors ideal for use on very high inertia loads and/or in applications where a considerable variation in load exists. These motors are commonly used on punch presses, shears, cranes, hoists, and elevators.
Speed
Table 14 - Motor Output - Comparison of NEMA Polyphase Designs

NEMA Design A B Starting Torque High Normal Locked Rotor Torque High Normal Breakdown Torque High Normal % Slip < 5% < 5% Applications Broad applications including fans, blowers, pumps, and machine tools. Normal starting torque for fans, blowers, rotary pumps, unloaded compressors, conveyors, metal cutting, machine tools, miscellaneous machinery. High inertia starts such as large centrifugal blowers, fly wheels and crusher drums. Loaded starts such as piston pumps, compressors and conveyors. Very high inertia and loaded starts. Choice of slip range to match application. Punch press, sheers and forming machine tools. Cranes, hoists, elevators and oil well pumping jacks.
Low
High
Low
Low
High D Normal High None 58% 813%
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Chapter 8
Calculating Torque (Acceleration Torque Required for Rotating Motion)
Some machines must be accelerated to a given speed in a certain period of time. The torque rating of the drive may have to be increased to accomplish this objective. The following equation may be used to calculate the average torque required to accelerate a known inertia (WK2). This torque must be added to all the other torque requirements of the machine when determining the drive and motors required peak torque output.
T= WK2 x (N) 308 x t
Where: T = Acceleration Torque (ft.-lb.) WK2 = total system inertia (ft.-lb.2) that the motor must accelerate. This value includes motor armature, reducer, and load. N = Change in speed required (RPM) t = time to accelerate total system load (seconds). Note: The number substituted for (WK2) in this equation must be in units of ft.-lb.2. Consult the conversion tables for the proper conversion factor. The same formula can be used to determine the minimum acceleration time of a given drive, or it can be used to establish whether a drive can accomplish the desired change in speed within the required time period.
Transposed formula:
T= WK2 x (N) 308 x t
General Rule If the running torque is greater than the accelerating torque, use the running torque as the full-load torque required to determine the motor horsepower. Note: The following equations for calculating horsepower are meant to be used for estimating purposes only. These equations do not include any allowance for machine friction, winding or other factors that must be considered when selecting a device for a machine application. After the machine torque is determined, the required horsepower is calculated using the formula:
TxN 5250
Hp =
Where: Hp = Horsepower T = Torque (ft.-lb.) N = Speed of motor at rated load (RPM)
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Chapter 8
If the calculated horsepower falls between standard available motor ratings, select the higher available horsepower rating. It is good practice to allow some margin when selecting the motor horsepower.
Inertia
Inertia is a measure of the bodys resistance to changes in velocity, whether the body is at rest or moving at a constant velocity. The velocity can be either linear or rotational. The moment of inertia (WK2) is the product of the weight (W) of an object and the square of the radius of gyration (K2). The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation. Because of this distribution of mass, a small diameter cylindrical part has a much lower inertia than a large diameter part. WK2 or WR2 Where: WR2 refers to the inertia of a rotating member that was calculated by assuming the weight of the object was concentrated around its rim at a distance R (radius) from the center (e.g., flywheel). WK2 refers to the inertia of a rotating member that was calculated by assuming the weight of the object was concentrated at some smaller radius, K (termed the radius of gyration). To determine the WK2 of a part, the weight is normally required (e.g., cylinder, pulley, gear).
Torque Formulas
T=
Hp x 5250 N
Where: Hp = Horsepower T = Torque (ft.-lb.) N = Speed of motor at rated load (RPM)
T=
FxR
Where: T = Torque (ft.-lb.) F = Force (lb.) R = Radius (ft.)
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Chapter 8
T (Accelerating) =
WK2 x (RPM) 308 x t
Where: T = Torque (ft.-lb.) WK2 = Inertia reflected to the motor shaft (ft.-lb.2) RPM = Change in speed t = Time to accelerate (s.) Note: To change in-lb-sec.2 to ft.-lb.2, multiply by 2.68. To change ft.-lb.2 to in-lb-sec.2, divide by 2.68.
AC Motor Formulas
Synchronous Speed =
Frequency x 120 Number of Poles
Where: Synchronous Speed = Synchronous Speed (RPM) Frequency = Frequency (Hz)

