SMC Flex User Manual

SMC-Flex™
Bulletin 150
User Manual
Important User Information Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that
each application and use meets all performance and safety requirements,
including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in

this guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Allen-Bradley does not assume responsibility or liability (to include
intellectual property liability) for actual use based upon the examples shown
in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,

Installation and Maintenance of Solid-State Control (available from your
local Allen-Bradley office), describes some important differences between
solid-state equipment and electromechanical devices that should be taken
into consideration when applying products such as those described in this
publication.
Reproduction of the contents of this copyrighted publication, in whole or

part, without written permission of Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety

considerations:
Identifies information about practices or circumstances

ATTENTION
that can lead to personal injury or death, property damage
!
or economic loss
Attention statements help you to:
• identify a hazard
• avoid a hazard
• recognize the consequences
IMPORTANT Identifies information that is critical for successful

application and understanding of the product.
Trademark List
Accu-Stop, Allen-Bradley Remote I/O, RSNetworx, PLC, PowerFlex, SLC, SMC, SMC-2, SMC-Flex, SMC PLUS,
SMC Dialog Plus, SMB, and STC are trademarks of Rockwell Automation. ControlNet is a trademark of ControlNet
International, Ltd. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association
(ODVA). Ethernet is a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation.
Modbus is a trademark or registered trademark of Schneider Automation Inc. Profibus is a registered trademark
of Profibus International.
European Communities (EC) If this product has the CE mark it is approved for installation within the
European Union and EEA regions. It has been designed and tested to meet
Directive Compliance the following directives.
EMC Directive
This product is tested to meet the Council Directive 89/336/EC

Electromagnetic Compatibility (EMC) per EN/IEC 60947-4-2.
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 73/23/EEC Low Voltage,

per EN/IEC 60947-4-2.
This equipment is classified as open equipment and must be mounted in an

enclosure during operation to provide safety protection.
Notes
Bulletin 150 SMC-Flex™
Table of Contents
Chapter 1 Other Related Documents .............................................................. 1-1
Product Overview Description .................................................................................... 1-1
Operation ...................................................................................... 1-2
Modes of Operation (Standard) ...................................................... 1-2
Soft Start ................................................................................. 1-2
Selectable Kickstart ................................................................ 1-3
Current Limit Start .................................................................. 1-3
Dual Ramp Start ..................................................................... 1-4
Full Voltage Start .................................................................... 1-4
Preset Slow Speed .................................................................. 1-5
Linear Speed Acceleration ....................................................... 1-6
Soft Stop ................................................................................ 1-7
Control Options .............................................................................. 1-8
Modes of Operation (Pump Control) ............................................... 1-8
Pump Control Option ............................................................... 1-8
Modes of Operation (Braking Control) ............................................ 1-9
SMB Smart Motor Braking Option ........................................ 1-9
Accu-Stop Option .............................................................. 1-10
Slow Speed with Braking Option ........................................... 1-10
Protection and Diagnostics .......................................................... 1-11
Overload ............................................................................... 1-11
Underload ............................................................................. 1-11
Undervoltage ........................................................................ 1-13
Overvoltage .......................................................................... 1-13
Unbalance ............................................................................ 1-13
Stall Protection and Jam Detection ....................................... 1-14
Ground Fault ......................................................................... 1-15
Thermistor/PTC Protection .................................................... 1-16
Excessive Starts/Hour ........................................................... 1-17
Overtemperature .................................................................. 1-18
Open Gate ............................................................................ 1-18
Line Faults ............................................................................ 1-18
Metering ...................................................................................... 1-19
Communication ........................................................................... 1-19
Programming .............................................................................. 1-20
Status Indication .......................................................................... 1-20
ii
Chapter 2 Receiving .......................................................................................2-1

Installation Unpacking ......................................................................................2-1
Inspecting ......................................................................................2-1
Storing ...........................................................................................2-1
General Precautions .......................................................................2-2
Heat Dissipation .............................................................................2-2
Enclosures .....................................................................................2-2
Enclosures ..............................................................................2-3
Mounting .......................................................................................2-4
Dimensions ....................................................................................2-4
Power Factor Correction Capacitors ................................................2-8
Protective Modules .........................................................................2-9
Motor Overload Protection ..............................................................2-9
Two-speed Motors ..................................................................2-9
Multi-motor Protection ............................................................2-9
Electromagnetic Compatibility (EMC) ............................................2-10
Enclosure ..............................................................................2-10
Wiring ...................................................................................2-10
Recommendations ................................................................2-10
Chapter 3 Terminal Locations .........................................................................3-1

Wiring Power Structure .............................................................................3-2
Power Wiring ...........................................................................3-3
Control Power ................................................................................3-4
Control Voltage ........................................................................3-4
Control Wiring .........................................................................3-5
Fan Power ......................................................................................3-5
Fan Terminations ....................................................................3-5
Control Terminal Designations ........................................................3-6
Wiring Diagrams ............................................................................3-7
Standard Controller ..................................................................3-7
Soft Stop, Pump Control, and SMB Smart Motor Braking .......3-21
Preset Slow Speed ................................................................3-25
Slow Speed with Braking .......................................................3-27
Sequence of Operation..................................................................3-28
Soft Stop ...............................................................................3-28
Preset Slow Speed ................................................................3-29
Pump Control ........................................................................3-30
SMB Smart Motor Braking Option ..........................................3-31
Accu-Stop .............................................................................3-32
Slow Speed with Braking .......................................................3-33
ii
Chapter 4 Overview ....................................................................................... 4-1

Programming Keypad Description ........................................................................ 4-1
Programming Menu ....................................................................... 4-1
Password ...................................................................................... 4-5
Parameter Management ................................................................ 4-6
Random Access Memory (RAM) .............................................. 4-6
Read-only Memory (ROM) ....................................................... 4-6
Electrically Erasable Programmable Read-only Memory
(EEPROM) ............................................................................... 4-6
Using Parameter Management with DPI HIM ........................... 4-7
Parameter Modification ................................................................. 4-8
Soft Start ....................................................................................... 4-9
Current Limit Start ......................................................................... 4-9
Dual Ramp Start .......................................................................... 4-10
Full Voltage Start ......................................................................... 4-11
Linear Speed ............................................................................... 4-11
Programming Parameters ............................................................ 4-12
Basic Set Up ................................................................................ 4-15
Motor Protection .......................................................................... 4-16
Example Settings ......................................................................... 4-17
Undervoltage ......................................................................... 4-17
Overvoltage ........................................................................... 4-17
Jam....................................................................................... 4-17
Underload.............................................................................. 4-17

Motor Information Motor Data Entry ........................................................................... 5-1

Metering Viewing Metering Data .................................................................. 6-1

Optional HIM Operation Human Interface Module ............................................................... 7-1
iiiiii
Chapter 8 Overview ........................................................................................8-1

