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Allen Bradley - Drives

SMC Plus

SMC Plus Selection Guide

SMC Plus Overview

The SMC Plus is a product line of Solid-State Motor Controllers (Bulletin 150) from Allen-Bradley/Rockwell Automation. These controllers provide smart microprocessor-based starting and/or stopping control for standard three-phase induction AC motors (the squirrel-cage types) rated from 1/3 horsepower (HP) to 1000 HP. The solid-state controller design offers exceptional control reliability in a compact enclosed package, with considerably fewer components compared to other electromechanical motor control devices.

Standard Features

All SMC Plus controller configurations are available with three standard starting modes of operation and self-calibration. The three starting modes include:

A) Soft Start Mode with Selectable Kickstart

With the Soft Start operation mode enabled, the induction motor being controlled by the SMC Plus controller is provided with a starting torque value that’s user-variable from 0%...90% of LRT (Locked Rotor Torque). From the preset initial torque value, the output voltage supplied to the induction motor is gradually ramped in the course of the acceleration ramp time. Users can adjust the configured acceleration ramp time from 0 seconds to 30 seconds.

If, during the Soft Start operation, the SMC Plus controller detects that the connected induction motor has attained the up-to-speed condition, it automatically switches the output voltage being supplied to the induction motor to full voltage. The Soft Start mode is also available with a user-adjustable setting for the current limit, which limits the supply current all through the voltage ramp operation.

The Selectable Kickstart feature at the onset of the voltage ramp operation (Soft Start operation mode) is designed to provide a current boost to break away motor loads requiring a high torque pulse to get started. It typically provides a high current pulse that’s 550% of the rated full load current. Users can adjust the kickstart time from 0.0 seconds to 2.0 seconds, allowing the motor being controlled to develop additional startup torque for loads that may require a boost to start off.

The Soft Start mode with Selectable Kickstart is widely used in most general-purpose control applications for three-phase AC induction motors.

B) Current Limit Start Mode

The Current Limit Starting operation mode provides a fixed-reduced-voltage motor startup by ensuring a constant supply of current to the motor being controlled. The feature is enabled when it’s necessary to regulate the maximum startup current of an induction motor. Users can adjust the limit of the starting current from 50% to 600% of the rated motor’s full load current. The starting current limit ramp time is also user-adjustable from 0 seconds to 30 seconds. If the SMC Plus controller detects that the induction motor has attained the up-to-speed condition in the course of the Current Limit Starting operation mode, it automatically switches the output voltage being supplied to the motor to full voltage.

Note: The Current Limit Starting mode can be used in conjunction with Torque Control, Soft Start, and Linear Speed Acceleration starting modes. This mode is also available with a Selectable Kickstart.

C) Full Voltage Start

An SMC Plus controller configured for Full Voltage starting mode functions like a solid-state across-the-line motor contactor, with locked-rotor torque and full inrush current being realized. Hence, this starting mode is commonly used in control applications that require across-the-line motor starting. You can program an SMC Plus controller for Full Voltage Start operation in which the output voltage being supplied to an AC induction motor gets to full voltage in five cycles, with a ramp time of fewer than 0.25 seconds.

D) The Energy Saver

The Energy Saver is also a standard feature incorporated with the SMC Plus (Bulletin 150) controllers. It’s generally used to save energy in applications where an AC induction motor is unloaded or lightly loaded for prolonged periods of time. When the feature is enabled, an SMC Plus controller can continuously monitor the connected motor load using its internal feedback circuitry.

Note: The Energy Saver is an integral (built-in) feature of the Allen-Bradley SMC Plus controllers. As such, it does not require any external wiring or extra panel space. Also, its setup procedure is not complicated.

Optional Features

The Allen-Bradley SMC Plus controllers are also available with various innovative starting and stopping control optional features that provide enhanced system performance. These options include:

A) Pump Control Option

This control option is used to minimize surges in a fluid pipework system and the resulting check valve slam or water hammer phenomenon caused by starting a motor-driven centrifugal pump at full speed and full voltage. If the Pump Control option is enabled at the time of stopping or starting a centrifugal pump, it reduces fluid surges by gradually decelerating or accelerating the driving motor.

The microprocessor of the SMC Plus controller featuring the Pump Control option analyzes the operating variables of the AC motor being controlled and generates control commands that reduce the likelihood of fluid surges occurring in the piping system. With this control option, the pump starting time is user-variable from 0 seconds to 30 seconds, while the stopping time can be modified from 0 seconds to 120 seconds.