Percent Slip = Synchronous Speed - Full-Load Speed Synchronous Speed x 100
Where: Full-Load Speed = Full Load Speed (RPM) Synchronous Speed = Synchronous Speed (RPM)
Reflected WK2 = WK2 of Load (Reduction Rate)2
Where: WK2 = Inertia (ft.-lb.2)
Torque Characteristics on Common Applications
This chart offers a quick guideline on the torque required to breakaway, start and run many common applications.
93
Chapter 8
Table 15 - Torque Characteristics on Common Applications

Application Agitators: Liquid Slurry Blowers, centrifugal: Valve closed Valve open Blowers, positive-displacement, rotary, bypassed Card machines, textile Centrifuges (extractors) Chippers, wood, starting empty Compressors, axial-vane, loaded Compressors, reciprocating, start unloaded Conveyors, belt (loaded) Conveyors, drag (or apron) Conveyors, screw (loaded) Conveyors, shaker-type (vibrating) Draw presses (flywheel) Drill presses Escalators, stairways (starting unloaded) Fans, centrifugal, ambient: Valve closed Valve open Fans, centrifugal, hot: Valve closed Valve open Fans, propeller, axial-flow Feeders, (belt) loaded Feeders, distributing, oscillating drive Feeders, screw, compacting rolls Feeders, screw, filter-cake Feeders, screw, dry Feeders, vibrating, motor-driven Frames, spinning, textile Grinders, metal Ironers, laundry (mangles) Jointers, woodworking Machines, bottling Machines, buffing, automatic Machines, cinder-block, vibrating Machines, keyseating Machines, polishing Mills, flour, grinding Mills, saw, band Mixers, chemical Mixers, concrete Mixers, dough Mixers, liquid Mixers, sand, centrifugal Mixers, sand, screw Mixers, slurry Load Torque as Percent of Full Load Drive Torque Breakaway Accelerating Peak Running
100 150 30 40 40 100 40 50 40 100 150 175 175 150 50 25 50 25 25 25 25 40 100 150 150 150 175 150 50 25 50 50 150 50 150 25 50 50 50 175 40 175 100 50 175 150 100 100 50 110 40 110 60 40 100 50 130 150 100 150 50 50 75 60 110 60 200 110 120 150 100 100 100 150 125 50 50 125 50 75 150 50 75 750 75 75 50 125 100 100 100 125 100 100 40 100 100 100 125 200 100 100 100 100 100 75 200 150 100 50 100 100 175 100 100 100 100 100 100 100 100 100 125 125 100 100 70 100 100 100 200 100 100 100 100 100 100 100
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Chapter 8
Application Mixers, solids Planers, woodworking Presses, pellet (flywheel) Presses, punch (flywheel) Pumps, adjustable-blade, vertical Pumps, centrifugal, discharge open Pumps, oil-field, flywheel Pumps, oil, lubricating Pumps, oil fuel Pumps, propeller Pumps, reciprocating, positive displacement Pumps, screw-type, primed, discharge open Pumps, Slurry-handling, discharge open Pumps, turbine, centrifugal, deep-well Pumps, vacuum (paper mill service) Pumps, vacuum (other applications) Pumps, vane-type, positive displacement Rolls, crushing (sugar cane) Rolls, flaking Sanders, woodworking, disk or belt Saws, band, metalworking Saws, circular, metal, cut-off Saws, circular, wood, production Saws, edger (see edgers) Saws, gang Screens, centrifugal (centrifuges) Screens, vibrating Separators, air (fan-type) Shears, flywheel-type Textile machinery Walkways, mechanized Washers, laundry
Load Torque as Percent of Full Load Drive Torque Breakaway Accelerating Peak Running
175 50 150 150 50 40 150 40 40 40 175 150 150 50 60 40 150 30 30 30 30 25 50 60 40 50 40 50 150 50 25 125 125 75 75 40 100 200 150 150 100 30 100 100 100 100 60 150 50 50 50 50 50 30 30 60 150 100 50 100 50 75 175 150 150 100 125 100 200 150 150 100 175 100 100 100 150 100 175 100 100 100 100 150 150 150 125 70 100 120 90 100 100
Electrical Formulas
Ohms Law:
E I = -R
Where: I = Current (Amperes) E = EMF or Voltage (Volts) R = Resistance (Ohms)
E R = I
E = IR
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Chapter 8
Power in DC Circuits:
P = IE IE kW = ----------1,000
Where: P = Power (Watts) I = Current (Amperes) E = EMF or Voltage (Volts) kW = Kilowatts kWH = Kilowatt-Hours
IE HP = --------746 I E Hour kWH = ------------------------1,000
IE kVA (1-phase) = ----------1,000