Communications Communication Ports .....................................................................8-1
Human Interface Module ................................................................8-1
Keypad Description .................................................................8-2
Connecting the Human Interface Module to the Controller .......8-3
HIM Control Enable ..................................................................8-4
Control Enable ................................................................................8-6
Loss of Communication and Network Faults ...................................8-6
SMC-Flex Specific Information .......................................................8-6
Default Input/Output Configuration .................................................8-7
Variable Input/Output Configuration ................................................8-7
SMC — Flex Bit Identification ........................................................8-8
Reference/Feedback ......................................................................8-9
Parameter Information ...................................................................8-9
Scale Factors for PLC Communication ............................................8-9
Read Example .........................................................................8-9
Write Example .........................................................................8-9
Display Text Unit Equivalents ..........................................................8-9
Configuring DataLinks ....................................................................8-9
Rules for Using DataLinks ......................................................8-10
Updating Firmware........................................................................8-10
Chapter 9 Overview ........................................................................................9-1

Diagnostics Protection Programming ..........................................................9-1
Fault Display ..................................................................................9-1
Clear Fault .....................................................................................9-2
Fault Buffer ....................................................................................9-2
Fault Codes .............................................................................9-3
Fault and Alarm Auxiliary Contact ...................................................9-3
Fault Definitions .............................................................................9-4
Chapter 10 Introduction ..................................................................................10-1

Troubleshooting Power Module Check ...................................................................10-6
iv
Appendix A Functional Design Specifications ................................................... A-1

Specifications Wiring Diagram ............................................................................. A-2
Electrical Ratings ........................................................................... A-2
Environmental ............................................................................... A-4
Mechanical .................................................................................... A-5
Other ............................................................................................. A-5
Approximate Dimensions and Shipping Weights ............................ A-6
Open Type Controllers ............................................................ A-6
Enclosed Type Line-Connected Controllers ............................. A-6
Enclosed Type Delta-Connected Controllers ............................ A-7
Appendix B
Parameter Information
Appendix C
Renewal Parts
Appendix D
Accessories
Appendix E
Renewal Part Cross Reference
vv
List of Figures
Chapter 1 Figure 1.1 Soft Start ...................................................................1-2
Product Overview Figure 1.2 Selectable Kickstart ...................................................1-3
Figure 1.3 Current Limit Start .....................................................1-3
Figure 1.4 Dual Ramp Start ........................................................1-4
Figure 1.5 Full Voltage Start ......................................................1-4
Figure 1.6 Preset Slow Speed .....................................................1-5
Figure 1.7 Linear Speed Acceleration .........................................1-6
Figure 1.8 Soft Stop ...................................................................1-7
Figure 1.9 Overload Trip Curves .................................................1-9
Figure 1.10 Restart Trip Curves after Auto Reset ..........................1-9
Figure 1.11 Stall Protection ........................................................1-11
Figure 1.12 Jam Detection ➀➁ ....................................................1-11
Figure 1.13 Overload Trip Curves ................................................1-12
Figure 1.14 PTC Sensor Characteristics per IEC-34-11-2 ...........1-14
Figure 1.15 DPI Location ............................................................1-16
Figure 1.16 Built-in Keypad and LCD ..........................................1-17
Figure 1.17 Control Terminals ....................................................1-17
Figure 1.18 Pump Control Option ................................................1-18
Figure 1.19 SMB Smart Motor Braking Option ...........................1-19
Figure 1.20 Accu-Stop Option .....................................................1-20
Figure 1.21 Slow Speed with Braking Option ..............................1-20
Chapter 2 Figure 2.1 Dimensions: 5…85 A Controllers ...............................2-5

Installation Figure 2.2 Dimensions: 108…251 A Controllers .........................2-6
Figure 2.3 Dimensions: 317…480 A Controllers .........................2-7
Figure 2.4 Typical Wiring Diagram for Power Factor Correction
Capacitors .................................................................2-8
Figure 2.5 Typical Wiring Diagram for Power Factor Correction
Capacitors and Contactor ...........................................2-8
Chapter 3 Figure 3.1 Wiring Terminal Locations (5…85 A) .........................3-1

Wiring Figure 3.2 Wiring Terminal Locations (108…480 A) ...................3-2
Figure 3.3 Line Power Wiring diagram ........................................3-3
Figure 3.4 Delta Power Wiring diagram ......................................3-4
Figure 3.5 5…480 A Fan Terminations .......................................3-6
Figure 3.6 SMC-Flex Controller Control Terminals .......................3-7
Figure 3.7 Typical Wiring Diagram for Standard Controller ..........3-8
Figure 3.8 Typical Wiring Diagram for Two-Wire Control with
No Stopping Control (No DPI Control) .........................3-9
Figure 3.9 Typical Wiring Diagram for Two-Wire Control with
Stopping Control ......................................................3-10
vi
Figure 3.10 Typical Wiring Diagram for Dual Ramp

Applications ............................................................ 3-11
Figure 3.11 Typical Wiring Diagram for Start-Stop Control via DPI
Communications ..................................................... 3-12
Figure 3.12 Typical Wiring Diagram for Retrofit Applications ...... 3-13
Figure 3.13 Typical Wiring Diagram for Isolation Applications
(DPI also) ................................................................ 3-14
Figure 3.14 Typical Wiring Diagram for Shunt Trip
Applications ............................................................ 3-15
Figure 3.15 Typical Wiring Diagram for Single-Speed Reversing
Applications ............................................................ 3-16
Figure 3.16 Typical Wiring Diagram for Two-speed
Applications ............................................................ 3-17
Figure 3.17 Typical Wiring Diagram for SMC-Off-Bypass
Control .................................................................... 3-18
Figure 3.18 Typical Wiring Diagram for Hand-Off-Auto (DPI)
Control .................................................................... 3-19
Figure 3.19 Typical Wiring Diagram for Hand-Off-Auto (DPI)
Control .................................................................... 3-20
Figure 3.20 Typical Wiring Diagram ........................................... 3-21
Figure 3.21 Typical Retrofit Wiring Diagram ............................... 3-22
Figure 3.22 Typical Wiring Diagram for Applications Requiring an
Isolation Contactor .................................................. 3-23
Figure 3.23 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control
(Soft Stop, Braking, and Pump Control Only)............ 3-24
Figure 3.24 Typical Wiring Diagram for the Preset Slow
Speed ..................................................................... 3-25
Figure 3.25 Typical Slow Speed Wiring Diagram for Hand-Off-Auto
(DPI) Control ............................................................ 3-26
Figure 3.26 Typical Wiring Diagram for the Slow Speed with
Braking ................................................................... 3-27
Figure 3.27 Soft Stop Sequence of Operation ............................. 3-28
Figure 3.28 Preset Slow Speed Sequence of Operation .............. 3-29
Figure 3.29 Pump Control Sequence of Operation ...................... 3-30
Figure 3.30 SMB Smart Motor Braking Sequence of
Operation ................................................................ 3-31
Figure 3.31 Accu-Stop Sequence of Operation ........................... 3-32
Figure 3.32 Slow Speed with Braking Sequence of Operation .... 3-33
Chapter 4 Figure 4.1 Menu Structure Hierarchy ......................................... 4-2

Programming Figure 4.2 Parameter Menu Structure ........................................ 4-3
Figure 4.3 Memory Block Diagram ............................................. 4-6
viivii
Chapter 8 Figure 8.1 SMC-Flex Controller with Human Interface Module ....8-4
Communications
Chapter 9 Figure 9.1 Fault Display ..............................................................9-1