B) Soft Stop Control Option

The Soft Stop control mode provides a voltage ramp-down time of 0…60 seconds for induction motor control applications requiring a lengthened coast-to-rest. In such applications, the load comes to a stop when the motor’s output voltage reduces to a point where the torque of the connected load is more than the generated motor torque. This control option is intended for frictional loads, which have a tendency to stop immediately if the supply voltage from the driving motor is removed. Note the Soft Stop ramp down time is programmed independently of the Soft Start acceleration ramp time.

C) Preset Slow Speed Control Option

This control option offers a predetermined slow speed for general-purpose positioning and alignment applications. In the motor’s forward direction, the predetermined speeds can be selected at either 7% of the rated motor speed (Low) or 15% of the rated motor speed (High). In the motor’s reverse direction, the Preset Slow Speed control option also provides two-speed settings, either 20% of the rated motor speed (High) or 10% of the rated motor speed (Low). The direction of the induction motor (reverse or forward) is selected using a DIP Switch. Also, users can adjust the slow speed current setting from 50% to 450% of the rated full load current.

D) SMB Smart Motor Braking Option

This control option provides a microcomputer-based motor braking technique that applies a three-phase braking current to a standard AC induction motor (squirrel-cage type) without requiring any additional braking equipment. The strength of the applied 3-phase braking current is user-variable from 150% – 400% of the rated full load current. The option is ideal for control applications that require reduced motor stopping times.

E) Accu-Stop Control Option

The Accu-Stop control feature incorporates the benefits of Preset Slow Speed and SMB Smart Motor Braking control options to provide precise stopping control for general-purpose positioning applications or to reduce excessive jogging to stop.

When Accu-Stop control mode is enabled, a three-phase, user-adjustable braking current (adjustable from 150%...400% of rated full load current) is supplied to the connected induction motor till it attains a predetermined slow speed (of either 15% (High) or 7% (Low) of rated motor speed). The motor is then held at the attained preset slow speed until the SMC Plus controller issues a stop command. Once this command is issued, a braking torque is applied to the induction motor until it brakes to stop. The slow-speed current value is user-variable from 50% to 450% of the motor’s rated full load current.

F) Slow Speed with Braking Option

This control option provides slow process setup speeds and braking-to-stop control. It is ideal for motor control applications that require a forward-direction jog speed for alignment or positioning and those requiring braking-to-stop control.

Selecting the Right SMC Plus Controller

AC induction motors have very complex performance dynamics; therefore, it’s necessary to have an SMC Plus controller that can provide robust motor control as per these dynamics. When choosing an SMC Plus controller, the choice should be based on the controller’s technical capabilities and the respective application conditions.

Discussed in this section are the key parameters you should take into account to ensure that you select the right SMC Plus controller for your starting and stopping control application.

1. Type of Load

Allen-Bradley SMC Plus controller models are available for 3-phase squirrel-cage type AC induction motors with the following ratings: 1…1000A (Amperes), current rating; 200…600V AC or 200…480V AC, three-phase input voltage rating; 50 Hz (Hertz) or 60 Hz, input frequency rating. In addition to controlling AC induction motors, the SMC Plus controllers can also be used to control resistive loads.

The available SMC Plus controller’s current ratings range from 24 to 1000 Amperes depending on the catalog number selected. It is always best to select an SMC Plus controller with a higher power rating than the rating of the induction motor to be controlled because using a motor controller with a lower power rating can often result in controller damage, and you’ll also not get the maximum mechanical performance range from your motor.

2. Standard and Optional Control Features

Once you have chosen an AC induction motor that meets the electrical requirements of your application, it’s then time to review the motor controller features you require. The standard features (Soft Start, Energy Saver, etc.) discussed in the section above are available with each SMC Plus controller model. However, if your application requires a specific control option, ensure that you select an SMC Plus controller that can provide that particular optional feature. For example, an SMC Plus controller featuring the Pump Control option would be ideal for centrifugal pump control applications.

Note: The Pump Control, Accu-Stop, Soft Stop, SMB Smart Motor Braking, Predetermined Slow Speed, and Slow Speed with Braking optional control features are mutually exclusive and should be specified when creating a purchase order for a given SMC Plus controller model. Also, it’s possible to upgrade an existing SMC Plus controller to a different control option by changing its control module. Only one control option can be added to a standard SMC Plus control unit.