Where: kVA = Kilovolt-Amperes I = Current (Amperes) E = EMF or Voltage (Volts)
I E 1.73 kVA (3-phase) = -----------------------1,000
I E PF kW (1-phase) = -------------------1,000 I E PF 1.42 kW (2-phase) = -----------------------------------1,000 I E PF 1.73 kW (3-phase) = -----------------------------------1,000 W kW PF = --------- = -----kVA VI
Where: kW = Kilowatts I = Current (Amperes) E = EMF or Voltage (Volts) PF = Power Factor W = Watts V = Volts kVA = Kilovolt-Amperes
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Chapter 8
Calculating Motor Amperes

HP 746 Motor Amperes = ------------------------------------------E 1.732 Eff PF kVA 1,000 Motor Amperes = ------------------------1.73 E kW 1,000 Motor Amperes = ---------------------------1.73 E PF
Where: HP = Horsepower E = EMF or Voltage (Volts) Eff = Efficiency of Motor (%/100) kVA = Kilovolt-Amperes kW = Kilowatts PF= Power Factor
Other Formulas
Calculating Accelerating Force for Linear Motion:

W V F (Acceleration) = -----------------1,933 t
Where: F = Force (lb.) W = Weight (lb.)
V = Change in Velocity (FPM)

t = Time to accelerate weight (seconds)
LRA = ----------------------------------------------------E 1.73

Where: LRA = Locked Rotor Amperes HP = Horsepower kVA = Kilovolt-Amperes E = EMF or Voltage (Volts)
Start kVA - 1,000 HP ---------------- HP
60 Hz LRA LRA @ Freq. X = -------------------60 ------------Freq. X

Where: 60 Hz LRA = Locked Rotor Amperes Freq. X = Desired frequency (Hz)
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Chapter 8
98
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Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada Outside United States or Canada 1.440.646.3434 Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact your local Rockwell Automation representative.
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Supercedes 150-AT002B-EN-P June 2004 Copyright 2013 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Application Techniques

SMC Flex Solid-State Smart Motor Controller

Important User Information

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Chapter 3 Special Application Considerations

Chapter 4 Product Line Applications Matrix

Chapter 5 Design Philosophy

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Chapter 6 Reduced Voltage Starting

Chapter 7 Solid-State Starters Using SCRs Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Chapter 8

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

SMC Flex Features

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

The following modes of operation are standard within a single controller:

Soft Start with Selectable Kickstart

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 2 - Soft Start

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 3 - Soft Start Sequence of Operation

Run Time (seconds)

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 4 - Soft Start Wiring Diagram

SMC-Flex Control Terminals

Aux #1 Normal/Up-to-Speed/ Bypass

Internal Auxilary Contacts

Current Limit Start with Selectable Kickstart

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 5 - Current Limit Start

Percent Full Load Current

Start Time (seconds)

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 6 - Current Limit Sequence of Operation

Percent Full Load Current 100% Coast-to-rest 50%

Run Time (seconds)

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 7 - Current Limit Wiring Diagram

SMC-Flex Control Terminals

Aux #1 Normal/Up-to-Speed/ Bypass

Internal Auxilary Contacts

Dual Ramp Start with Selectable Kickstart

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 8 - Dual Ramp Start

Initial que #2 Ramp #1 Initial que #1

Start #1 Start #2 Time in Seconds

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 9 - Dual Ramp Start Sequence of Operation

Run n #1 Run #2 Time (seconds)

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 10 - Dual Ramp Start Wiring Diagram

SMC-Flex Control Terminals

Aux #1 Normal/Up-to-Speed/ Bypass

Internal Auxilary Contacts

Full Voltage Start

Rockwell Automation Publication 150-AT002C-EN-P - March 2013

Figure 11 - Full Voltage Start

The basic parameter setup for Full Voltage Start follows: