SMC Flex Selection Guide
SMC-Flex is a Smart Motor Controller (SMC) by Allen-Bradley. It’s a compact, multifunctional solid-state controller which provides microprocessor-based control starting for three-phase Wye-Delta (6-lead) motors of up to 650 Hp or standard squirrel-cage induction motors of up to 400 Hp, and resistive loads. The SMC-Flex is characterized by the availability of seven standard modes of operation within a single controller. Its modular design features state-of-the-art performance, intelligence, and diagnostics, as well as flexible communication options, removable control modules, a fan assembly, and power modules, all in a cost-effective package.
Some of the key features of SMC-Flex controllers include its modular design for simplified installation and routine maintenance, a built-in personal computer (PC) or keypad and LCD software setup, an integrated Run Contactor/Silicon-Controlled Rectifier (SCR) Bypass, three slow-speed modes, and nine Start/Stop modes, full metering and diagnostics, three-phase control, and electronic overload protection.
The integrated keypad, LCD, and flexible communication options provide advanced performance, diagnostics, and optimized configuration. Also, as a standard, SMC-Flex controllers contain a built-in overload system that provides advanced electrical overload protection.
While SMC-Flex controllers include many innovative features in their design, they’re still easy to install, configure and operate. You can make use of as many or as few of the controller’s features as your application requires. In general, SMC-Flex controllers are ideal for applications where: (i) Solid-state starting is required for Star-Delta motor application. (ii) Space is a constraint and enclosure size must be reduced. (iii) Current restrictions are imposed on companies’ power lines; since SMC-Flex controllers can provide different product-line current ratings including 108A…480A, 200…600V, at a frequency of 50/60Hz. (iv) Sudden starts and stops can damage materials in the production lines. (v) Equipment can be damaged by a step-change in torque. (vi) Across-the-line starting can damage belts, chains, and gears. Therefore, it’s recommended that you select a standard SMC-Flex controller that will meet your application requirements. This article provides the selection criteria for SMC-Flex controllers.
Selection Criteria
Whenever you’re selecting an SMC-Flex controller, be sure to consider the electrical specifications, standard modes of operations, control options, communications, standards compliance and certifications, starter protection features, metering, and other features.
Electrical Specifications
Select the proper SMC-Flex controller as per the electrical ratings of the motor used in your application. Consider the following motor ratings:
- Maximum Output Voltage: This is the voltage that the motor outputs.
- Rated Power: The maximum power that will be used by the motor being controlled.
- Continuous Output Current: This term is used to describe the current which the motor will carry continuously in the air without exceeding temperature limits.
- Peak Output Current: Which is the maximum output current capacity within a short period.
- AC Supply Voltage: This is the range of the AC input voltage which will operate the SMC-Flex controller
- DC Supply Voltage: This is the range of DC input voltage from the motor that will operate the SMC-Flex controller.
- AC Input Frequency: This is the frequency that the SMC-Flex controller accepts from the connected motor. SMC-Flex motor controllers use either 50/60Hz or 400Hz AC input frequency. Single-phase AC inputs are used for low voltage control applications and are the most common phase. Three-phase AC inputs are used for higher voltage applications. An SMC-Flex controller with three-phase inputs can be used to overcome high starting loads. After the initial inertial load is overcome with higher torque, the controller switches the motor to a more efficient low-torque star-delta configuration.
Note, that the SMC-Flex controllers can operate Wye-delta (Star-delta) motors rated at 1.8 amperes to 1600 amperes, and up to 690 volts AC at a frequency of 50/60Hz. They can also operate standard squirrel-cage induction motors rated from 1A to 1250A. Before you apply power to the selected controller, verify the specified voltage on the product. Because the control power input can range between 100 and 240 volts AC, as well as 24V AC/DC, depending upon the selected type of SMC-Flex controller.
For control applications involving Line-connected motors, refer to the SMC-Flex selection tables for use with Line-connected motors in the manuals provided by the SMC manufacturer. The various controllers that can be used with Line-connected motors include: (i) 200/208V AC SMC-Flex Controllers; (ii) 230VAC SMC-Flex Controllers; (iii) 400/415/460VAC SMC-Flex Controllers; (iv) 690VAC SMC-Flex Controllers; and (v) 500/575VAC SMC-Flex Controllers.