3. Environmental Specifications

The recommended environmental specifications for all SMC Plus controller models are as follows:

  • Operating Temperature: 0°C … +50°C
  • Storage Temperature: –40°C … +85°C
  • Relative Humidity: 5% to 95% (non–condensing)
  • Altitude: 2000 meters without derating
  • Noise and RF (Radio Frequency) Immunity: Surge transient 3kV (kilovolts) peak, 1500 Volts showering arc
  • Allowable Shock Limit: 30 G shock peak acceleration for 11 milliseconds
  • Acceptable Level of Vibration: 2.5 G vibration for 60 minutes
  • Enclosures: NEMA Type 1 Ventilated enclosures for open-style SMC Plus controllers. For non-ventilated or NEMA Type 12 enclosures, a bypass contactor should be used along with the SMC Plus controller.

4. Standards Compliance

When selecting an Open Type SMC Plus controller model, ensure that the selected motor controller includes the following standards’ compliance approvals.

  • UL Listed (Open Type) (File Number E96956)
  • CE Marked Per Low Voltage (Open Type). European Directive 73/23/EEC, 93/68/EEC.
  • CSA Certified (Open Type) (File Number LR1234)

5. Protective Modules

Select an appropriate protective module for your SMC Plus controller. Protective modules containing power factor correction capacitors and Metal Oxide Varistors (MOVs) are installed on the load- or line-side of the SMC Plus controllers to protect power components from transient voltages and/or electrical noise. For control applications requiring both load and line side protection, two SMC Plus protective modules should be ordered.

The Metal Oxide Varistors in the SMC Plus protective modules clip electrical transients developed on the system’s power lines and prevent such voltage surges from damaging the Silicon Controlled Rectifiers (SCRs) in the SMC Plus controllers. At the same time, the capacitors are used to shunt away electrical noise energy from the SMC Plus controller electronics.

Rockwell Automation provides the following protective modules for use with the SMC Plus controller product line.

  • 480V Field Installed Protective Module, with 24…54A nominal current rating. Catalog No.150-N84
  • 600V Field Installed Protective Module, with 24…54A nominal current rating. Catalog No.150-N86
  • 480V Field Installed Protective Module, with 97…360A nominal current rating. Catalog No.150-N84L
  • 600V Field Installed Protective Module, with 97…360A nominal current rating. Catalog No.150-N86L

Note: Protective modules are incorporated as standard features on SMC Plus controllers rated from 500…1000 Amperes.

In general, the occurrence of the following two situations would necessitate the use of protective modules in SMC Plus controller circuits.

  1. The occurrence of transient spikes on the lines powering the SMC Plus controller or on the lines powering the connected motor load from the SMC Plus controller. Such voltage spikes can be created on the power lines by lightning strikes or when devices with current-carrying inductances are open-circuited. When switch contacts open the circuits containing these devices, magnetic energy is released, which causes transient spikes. Examples of such devices include transformers, lightly loaded motors, electromechanical brakes, and solenoids.
  2. The presence of fast-rising wavefronts (not necessarily high-peak voltages) in the system in which the SMC Plus controller is installed. This type of response can be caused by lightning strikes. In addition, if the SMC Plus controller is installed on the same power bus as other SCR-based devices, such as welding equipment, DC/AC motor drives, or induction heaters, the firing of the SCRs in such devices can cause high-frequency noise. This type of electrical noise can slip into the SMC Plus controller as stray capacitance.

Note: You should first disconnect the SMC Plus controller from the power source when installing or inspecting the protective modules. Also, periodically inspect the protective module for discoloration or damage, and replace it if necessary.

6. IEC Terminal Covers

These are essential accessories for motor controllers. The available Allen-Bradley IEC terminal covers for use with the SMC Plus controllers include the following:

  • Catalog No. 150-NT1: These are IEC load- and line-side termination covers for 97–135 Ampere-rated SMC Plus controllers.
  • Catalog No.  150-NT2: These are IEC line- and load-side termination covers for 180–360 Ampere-rated SMC Plus controllers.

7. Terminal Lug Kits

Terminal lugs are designed to allow the connection of electrical devices and cables to a terminal block. They are available in a wide variety of sizes and shapes and can often be easily mounted to any chassis or stud. The terminal lugs listed below are included with various SMC Plus controllers.