Diagnostics
Chapter 10 Figure 10.1 Troubleshooting Flowchart .......................................10-2

Troubleshooting
Appendix A Figure A.1 Wiring Diagram ..........................................................A-2
viii
Chapter 1
Product Overview
Other Related Documents • Quick Start — Publication 150-QS001_①-EN-P
• Renewal Part Instructions — 41053-277-01 (5…85 A)
41053-228-01 (108…480 A)
• Selection Guide — Publication 150-SG008_①-EN-P
• Application Guide — Publication 150-AT002_①-EN-P
Description The SMC-Flex™ controller offers a full range of starting modes as

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 (requires
Tach feedback)
• Soft Stop
Other features that offer further user benefit include:
• Expanded protective features
• Metering
• Communication capability
Innovative starting and stopping options provide enhanced
performance:
• Pump Control
• Braking Control
• Smart Motor Braking (SMB™)
• Accu-Stop™
• Slow Speed with Braking
These modes, features, and options are further described in this
chapter.
➀ Latest revision
1-2 Product Overview
Operation The SMC-Flex controller can operate three-phase squirrel-cage

motors rated 1…480 A or wye-delta motors rated 1.8…831 A;
200…480V AC or 200…600V AC; 50/60 Hz. Depending upon the
catalog number ordered, the controller will accept a control power
input of either 100…240V AC or 24V AC/DC. If the control power
input option is 100…240V AC, the controller’s microprocessor will
self-adjust to the input control voltage.
Note that the motor FLA must fall within the range of the SMC-Flex
as specified in the selection guide for proper operation.
Modes of Operation (Standard) Soft Start ①

This mode has the most general application. The motor is given an
initial torque setting, which is user-adjustable from 0…90% of locked
rotor torque. From the initial torque level, the output voltage to the
motor is steplessly increased during the acceleration ramp time. The
acceleration ramp time is user-adjustable from 0…30 seconds. If the
SMC-Flex controller senses that the motor has reached the up-to-
speed condition during the voltage ramp operation, the internal
bypass contactor will be pulled in.
Figure 1.1 Soft Start
Percent
Voltage
100%
Initial
Torque
Start Run
Time (seconds)
➀ Kickstart is also available with Soft Start.

Product Overview 1-3
Selectable Kickstart
This feature provides a boost at startup to break away loads that
require a pulse of high torque to get started. This is intended to
provide a pulse of current that is selectable from 0…90% of locked
rotor torque. Selectable kickstart is user-adjustable from
0.0…2.0 seconds.
Figure 1.2 Selectable Kickstart
Percent
Voltage
100%
Coast-to-rest
Soft Stop
Initial
Torque
Start Run Soft Stop
Time (seconds)
Current Limit Start ➀

This starting mode provides a true current limit start; it is used when
limiting maximum starting current is necessary. The Current Limit
level is user-adjustable from 50…600% of the motor full load ampere
rating; and the current limit time is user-adjustable from 0…30
seconds. If the SMC-Flex controller senses that the motor has reached
the up-to-speed condition during the current limit starting mode, the
internal bypass contactor will be pulled in.
Figure 1.3 Current Limit Start
600%
Percent Full
Load Current
50%
Start
Time (seconds)
➀ Kickstart is also available with Current Limit Start.

Dual Ramp Start ➀

This starting mode is useful on applications that have varying loads
(and therefore varying starting torque requirements). Dual Ramp Start
allows the user to select between two separate Soft Start profiles with
separately adjustable ramp times and initial torque settings.
Figure 1.4 Dual Ramp Start

Percent
Voltage
Ramp #2
100%
Initial Torque
#2
Ramp #1
Initial Torque
#1
Start #1 Run #1
Start #2 Run #2
Time (seconds)
➀ Dual Ramp Start is available only with the standard controller.
Full Voltage Start

This starting mode is used for applications requiring across-the-line
starting. The output voltage to the motor will reach full voltage within
1/4 second.
Figure 1.5 Full Voltage Start
100%
Percent
Voltage
Time (seconds)
Preset Slow Speed

This option can be used in applications that require a slow speed jog
for general purpose positioning. Preset Slow Speed provides either
7% of base speed (low) or 15% of base speed (high) settings in the
forward direction. Reverse can also be programmed and offers 10%
of base speed (low) and 20% of base speed (high) settings.
Figure 1.6 Preset Slow Speed
100%
Motor
Speed
Forward
15% - High
7% - Low
Time (seconds) Start Run

10% - Low
20% - High
Reverse
ATTENTION Slow speed running is not intended for continuous

operation due to reduced motor cooling.
!
Linear Speed Acceleration ➀

The SMC-Flex has the ability to control the motor speed during
starting and stopping maneuvers. A tach input (0…5V DC) is
required to perform this start mode. The start time is selectable from
0…30 seconds and determines the time the motor will ramp from 0
speed to full speed. Kickstart is available with this option.
Figure 1.7 Linear Speed Acceleration
Percent
Speed
100%
Start Run Stop
Time (seconds)
➀ Kickstart is also available with Linear Speed Acceleration.
ATTENTION Linear Stop is not intended to be used as an

emergency stop. Refer to the applicable standards
!
for emergency stop requirements.
The Linear Stop does not need to be set up even if the linear start has
been programmed. The Linear Stop can not brake the motor/load and
reduce the stopping time.
Soft Stop
This option can be used in applications that require an extended coast-
to-rest. The voltage ramp down time is user-adjustable from
0…120 seconds and is adjusted independently from the starting time.
The load will stop when the output voltage drops to a point where the
load torque is greater than the developed motor torque.
Figure 1.8 Soft Stop
Percent
Voltage
100%
Coast-to-rest
Soft Stop
Initial
Torque
Start Run Soft Stop
Time (seconds)
ATTENTION Soft Stop is not intended to be used as an emergency

stop. Refer to the applicable standards for
!
emergency stop requirements.
Control Options The SMC-Flex controller offers the control options described below.
Important: The options listed in this section are mutually exclusive

and must be specified when ordering. An existing
controller may be upgraded to another control option by
replacing the control module. Consult your local
Allen-Bradley distributor.
Modes of Operation Pump Control Option ➀

(Pump Control) This option reduces surges during the starting and stopping of a
centrifugal pump by smoothly accelerating and decelerating the
motor. The microprocessor analyzes the motor variables and
generates commands that control the motor and reduce the possibility
of surges occurring in the system.
The starting time is programmable from 0…30 seconds, and the
stopping time is programmable from 0…120 seconds.
Figure 1.9 Pump Control Option
100%
Motor
Speed
Pump Start Run Pump Stop
Time (seconds)
➀ Kickstart is also available with Pump Control.
ATTENTION Pump stopping is not intended to be used as an

emergency stop. Refer to the applicable standard for
!
ATTENTION Pump stopping may cause motor heating depending

on the mechanical dynamics of the pumping system.
!
Therefore, select the lowest stopping time setting
that will satisfactorily stop the pump.
Modes of Operation SMB Smart Motor Braking Option

(Braking Control) This option can be used in applications that require reduced stopping
times. The SMC-Flex controller incorporates a microprocessor-based
system that applies braking current to a motor without any additional
equipment. This option offers a user-adjustable braking current
setting from 0% to 400% of the motor’s full load current rating.
Further, it provides automatic shut-off at zero speed detection.
Figure 1.10 SMB Smart Motor Braking Option
100%
Smart Motor Braking
Motor
Speed
Coast-to-rest
Start Run Brake

Automatic Zero Speed
Time (seconds)
Shut-off
Note: All braking current settings in the range of 1…100% will

provide 100% braking current to the motor.
ATTENTION SMB Smart Motor Braking is not intended to be used

as an emergency stop. Refer to applicable standards
!
Accu-Stop Option
This option combines the benefits of the SMB Smart Motor Braking
and Preset Slow Speed options. For general purpose positioning, the
Accu-Stop option provides a brake from full speed to the preset slow
speed setting, then brakes to stop.
Figure 1.11 Accu-Stop Option
ATTENTION Accu-Stop and Slow Speed with Braking are not

intended to be used as an emergency stop. Refer to
!
applicable standards for emergency stop
requirements.
Slow Speed with Braking Option

The Slow Speed with Braking option provides a jog speed for process
set-up and braking-to-stop at the end of the cycle.
Figure 1.12 Slow Speed with Braking Option

Protection and Diagnostics The SMC-Flex controller provides the protective and diagnostic
features described below.
Overload
The SMC-Flex controller meets applicable requirements as a motor
overload protective device. Thermal memory provides added
protection and is maintained even when control power is removed.
The built-in overload controls the value stored in Parameter 12, Motor
Thermal Usage; an Overload Fault will occur when this value reaches
100%. The programming parameters below provide application
flexibility and easy setup.
Parameter Range
Overload Class Off, 10, 15, 20, 30
Overload Reset Manual – Auto
Motor FLC 1.0…1000 A
Service Factor 0.01…1.99
Notes: (1) The factory default setting for Overload Class, which is
“Off,” disables overload protection. An overload trip
class and the motor’s full load current rating must be
programmed to enable overload protection.
(2) Automatic reset of an overload fault requires the start
input to be cycled in a 2-wire control scheme.
The trip rating is 117% of the programmed FLC.
Figure 1.13 and Figure 1.14 provide the overload trip curves for the
available trip classes.
Underload ➀
Utilizing the underload protection of the SMC-Flex controller, motor
operation can be halted if a sudden drop in current is sensed.
The SMC-Flex controller provides an adjustable underload trip

setting from 0…99% of the programmed motor full load current
rating. Trip delay time can be adjusted from 0…99 seconds.
➀ Underload protection is disabled during slow speed and braking operations.

Figure 1.13 Overload Trip Curves
Class 10 Class 15 Class 20 Class 30

1000.0 10000.0 10000.0 10000.0
100.0 1000.0 1000.0

1000.0
Approximate Trip Time (seconds)

10.0 100.0 100.0
100.0
1.0 10.0 10.0 10.0
0.1
1.0 1.0 1.0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Multiples of FLC Multiples of FLC Multiples of FLC Multiples of FLC

Approximate trip time
Approximate trip time for
for 3-phase
3-phasebalanced
balanced Approximatetrip
Approximate triptime
timefor
for3-phase
3-phasebalanced
balanced
condition from cold
condition from cold start.
start. condition from
condition from cold
hot start.
start.
Figure 1.14 Restart Trip Curves after Auto Reset

100000
1000
Seconds
100
Class 10
10
Class 15
Class 20
Class 30
1 Auto Reset Times:
Class 10 = 90s
Class 15 = 135s
Class 20 = 180s
Class 30 = 270s
0
100% 1000%
Percent Full Load Current Setting
Undervoltage ➀
Utilizing the undervoltage protection of the SMC-Flex, motor
operation can be halted if a sudden drop in voltage is detected.
The SMC-Flex controller provides an adjustable undervoltage trip

setting from 0…99% of the programmed motor voltage. Trip delay
time can be adjusted from 0…99 seconds.
An alarm (pre-fault) indication level can be programmed to indicate

the unit is getting close to faulting. The alarm modification
information is displayed through the LCD, HIM, Communication (if
applicable) and alarm contact closing.
Overvoltage ➀
Utilizing the overvoltage protection of the SMC-Flex, motor
operation can be halted if a sudden increase in voltage is detected.
The SMC-Flex controller provides an adjustable overvoltage trip

setting from 0…199% of the programmed motor voltage. Trip delay
time can be adjusted from 0…99 seconds.

Unbalance ➀
The SMC-Flex is able to detect an unbalance in line voltages. Motor
operation can be halted if the unbalance is greater than the desired
range.
The SMC-Flex controller provides an adjustable unbalance setting

from 0…25% of the line voltages. Trip delay time can be adjusted
from 0…99 seconds.

➀ Undervoltage, overvoltage, and voltage unbalance protection are disabled during braking operation.
Stall Protection and Jam Detection

The SMC-Flex controller provides both stall protection and jam
detection for enhanced motor and system protection.
• Stall protection is user-adjustable from 0.0…10.0 seconds (in
addition to the ramp time programmed).
Figure 1.15 Stall Protection
600%
Percent
Full
Load
Current
Programmed Start Time Stall

Time (seconds)
• An alarm (pre-fault) indication level can be programmed to

indicate the unit is getting close to faulting. The alarm
modification information is displayed through the LCD, HIM,
Communication (if applicable) and alarm contact closing.
• Jam detection allows the user to determine the jam level (up to
1000% of the motor’s FLC rating) and the delay time (up to
99.0 seconds) for application flexibility.
Figure 1.16 Jam Detection ➀➁
Percent
Full
Load User Programmed Trip Level
Current
100%
Running Jam
Time (seconds)
➀ Jam detection is disabled during slow speed and braking operation.

➁ Unit will self-protect in a jam condition.
Ground Fault
In isolated or high impedance-grounded systems, core-balanced
current sensors are typically used to detect low level ground faults
caused by insulation breakdowns or entry of foreign objects.
Detection of such ground faults can be used to interrupt the system to
prevent further damage, or to alert the appropriate personnel to
perform timely maintenance.
The SMC-Flex’s ground fault detection capabilities consist of

installing a Cat. No. 825-CBCT core balance current transformer for
1…5A core-balanced ground fault protection with the option of
enabling Ground Fault Trip, Ground Fault Alarm, or both.
Figure 1.17
1
1 2
BLACK
WHITE
SHIELD
3 SHIELD
BLACK
WHITE
➀ Customer supplied.
➁ Cat. No. 825-CBCT
Ground Fault Trip

The SMC-Flex will trip with a ground fault indication if:
• No other fault currently exists

• Ground fault protection is enabled
• GF Inhibit Time has expired
• GF Current is equal to or greater than the GF Trip Level for a
time period greater than the GF Trip Delay
Parameter 75, Gnd Flt Inh Time, allows the installer to inhibit a
ground fault trip from occurring during the motor starting sequence
and is adjustable from 0…250 seconds.
Parameter 74, Gnd Flt Delay, allows the installer to define the time
period a ground fault condition must be present before a trip occurs. It
is adjustable from 0.1…25 seconds.
Parameter 73, Gnd Flt Level, allows the installer to define the ground
fault current at which the SMC-Flex will trip. It is adjustable from
1.0…5.0 A.
Important: The ground fault inhibit timer starts after the maximum
phase of load current transitions from 0 A to 30% of the
device’s minimum FLA Setting or the GF Current is
greater than or equal to 0.5 A. The SMC-Flex does not
begin monitoring for a ground fault condition until the
Gnd Flt Inh Time expires.
Ground Fault Alarm

The SMC-Flex will indicate a Ground Fault Alarm if:
• No warning currently exists

• Ground fault alarm is enabled
• GF Inhibit Time has expired
• GF Current is equal to or greater than the Gnd Flt A Lvl
Parameter 77, Gnd Flt A Lvl, allows the installer to define the ground
fault current at which the SMC-Flex will indicate a warning. It is
adjustable from 1.0…5.0 A.
Parameter 78, Gnd Flt A Dly, allows the installer to define the time
period a ground fault alarm condition must be present before a trip
occurs. It is adjustable from 0.1…25 seconds.
Thermistor/PTC Protection
The SMC-Flex provides terminals 23 and 24 for the connection of
positive temperature coefficient (PTC) thermistor sensors. PTC
sensors are commonly embedded in motor stator windings to monitor
the motor winding temperature. When the motor winding temperature
reaches the PTC sensor’s temperature rating, the PTC sensor’s
resistance transitions from a low to high value. Since PTC sensors
react to actual temperature, enhanced motor protection can be
provided to address such conditions as obstructed cooling and high
ambient temperatures.
The following table defines the SMC-Flex PTC thermistor input and
response ratings:
Table 1.A PTC Input Ratings
Response resistance 3400 Ω ±150 Ω

Reset resistance 1600 Ω ±100 Ω
Short-circuit Trip Resistance 25 Ω ±10 Ω
Maximum Voltage at PTC Terminals (RPTC = 4kΩ) < 7.5V
Maximum Voltage at PTC Terminals (RPTC = open) 30V
Maximum Number of Sensors 6
Maximum Cold Resistance of PTC Sensor Chain 1500 Ω
Response Time 800 ms
The following figure illustrates the required PTC sensor
characteristics, per IEC-34-11-2.
Figure 1.18 PTC Sensor Characteristics per IEC-34-11-2

4000
1330
550
250
100
20
10
-20°C TNF-20K TNF+15K
0°C TNF- 5K TNF+ 5K
TNF
PTC Trip
The SMC-Flex will trip with a PTC indication if:
• No other fault currently exists

• PTC protection is enabled
• The resistance across terminals 23 and 24 is either greater than
the relay’s response resistance or less than the short-circuit trip
resistance.
Excessive Starts/Hour
The SMC-Flex controller allows the user to program the allowed
number of starts per hour (up to 99). This helps eliminate motor stress
caused by repeated starting over a short time period.
Overtemperature
The SMC-Flex controller monitors the temperature of the SCRs and
Bypass by using internal thermistors. When the power poles’
maximum rated temperature is reached, the unit will shut down and
restart is inhibited.
An overtemperature condition can indicate inadequate ventilation,

high ambient temperature, overloading, or excessive cycling. After
the temperature is reduced to allowable levels, the fault can be
cleared.
Open Gate
An open gate fault indicates that improper SCR firing, typically
caused by an open SCR gate, has been detected on one of the power
poles. Before the controller shuts down, it will attempt to start the
motor a total of three times.
Line Faults
The SMC-Flex controller continually monitors line conditions for
abnormal factors. Pre-start protection includes:
• Line Fault (with phase indication)
– Line voltage loss
– Missing load connection
– Shorted SCR
Running protection includes:
• Line Fault (no phase indication)
– Line voltage loss
– Missing load connection
Phase Reversal➀ protection can be toggled either On or Off.
➀ Phase Reversal protection is functional only at pre-start.

Metering Power monitoring parameters include:

• Three-phase current
• Three-phase voltage
• Power in kW
• Power usage in kWH
• Power factor
• Motor thermal capacity usage
• Elapsed time
Notes: (1) Voltage measurement is not available during the braking
operation of the SMB Smart Motor Braking, Accu-Stop,
and Slow Speed with Braking control options.
(2) The elapsed time and kWH values are automatically
saved to memory every 12 hours.
(3) Motor thermal capacity usage is determined by the built-
in electronic thermal overload. An overload fault occurs
when this value reaches 100%.
Communication A serial interface port (DPI) is provided as standard, which allows

connection to the Bulletin 20-HIM LCD interface modules.
Figure 1.19 DPI Location
DPI
ATTENTION Two peripheral devices can be connected to the DPI.

The maximum output current through the DPI is 280
!
mA.
Programming Setup is easy with the built-in keypad and three-line, sixteen character
backlit LCD. Parameters are organized in a three-level menu
structure, using a text format for straightforward programming.
Figure 1.20 Built-in Keypad and LCD

Port 5 — DPI
Communications
Port 2
Ports 2 and 3 when two

HIMs are connected with
a splitter
Status Indication Four programmable hard contact outputs are provided as standard:
• The Auxiliary #1 Contact is N.O. programmable for

Normal/Up-to-speed/External Bypass.
• The fault Contact is for fault indication and is programmable for
N.O./N.C.
• The alarm Contact is for alarm indication and is programmable
for N.O./N.C.
• The Auxiliary #2 Contact is for normal indication and is
programmable for N.O./N.C.
Figure 1.21 Control Terminals
11 12 13 14 15 16 17 18 19 20 21 22
Aux #1
SMC-Flex Normal/Up-to-Speed/External Bypass
Control Terminals
23 24 25 26 27 28 29 30 31 32 33 34
PTC TACH Ground Fault Alarm Aux #2

Input Input Fault Contact Contact Normal
Figure 1.22
Chapter 2
Installation
Receiving It is the user’s responsibility to thoroughly inspect the equipment
before accepting the shipment from the freight company. Check the
item(s) received against the purchase order. If any items are damaged,
it is the responsibility of the user not to accept delivery until the
freight agent has noted the damage on the freight bill. Should any
concealed damage be found during unpacking, it is again the
responsibility of the user to notify the freight agent. The shipping
container must be left intact and the freight agent should be requested
to make a visual inspection of the equipment.
Unpacking Remove all packing material, wedges, or braces from within and
around the controller.
Inspecting After unpacking, check the item(s’) nameplate catalog number

against the purchase order.
Storing The controller should remain in its shipping container prior to

installation. If the equipment is not to be used for a period of time, it
must be stored according to the following instructions in order to
maintain warranty coverage.
• Store in a clean, dry location.
• Store within an ambient temperature range of –20°C to +75°C
(–4°F to +167°F).
• Store within a relative humidity range of 0% to 95%,
noncondensing.
• Do not store equipment where it could be exposed to a corrosive
atmosphere.
• Do not store equipment in a construction area.
2-2 Installation
General Precautions In addition to the precautions listed throughout this manual, the
following statements, which are general to the system, must be read
and understood.
ATTENTION The controller contains ESD- (electrostatic

discharge) sensitive parts and assemblies. Static
!
control precautions are required when installing,
testing, servicing, or repairing the assembly.
Component damage may result if ESD control
procedures are not followed. If you are not familiar
with static control procedures, refer to applicable
ESD protection handbooks.
ATTENTION An incorrectly applied or installed controller can

damage components or reduce product life. Wiring
!
or application errors, such as undersizing the motor,
incorrect or inadequate AC supply, or excessive
ambient temperatures, may result in malfunction of
the system.
ATTENTION Only personnel familiar with the controller and

associated machinery should plan or implement the
!
installation, start-up, and subsequent maintenance
of the system. Failure to do this may result in
personal injury and/or equipment damage.
ATTENTION Hazardous voltages that can cause shock, burn, or

death are present on L1, L2, L3, T1, T2, T3, T4, T5,
!
and T6.
Power terminal covers can be installed to prevent

inadvertent contact with terminals. Disconnect the
main power before servicing the motor controller or
associated wiring.
Heat Dissipation The following table provides the maximum heat dissipation at rated
current for the controllers. For currents lower than rated value, heat
dissipation will be reduced.
Table 2.A Maximum Heat Dissipation

SMC Rating 5A 25 A 43 A 60 A 85 A 108 A 135 A 201 A 251 A 317 A 361 A 480 A
Max. Watts 95 95 106 122 155 167 176 200 218 225 245 290
Enclosures The open-style design of the SMC-Flex controller requires that it be

installed in an enclosure. The internal temperature of the enclosure
must be kept within the range of 0…50°C.
Installation 2-3
Enclosures
For Type 12 (IP54) enclosures, the following guidelines are
recommended to limit the maximum controller ambient temperature.
There should be a clearance of at least 15 cm (6 in.) above and below
the controller. This area allows air to flow through the heatsink.
Table 2.B Minimum Enclosure Size
Controller IP65 (Type 4/12)

Rating (A) B Height A Width C Depth
Non-Combination Controller [mm (in.)]
5 610 (24) 406 (16) 229 (9)
25 610 (24) 406 (16) 229 (9)
43 610 (24) 406 (16) 229 (9)
60 610 (24) 406 (16) 229 (9)
85 610 (24) 406 (16) 229 (9)
108 762 (30) 610 (24) 305 (12)
135 965 (38) 762 (30) 356 (14)
201 965 (38) 762 (30) 356 (14)
251 1295 (51) 914 (36) 356 (14)
317 1524 (60) 914 (36) 356 (14)
361 2134 (84) 1016 (40) 457 (18)
480 2286 (90) 1778 (70) 508 (20)
Combination Controllers with Fusible Disconnect
5 610 (24) 406 (16) 229 (9)
25 610 (24) 406 (16) 229 (9)
43 610 (24) 406 (16) 229 (9)
60 610 (24) 406 (16) 229 (9)
85 610 (24) 406 (16) 229 (9)
108 762 (30) 610 (24) 305 (12)
135 762 (30) 610 (24) 305 (12)
201 965 (38) 762 (30) 356 (14)
251 965 (38) 762 (30) 356 (14)
317 1524 (60) 965 (38) 356 (14)
361 1524 (60) 965 (38) 356 (14)
480 ➀ 1524 (60) 965 (38) 356 (14)
480 ➁ 2286 (90) 889 (35) 508 (20)
Combination Controllers with Circuit Breaker
5 610 (24) 406 (16) 229 (9)
25 610 (24) 406 (16) 229 (9)
43 610 (24) 406 (16) 229 (9)
60 610 (24) 406 (16) 229 (9)
85 610 (24) 406 (16) 229 (9)
108 762 (30) 610 (24) 305 (12)
135 762 (30) 610 (24) 305 (12)
201 965 (38) 762 (30) 356 (14)
251 965 (38) 762 (30) 356 (14)
317 1295 (51) 914 (36) 356 (14)
361 1295 (51) 914 (36) 356 (14)
480 1295 (51) 914 (36) 356 (14)
➀ Use this row for 460V -58 and 575V -59.

➁ Use this row for 460V -59 and 575V -60 and -61.
2-4 Installation
Mounting All units are fan cooled. It is important to locate the controller in a
position that allows air to flow vertically through the power module.
The controller must be mounted in a vertical plane and have a
minimum of 15 cm (6 in.) free space above and below the
controller.
Dimensions Figure 2.1 shows the SMC-Flex product dimensions for the 5…85 A
devices. Figure 2.2 shows the dimensions for 108…251 A devices.
Figure 2.3 shows the dimensions for 317…480 A devices.
Installation 2-5
Figure 2.1 Dimensions: 5…85 A Controllers
D
A
A B C Approx.
Unit D E F H
Width Height Depth Ship. Wt.
5…85 A mm 150.1 307 203.1 120 291 119.8 14.1 5.7 kg

Controller
in. 5.91 12.09 8.00 4.72 11.46 4.72 0.56 12.6 lb.
All dimensions are approximate and are not intended for manufacturing purposes. Consult your
local Allen-Bradley distributor for complete dimension drawings.
2-6 Installation
50.8
(2.0)
24.9 13.5
(.980) (.531)
25 48
(.984) (1.890)
M10 X 1.5
#8-32 UNC-2B
DETAIL AA
SCALE 1.000
19.7
(.776) Ø11.5
(.453)
F
6.4
G (.250)
Ø27.5
(1.083)
164.126
(6.46)
SEE DETAIL AA
245.689
(9.67)
E 80
(3.15)
152.749
(6.01)
D
Ø13 40.9
(.513) (1.6)
A
A B C Approx.
Unit D E F G H I
108…251 A mm 225 560 253.8 150 504.1 157.25 91.189 44.311 79.811 30.4 kg
Controller
in. 8.858 22.047 9.992 5.906 19.847 6.2 3.59 1.74 3.14 67 lb.
Installation 2-7

63.5
(2.50)
32.74 17.48
(1.29) (.68)
48
(1.89)
22.5 C
DETAIL BB (.89)
M12 x 1.75 SCALE 1.000
#8-32 UNC-2B
30.5
(1.20) F
Ø12.522
(.49)
6.35
(.25)
G
Ø 27.5
(1.08)
178.938
260.5 (7.04)
(10.26) SEE DETAIL BB
B
80
(3.15)
177.938
(7.01)
I
H
Ø13.022
(.51)
D 40.9
(1.6)
A B C Approx.
Unit D E F G H I
317…480 A mm 290 600 276.5 200 539.18 182.25 104.5 55.5 103.5 45.8 kg
Controller
in. 11.42 23.62 10.89 7.87 21.23 7.18 4.11 2.19 4.07 101 lb.
2-8 Installation
Power Factor The controller can be installed on a system with power factor
Correction Capacitors correction (PFC) capacitors. The capacitors must be located on the
line side of the controller. This must be done to prevent damage to the
SCRs in the SMC-Flex controller.
When discharged, a capacitor essentially has zero impedance. For

switching, sufficient impedance should be connected in series with
the capacitor bank to limit the inrush current. One method for limiting
the surge current is to add inductance in the capacitor’s conductors.
This can be accomplished by creating turns or coils in the power
connections to the capacitors.
• 250V — 15 cm (6 in.) diameter coil, 6 loops

• 480…600V — 15 cm (6 in.) diameter coil, 8 loops
Take care in mounting the coils so that they are not stacked directly
on top of each other; stacking will cause a cancelling effect. Also,
mount the coils on insulated supports away from metal parts so they
will not act as induction heaters. If an isolation contactor is used, put
capacitors in front of contactor.
Note: For further instructions, consult the PFC capacitor vendor.
Figure 2.4 Typical Wiring Diagram for Power Factor Correction Capacitors
L1/1 T1/2
3-Phase
➀
L2/3 T2/4 M
Input Power
L3/5 T3/6
Branch
SMC-Flex
Protection
Controller
➀ ➁
➀ Customer Supplied
➁ Overload protection is included as a
Power Factor
standard feature of the SMC-Flex controller.
Correction Capacitors
➀
Figure 2.5 Typical Wiring Diagram for Power Factor Correction Capacitors
and Contactor
L1/1 T1/2
3-Phase
➀
L2/3 T2/4 M
Input Power
L3/5 T3/6
➂
Branch
SMC-Flex
Protection
Controller
➀ ➁
➀ Customer Supplied
➁ Overload protection is included as a
Power Factor
standard feature of the SMC-Flex controller.
Correction Capacitors
➀ ➂ Energize 1/2 second before start command
to SMC.
Installation 2-9
Protective Modules Protective modules containing metal oxide varistors (MOVs) can be
installed on controllers rated 5…480 A to protect the power
components from electrical transients. The protective modules clip
voltage transients generated on the lines to prevent such surges from
damaging the SCRs.
ATTENTION When installing or inspecting the protective module,

make sure that the controller has been disconnected
!
from the power source. The protective module
should be inspected periodically for damage or
discoloration. Replace if necessary.
Motor Overload Thermal motor overload protection is provided as standard with the
Protection SMC-Flex controller. If the overload trip class is less than the
acceleration time of the motor, nuisance tripping may occur.
ATTENTION Overload protection should be properly coordinated

with the motor.
!
Two applications require special consideration: two-speed motors,
and multi-motor protection.
Two-speed Motors
The SMC-Flex controller has overload protection available for single
speed motors. When the SMC-Flex controller is applied to a two-
speed motor, the Overload Class parameter must be programmed to
OFF and separate overload relays must be provided for each speed.
Multi-motor Protection
If the SMC-Flex controller is controlling more than one motor,
individual overload protection is required for each motor.
2-10 Installation
Electromagnetic Compatibility (EMC)

ATTENTION This product has been designed for Class A
equipment. Use of the product in domestic
!
environments may cause radio interference, in
which case, the installer may need to employ
additional mitigation methods.
The following guidelines are provided for EMC installation

compliance.
Enclosure
Install the product in a grounded metal enclosure.
Wiring
Wire in an industrial control application can be divided into three
groups: power, control, and signal. The following recommendations
for physical separation between these groups is provided to reduce the
coupling effect.
• Different wire groups should cross at 90° inside an enclosure.
• Minimum spacing between different wire groups in the same tray
should be 16 cm (6 in.).
• Wire runs outside an enclosure should be run in conduit or have
shielding/armor with equivalent attenuation.
• Different wire groups should be run in separate conduits.
• Minimum spacing between conduits containing different wire
groups should be 8 cm (3 in.).
• For additional guidelines, please refer to Wiring and Ground
guidelines, publication DRIVES-IN001A-EN-P.
Additional Requirements
• If linear acceleration is used, a separate conduit or wire way
should be used for the tachometer leads.
• Wire earth ground to control terminal 14.
• Use shielded wire for PTC, Tachometer, and ground fault input.
• Terminate shielded wires to terminal 14.
• Ground fault CT must be inside or within 3 m of metal enclosure.
To meet product susceptibility requirements, ferrite cores need to be
added to the communication lines. When using an external HIM (or
DPI interface), a core should be added to the HIM cable near the
SMC-Flex control module. The recommended core is Fair-Rite
no. 0431167281 or equivalent. When using a DeviceNet circuit, two
cores need to be added to the DeviceNet cable near the SMC-Flex
control module. The recommended cores are TDK ZCAT2023 0930H
and TDK ZCAT2035 0930 or equivalent. All cores specified are the
split type cores and can be added to existing connections.
Chapter 3
Wiring
Terminal Locations The SMC-Flex controller wiring terminal locations are shown in
Figure 3.2. Make wiring connections as indicated in the typical
connection diagrams. Incoming three-phase power connections are
made to terminals L1/1, L2/3, and L3/5. Load connections to Line
motors are made to T1/2, T2/4, and T3/6, while load connections to
inside-the-Delta motors are made to T1/2, T2/4, T3/6, T4/8, T5/10,
and T6/12.
Figure 3.1 Wiring Terminal Locations (5…85 A)
➀
3
➀
3 2 3
Table 3.A Wiring Terminal Locations
1 Incoming Line Termination
2 Line Motor Connections
3 Delta Motor Connections
4 Control Terminations
5 Fan Terminations
➀ IP20 protective covers on Delta termination must be removed when connecting in a Delta
configuration.
3-2 Wiring
Figure 3.2 Wiring Terminal Locations (108…480 A)
3 2 3
Table 3.A Wiring Terminal Locations
1 Incoming Line Termination
2 Line Motor Connections
3 Delta Motor Connections
4 Control Terminations
5 Fan Terminations
Power Structure The SMC-Flex product has an integrated mechanical run contactor on
each phase of the motor to minimize heat generation during run time.
These contacts are pulled in sequentially in the 108…480 A units. In
the 5…85 A units, these contacts are pulled in, all at once. The
SMC-Flex product also has a CT, built in on each phase of the motor
to provide current readings.
Wiring 3-3
Power Wiring
The SMC-Flex can be connected to a Line-controlled motor as shown
in Figure 3.3. Current ratings for the motor must be in the range of
1 A…480 A.
Figure 3.3 Line Power Wiring diagram

1/L1 3/L2 5/L3
12/T6 8/T4 10/T5

2/T1 4/T2 6/T3
The SMC-Flex can be connected to a Wye-Delta motor in an inside-

the-Delta wiring configuration as shown in Figure 3.4. Current ratings
for the motor must be in the range of 1.8…831 A.
3-4 Wiring
Figure 3.4 Delta Power Wiring diagram

1/L 3/L2 5/L3
12/T6 2/T1 8/T4 4/T2 10/T5 6/T3
M
3~
Power lugs are available as optional kits. Each kit contains three lugs.
The number of terminal lugs required is listed in the table below.
Table 3.A also provides the lug wire capacity and the tightening
torque requirements.
ATTENTION Terminal covers are available which can make the

product deadfront (IP2X) safe. See Appendix D for
!
the appropriate catalog numbers for ordering.
Table 3.A Lug Wire Capacity and Tightening Torque
SMC Lug Kit Wire Strip Conductor Max. No. Lugs/Pole Tightening Torque
Rating Cat. No. Length Range Line Side Load Side Wire — Lug Lug — Busbar
5…85 A — 18…20 mm 2.5…85 mm2 — — 14.7 N•m —
(#14…3/0 AWG) (130 lb.-in.)
108…135 A 199-LF1 18…20 mm 16…120 mm2 6 6 31 N•m 23 N•m
(Series A) (#6…250 MCM) (275 lb.-in.) (200 lb.-in.)
201…251 A 199-LF1 18…20 mm 16…120 mm2 6 6 31 N•m 23 N•m
(#6…250 MCM) (275 lb.-in.) (200 lb.-in.)
317…480 A 199-LG1 18…25 mm 25…240 mm2 6 6 42 N•m 45 N•m
(#4…500 MCM) (375 lb.-in.) (400 lb.-in.)
Wiring 3-5
Control Power Control Voltage