Likewise, for Delta-connected motors, refer to the SMC-Flex selection tables for use with Delta-connected motors in the manuals provided by the SMC manufacturer. Some of the controllers which can be used with Delta-connected motors include: (i) 230V AC SMC-Flex Controllers; (ii) 400/415/460V AC SMC-Flex Controllers; (iii) 230V AC SMC-Flex Controllers; and (iv) 500/575V AC SMC-Flex Controllers.
To get the best selection results for both cases, especially where frequent starting and stopping operations are involved or when you’re not sure if the motor is Delta-connected or Line-connected, it is highly recommended that you use the available sizing and selection tools for SMC controllers.
Standard Modes of Operation
Ensure that you select an SMC-Flex controller whose standard modes of operation exactly match your application requirements. Alternatively, you can select an SMC-Flex controller with specific standard modes of operation depending on your motor application. The following modes of operation are considered a standard within an SMC-Flex controller:
- Soft Start: This operational mode covers most of the general motor control applications. In this mode: an initial torque setting, which is user-adjustable from 0% to 90%, is input to the motor. During the acceleration ramp time, the output voltage to the motor is continuously increased from the initial torque level. If the SMC-Flex controller senses that the motor has attained full speed it will pull in its internal bypass RUN contactor. Note, that this mode should allow you to adjust the acceleration ramp time from 0…30 seconds. For this reason, a selectable Kickstart is available with Soft Start mode.
- Soft Stop: This operation mode can be used in applications that require lengthened stop time. You should be able to adjust the voltage ramp downtime from 0 to 120 seconds, independently from the start time. When the output voltage drops to a point where the load torque exceeds the developed motor torque, then the load will stop.
- Selectable Kickstart: This feature provides a current boost during motor startup to break away heavy loads, which may require a current pulse of higher torque to get started. It is intended to provide a current pulse that is selectable from 0% to 90% of the locked torque rotor, for a selected period of time. This mode is user-adjustable from 0.0 seconds to 2.0 seconds.
- Current Limit Start: This mode provides the correct current limit start. It’s ideal for applications where it is necessary to limit the maximum current used for motor starting. Ensure that while in this mode, you can adjust the Current Limit Level from 50 to 600% of the motor’s full load ampere rating. Also, using the SMC-Flex controller, the Current Limit Time should be adjustable from 0 to 30 seconds. A selectable Kickstart is also accessible with Current Limit Start mode.
- Dual Ramp Start: This starting mode is well-suited for motor applications with varying loads, hence varying initial torque and start time requirements. It should allow you to select between two different startup profiles with initial torque and ramp times settings being separately adjustable. Note, that the Dual Ramp Start mode is only available with standard SMC-Flex controllers.
- Full Voltage Start: In this mode, the SMC-Flex controller functions as a solid-state contactor. It is used in applications that require across-the-line starting. With the full voltage start mode, you should be able to realize the full inrush current and locked-rotor torque. Also, in this mode, the SMC-Flex controller can be programmed to provide full voltage during motor start. In such a case, the motor’s output voltage should reach full voltage in just 0.25 seconds.
- Linear Speed Acceleration: With this type of acceleration mode, the SMC-Flex controller can control the motor speed during starting and stopping operations, as well as maintain the motor acceleration at a constant rate through a closed-loop feedback system. You’ll require to supply a tachometer input (0 to 5V DC, 4.5V DC = 100% speed) to perform this start mode. Note, a Kickstart feature is available with this mode to provide a selectable start time from 0 to 30 seconds. The start time determines the time the motor will take to accelerate from 0 speed to full speed.
- Preset Slow Speed: This option is highly suitable in general motor applications which require slow speed to position materials. You can set the Preset Slow Speed mode to LOW (7% of base speed), or HIGH (15% of base speed) in the forward direction. Also, you can program the SMC-Flex to reverse direction while in this mode. The reverse speed settings include LOW (10% of base speed) and HIGH (20% of base speed).