  • Catalog No. 199-LF1: Included with 97…360A rated SMC Plus controllers.
  • Catalog No. 199-LG1: Included with 500…720A rated SMC Plus controllers.
  • Catalog No. 199-LJ1: Included with 850…1000A rated SMC Plus controllers.

Note: Your SMC Plus controller purchase order should include: (i) the catalog no. of the SMC Plus controller you have selected, (ii) necessary modifications, and (iii) the catalog numbers of any control options or accessories if required.

Browse our selection of SMC Plus units

AutomationStop.com's online catalog offers one of the largest selections of preowned SMC Plus units in the world.

150-A135NBD

The Allen-Bradley SMC Plus series 150-A135NBD controller is a soft starter type of motor controller. It operates with 208 to 480 Volts AC of 3-phase voltage at 50 to 60 Hertz of frequency. The 150-A135NBD motor controller is an open controller with 1 NC contactor and 1 NO contactor. Its current rating is 135 Amps. The 150-A135NBD motor controller supports a soft start option for starting a motor, in addition to other motor-starting options.

150-A135NCD

The Allen-Bradley SMC Plus 150-A135NCD controller is a smart motor controller with several motor-starting options. These options include a full voltage starting option, a current limit starting option, and a soft starting option. The 150-A135NCD controller also supports a soft stopping option. The current rating of the 150-A135NCD controller is 135 Amperes and the full line voltage range for this controller is from 200 to 600 Volts AC.

150-A180NBD

The Allen-Bradley 150-A180NBD motor controller is an SMC Plus motor controller with a protective enclosure that can only be used as a non-combination type of motor controller. It can operate at up to 480V AC of line voltage. The 150-A180NBD controller has a current rating of 180 Amperes and an output power rating of 150 Horsepower maximum. In addition to its line voltage, this controller uses 100-240V AC of 1-phase control voltage when it operates.

150-A180NCD

The Allen-Bradley SMC Plus 150-A180NCD controller can control a compatible induction motor which is powered by 3-phase AC input voltage. This controller supports several different starting modes that can be used with different motors or in different applications. The 150-A180NCD motor controller operates with a line voltage rating of 200-600V AC. Its current rating is 180 Amps. The 150-A180NCD controller comes in an open enclosure and it is a compact device.

150-A240NBD

The Allen-Bradley SMC Plus series 150-A240NBD smart motor controller is a solid-state control module that can start and stop an industrial motor in a variety of ways. It can also support a pump control option. The 150-A240NBD controller uses 3-phase line voltage and its line voltage range is from 200 to 460V AC. Additionally, it supports a control voltage range from 100 to 240V AC. The 150-A240NBD controller comes in an open enclosure.

150-A240NCD

The 150-A240NCD motor controller is a Bulletin 150 Allen-Bradley SMC Plus motor control device that supports 240 Amps of current and 575V AC of maximum 3-phase input voltage. Its enclosure option is an open enclosure that cannot protect it from liquids, debris, dust, or chemicals. The 150-A240NCD controller should only be used in a non-hazardous operating environment. It does not have a thermal overload option but it can support several special motor control options in addition to its standard control options.

150-A24NBD

The Allen-Bradley SMC Plus series 150-A24NBD smart motor controller operates with 3-phase AC line voltage and with 1-phase AC control voltage. Its line voltage range is 200-460V AC at 50 to 60 Hertz and its control voltage range is 100-240V AC. The 150-A24NBD controller can start a connected motor with a variety of different starting modes, including the kick start mode, the full voltage starting mode, and the current limit starting mode.

150-A24NCD

The Allen-Bradley 150-A24NCD controller is a motor controller in the SMC Plus line with a maximum 3-phase input voltage rating of 575 Volts AC. This controller can use its soft start, full voltage start, or current limit start mode to start up an induction motor in different applications. The 150-A24NCD controller supports 20 Horsepower of motor output at 575 Volts AC. This controller weighs approximately 10 pounds and has an open enclosure.

150-A35NBD

The 150-A35NBD controller is an Allen-Bradley SMC Plus series controller for squirrel-cage types of induction motors that uses 3-phase AC input. It can control a motor with a Horsepower rating of 25 Hp. Additionally, the 150-A35NBD controller operates with 35 Amps of current and 200-480V AC of line voltage. If the 150-A35NBD controller is controlling a motor with a light load, it can uses its energy saver option to operate efficiently and to save energy.