Control Options
SMC-Flex controllers provide two main control options: Pump Option and Braking Option. The control options available within these two categories are mutually exclusive, as in you can only use one control option at a time. Therefore, whenever you’re selecting an SMC-Flex controller, you must specify the exact control option required for your application. Also, you can upgrade an existing SMC-Flex controller to another control option by replacing its control module.
- Pump Control: This control option is used to reduce fluid surges during the starting and stopping operations of a centrifugal pump. It achieves this by smoothly accelerating and decelerating the motor. The SMC-Flex controller analyzes the motor variables (i.e., torque and speed) and generates commands to control the motor and reduce the possibility of fluid surges in the pump system. Note, with this option you should be able to program the starting time from 0 to 30 seconds, as well as the stopping time from 0 to 120 seconds. Also, the pump control module provides an integrated anti-backspin time.
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Braking Option: The control options within this category include:
- Smart Motor Braking: This control option is used in applications that require reduced stopping times (requiring the motor to stop quickly). The SMC-Flex controller applies an adjustable braking current to a motor through its microprocessor-based system, without the need for additional equipment. Furthermore, it provides an automatic motor shut-off at zero speed detection. With this option, you should be able to adjust the braking current from 0 to 400% of the motor’s full-load current rating. Note, that the Smart Motor Braking control option is not intended for use as an Emergency Stop.
- Accu-Stop: The option provides controlled position stopping by combining the benefits of the Preset Slow Speed mode and Smart Motor Braking (SMB) option. In general-purpose motor applications, the Accu-Stop control option enables braking from top speed to the preset slow speed, then braking to a stop. Please take note that you cannot use this option as an Emergency Stop.
- Slow Speed with Braking: This option provides a jog speed during process set-up and braking-to-stop at the end of the cycle. It is used on applications that require braking control to stop and also requires a slow forward speed for alignment or positioning.
Communications
The SMC-Flex controllers provide advanced and flexible communications capabilities, allowing you to start and stop the controllers from multiple locations. Also, these controllers provide diagnostic information through the use of the available communication interfaces. The Allen-Bradley SMC-Flex controllers communicate using the Device Peripheral Interface (DPI) Protocol. Hence, all standard DPI-supported communication protocols used by other devices, such as PowerFlex drives, can be used in the SMC-Flex controllers.
This is because the DPI communication method enables almost any DPI-supported Human Interface Module (HIM), network communication modules (20-COMM-X), or PC software, to be used with the SMC-Flex controllers. However, other devices are DPI-supported but are not supported by the SMC-Flex controllers, such as ScanPort devices. Therefore, ensure that you select the DPI communication cards that are compatible with the selected SMC-Flex controller, and the selected card should also meet your application’s communication requirements.
Communication Modules
Standard DPI-supported communication cards are available for different protocols including Ethernet, ControlNet, Remote I/O, DeviceNet, Profibus, Modbus, Interbus, and RS485-DF1.
Allen-Bradley provides a variety of DPI-supported Communication interfaces, from which you can select the most appropriate modules to use with your SMC-Flex controller. For programming and configuration information of a specific communication interface protocol, refer to the user manual for the communication module in question. The available 20-COMM Communication Modules include the 20-COMM-S RS-485 Communication Adapter, the 20-COMM-P PROFIBUS DP Communication Adapter, the 20-COMM-C ControlNet Communication Adapter (Coax), the 20-COMM-I Interbus Communication Adapter, the 20-COMM-M Modbus/TCP Communication Adapter, 20-COMM-H RS-485 HVAC Communication Adapter, the 20-COMM-E EtherNet/IP Communication Adapter, the 20-COMM-D DeviceNet Communication Adapter, the 20-COMM-ER Dual-port EtherNet/IP Communication Adapter, and the 20-COMM-Q ControlNet Communication Adapter (Fiber).
Note: SMC-Flex controllers support three DPI ports for communication. Port ##1 is usually not available for use. Port ##2 and ##3 are serial interface DPI ports provided as standard on the side of the SMC-Flex controller and are typically used to interface with optional Bulletin 20 HIM modules. Port ##2 is the default connection with Port ##3 available by installing a DPI splitter on Port ##2. Port ##5 is supported by connecting one of the 20-COMM-X communication cards listed in the table above to the internal DPI comm card connection.
Human Interface Modules
You can program an SMC-FLEX controller with either the integrated LCD and keypad or with the available optional Allen-Bradley HIM LCD modules. The HIM LCD modules include:
- Hand-held HIM with LCD and Full Numeric Keypad; Catalog No. 20-HIM-A3.
- To connect this module to the SMC-Flex controller, you will require a 20-HIM-H10 cable.
- Hand-held HIM with LCD, Programmer only; Catalog No. 20-HIM-A5.
- This HIM module requires a 20-HIM-H10 cable to connect to an SMC-Flex controller.
- Door-mounted HIM with Remote (panel mount) LCD Display, Full Numeric Keypad; Catalog No. 20-HIM-C3S.
- Door-mounted HIM module with LCD Display, the programmer only (includes 3 m cable); Catalog No. 20-HIM-C5S.
Standards Compliance/Certifications
Ensure that the selected SMC-Flex controller complies with the following standards:
- CSA C22.2 No.14
- UL 508
- EN/IEC 60947-4-2
- EN/IEC 60947-1 Also, the SMC-Flex controller should have the following certifications/approvals:
- CCC Certified
- C-UL-us Listed (Open Type SMC-Flex) (Guides NMFT7, NMFT; File No. E96956)
- CE Marked
- CSA Certified (File No. LR 1234)
Start Protection Features
The selected SMC-Flex controller should include the following Starter protection features:
- Electronic Motor Overload Protection: As a standard, the SMC Flex controller should incorporate electronic motor overload protection. An I2t algorithm is used to accomplish this overload protection electronically.
- Undervoltage Protection: This protection feature enables the SMC Flex controller to stop the motor operations whenever it detects a drop in the incoming line voltage. You can adjust the Undervoltage trip level from 0% to 99%, as a percentage of the programmed line voltage.
- Overvoltage Protection: If the SMC Flex controller senses a rise in the incoming line voltage, its overvoltage protection feature will halt the motor operations. You should be able to adjust the overvoltage trip level from 0% to 199%, as a percentage of the programmed line voltage. With this feature, you can also program an overvoltage trip delay time of 0 to 99 seconds.
- Underload Protection: This feature allows the SMC-Flex controller to stop motor operations if a drop in current is detected. The selected SMC-Flex controller should provide an underload trip setting, that can be adjusted from 0% to 99% of the full-load current rating for the motor in use. It should also have a trip delay time setting adjustable from 0 to 99 seconds.
- Voltage Unbalance Protection: The SMC-Flex should be able to halt motor operation when the calculated voltage unbalances get to the user-programmed trip level. You should be able to program the voltage to unbalance trip level setting from 0% to 25% unbalance.
- Stall Protection and Jam Detection: In the event of a stall or a jam, motors can experience locked-rotor currents; thereby, developing high torque levels. These conditions result in mechanical damage to the connected load or in winding insulation breakdown. Thus, the selected SMC Flex controller should provide both Jam detection and stall protection features for enhanced motor and control system protection.
Metering
In addition to operating a connected motor, the SMC-Flex controller also monitors other motor parameters while in operation to provide full-function metering. Therefore, the selected SMC-Flex controller should contain specific power monitoring parameters as a standard. These metering parameters include three-phase current, power factor, three-phase voltage, motor thermal capacity usage, power ratings (MW or kW), power usage (MWH or kWH), and the elapsed time.
Other Features
Other key features which you should ensure are included in the SMC-Flex controller you intend to purchase are:
- LCD Display: The selected SMC-Flex controller should include a built-in 16-character three-line backlit LCD to provide parameter identification using informative and clear text. Also with this display, you should be able to easily and quickly perform controller setup without the need for a reference manual.
- Keypad Programming: The SMC-Flex controller should have a five-button keypad on the front for programming the controller’s operating parameters. The five buttons include a Select button, an Escape button, Up and Down arrows, and an Enter button.
- Auxiliary Contacts: As a standard, an SMC-Flex controller should include four hard contacts that are fully programmable. Aux ##1 contact is programmable for Normal/External Bypass/Up-to-Speed/Alarm/Fault/Network, while Aux ##2, Aux ##3, and Aux ##4 contacts are configured to be normally open (N.O.)/normally closed (N.C.).