150-A35NCD

The Allen-Bradley 150-A35NCD solid-state controller from the SMC Plus controller line was designed with an open enclosure and designed to operate at 200-600V AC of line voltage. It can control an induction motor in different types of applications, including applications in packaging machine or extruding systems. The 150-A35NCD controller can also control some resistive loads. It supports motor Horsepower ratings of up to 30 Hp. The 150-A35NCD controller also operates at 35 Amps of current.

150-A360NBD

The 150-A360NBD smart motor controller from the Allen-Bradley SMC Plus series is a squirrel-cage induction motor controller which uses a microprocessor. It is a solid-state type of control device. The 150-A360NBD controller operates with 200-480V AC of 3-phase voltage at 50-60 Hz. It also operates with 360 Amps of current and up to 300 Horsepower of motor output. The 150-A360NBD controller can support several stopping options, but only designated emergency stopping options should be used to stop the controller in an emergency situation.

150-A360NBDA

The Allen-Bradley SMC Plus series 150-A360NBDA motor controller can be used in induction motor-controlling applications and in resistive load-controlling applications. It supports 5 to 300 Horsepower of motor output power. The 150-A360NBDA controller uses 3-phase input voltage and its input range is between 200 and 480V AC at 47 to 63 Hertz. Its enclosure is open. The 150-A360NBDA controller supports a soft stop option for stopping the connected motor gently.

150-A54NBD

The Allen-Bradley SMC Plus series 150-A54NBD motor controller is a smart type of motor controller that can start and stop a motor in different ways in different kinds of applications. This controller operates at 200-480V AC of line voltage and at 1-40 Horsepower of output power. The 150-A54NBD motor controller is compact and it is often used as a controller for induction motors. This controller includes several diagnostics features.

150-A54NCD

The 150-A54NCD smart motor controller, part of the SMC Plus range from Allen-Bradley, employs microcomputer technology to manage motor operations. It can accommodate a maximum current of 54 Amps and an input line voltage of 575 Volts AC with a 60 Hertz frequency. It is essential to note that the 150-A54NCD smart motor controller does not include any protective enclosure or thermal overload feature. At maximum capacity, it can control motors that generate up to 50 Horsepower and 37 kilowatts of output power.

150-A97NBD

The Allen-Bradley SMC Plus series 150-A97NBD smart motor controller supports a soft start option in addition to several other start and stop options for industrial motors. It operates at 208 to 480V AC of rated line voltage. The 150-A97NBD controller has an enclosure which is open and it is a microprocessor-based controller. This controller also has an energy saver feature. The 150-A97NBD controller operates with 97 Amps of current.

150-A97NCD

The Allen Bradley's 150-A97NCD is a solid-state soft starter designed to smooth startup 3-phase AC induction motors up to 75 Hp at 575V, with a rated current of 97A. As a part of Allen Bradley's SMC PLUS™ series, it provides several operation modes and protection features. It is user-configurable via DIP switches, allowing customization of startup voltage ramp time, from 2 to 30 seconds in soft start mode or less than 1/4 seconds for full voltage start mode applications requiring DOL operation.

40888-899-02

The Allen-Bradley SMC Plus series 40888-899-02 control module is a replacement part for smart motor controllers in the SMC Plus product line. It can support 100-240V AC (single-phase) control voltage and 200-600V AC of input voltage. The 40888-899-02 replacement control module supports DIP switches for configuration and it does not have any communication options. This module can support current ratings of up to 1000 Amps and Horsepower ratings of up to 1000 Horsepower.

40888-899-14

The Allen-Bradley 40888-899-14 module is a pump control module from the SMC Plus controller series. It can be used to control a motor in a pump system. The 40888-899-14 module is a solid-state pump control module. It has an enclosure with a low ingress protection rating of IP 20. The 40888-899-14 module is powered by 200 to 480 Volts AC of 3-phase input voltage at 50/60 Hertz.

40888-313-51

The Allen-Bradley SMC Plus series 40888-313-51 control module was designed to be a replacement control module for motor starters in the SMC Plus series. This module can operate at 200 to 600 Volts AC of input voltage and at 100 to 240 Volts AC (1-phase) of control voltage. The 40888-313-51 control module can be configured with DIP switches and it has no communication options. This control module has an internal microprocessor.

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