The SMC-Flex controller will accept a control power input of
100…240V AC, (–15/+10%), 1 phase, 50/60 Hz or 24V AC/DC.
Refer to the product nameplate to verify the control power input
voltage.
Connect control power to the controller at terminals 11 and 12. The
control power requirement for the control module is 75 VA. For
controllers rated 5…480 A, control power is also required for the
heatsink fans as defined in Table 3.C. Depending on the specific
application, additional control circuit transformer VA capacity may
be required.
3-6 Wiring
Control Wiring
Table 3.B provides the control terminal wire capacity, the tightening
torque requirements, and the wire strip length. Each control terminal
will accept a maximum of two wires.
Table 3.B Control Wiring and Tightening Torque
Wire Size Torque Wire Strip Length
0.75…2.5 mm2 (#18…14 AWG) 0.6 N•m (5 lb.-in.) 5.6…8.6 mm (0.22…0.34 in.)
Fan Power Controllers rated 5…480 A have heatsink fan(s). Refer to Table 3.C
for the control power VA requirements of the heatsink fans.
Fan Terminations
See Figure 3.2 for fan power connection locations.
ATTENTION The fan jumpers have been factory installed for 110/
120 VAC input. Refer to Figure 3.5 for 220/240 VAC
!
fan wiring.
Figure 3.5 5…480 A Fan Terminations

Factory Set Optional
110/120 VAC 220/240 VAC
1 1
To To
2 Supply 2 Supply
Jumpers Jumper
3 3
4 4
Table 3.C Heatsink Fan Control Power

SMC Rating Heatsink Fan VA
5…85 A 15
108…480 A 50
Wiring 3-7
Control Terminal Designations As shown in Figure 3.6, the SMC-Flex controller contains 24 control
terminals on the front of the controller.
Figure 3.6 SMC-Flex Controller Control Terminals
Terminal Terminal
Description Description
Number Number
11 Control Power Input ➀ 23 PTC Input ➁
12 Control Power Common ➀ 24 PTC Input ➁
13 Controller Enable Input ➁ 25 Tach Input
14 Control Module Ground 26 Tach Input
15 Option Input #2 ➀➁ 27 Ground Fault Transformer Input ➁
16 Option Input #1 ➀➁ 28 Ground Fault Transformer Input ➁
17 Start Input ➀➁ 29 Fault Contact (N.O./N.C.) ➀
18 Stop Input ➀➁ 30 Fault Contact (N.O./N.C.) ➀
19 N.O. Aux. Contact #1 31 Alarm Contact (N.O./N.C.) ➀
(Normal/Up-to-Speed/External Bypass) ➀➂
20 N.O. Aux. Contact #1 32 Alarm Contact (N.O./N.C.) ➀
(Normal/Up-to-Speed/External Bypass) ➀➂
21 Not Used 33 Aux Contact #2 Normal (N.O./N.C.) ➀
22 Not Used 34 Aux Contact #2 Normal (N.O./N.C.) ➀
➀ RC Snubbers are required on loads connected to auxiliary.

➁ 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.
➂ External Bypass operates an external contactor and overload relay once the motor reaches full
speed. The SMC-FLEX overload functionality, diagnostics and metering are disabled when the
external bypass is activated. Proper sizing of the contactor and overload is required.
3-8 Wiring
Standard Controller Wiring Figure 3.7 through Figure 3.18 show typical wiring for the SMC-Flex
Diagrams controller.
Figure 3.7 Typical Wiring Diagram for Standard Controller
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
Controller
➀ ➀
Stop
➀
Start
➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Control Terminals Aux #1
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➁ Refer to the controller nameplate to verify the rating of the control power input voltage.
Wiring 3-9
Figure 3.8 Typical Wiring Diagram for Two-Wire Control with No Stopping
Control (No DPI Control)
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
Controller
➀ ➀
Two-Wire
Device ➀
➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34
PTC TACH Ground Aux #2

Fault Alarm
Input Input Fault Normal
Contact Contact
Notes: (1) Programmable controller interfacing in this diagram refers to hard-wiring between the
PLC’s output contacts and the SMC-Flex controller’s control terminals.
(2) The OFF state leakage current for a solid-state device must be less than 6 mA.
3-10 Wiring
Figure 3.9 Typical Wiring Diagram for Two-Wire Control with Stopping
Control (No DPI Control)
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
Controller
➀ ➀
Two-Wire
Device ➀
➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Fault Alarm
Contact Contact
Notes: (1) Programmable controller interfacing in this diagram refers to hard-wiring between the
PLC’s output contacts and the SMC-Flex controller’s control terminals.
(2) The OFF state leakage current for a solid-state device must be less than 6 mA.
Wiring 3-11
Figure 3.10 Typical Wiring Diagram for Dual Ramp Applications
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀ Branch ➀ SMC-Flex
Protection Controller
➀ ➀
Stop
Start
Ramp 1 Ramp 2 ➀
➀
➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Fault Alarm
Contact Contact
Note: The Dual Ramp feature is available only with the standard control version.
3-12 Wiring
Figure 3.11 Typical Wiring Diagram for Start-Stop Control via DPI
Communications
Note: Use this wiring diagram when start-stop will come from
either a Bulletin 20-HIM LCD interface module or a
Bulletin 20-COMM communication module connected to the
SMC-Flex.
Note: Logic mask must be properly configured, see Chapter 8.
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
➀ Controller
➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Wiring 3-13
Figure 3.12 Typical Wiring Diagram for Retrofit Applications
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch Existing Motor
SMC-Flex
Protection Starter ➀➁
Controller
➀ ➀
OL ➀
M
➀
Start
Stop ➀
➀
M ➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34
PTC TACH Ground Fault Alarm Aux #2 ➃

➁ Overload protection should be disabled in the SMC-Flex controller.
➂ Refer to the controller nameplate to verify the rating of the control power input voltage.
➃ Aux #2 should be set for N.O.
3-14 Wiring
Figure 3.13 Typical Wiring Diagram for Isolation Applications (DPI also)
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀ Isolation
➀
➀ Branch Contactor SMC-Flex
Protection
(IC) Controller
➀ ➀
IC
➀
Stop
➀
Start
➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex Aux #1
Control Terminals Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➂
Contact Contact
➂ Aux #2 should be set for N.O..
Wiring 3-15
Figure 3.14 Typical Wiring Diagram for Shunt Trip Applications
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
Branch
➀
➀ SMC-Flex
Protection
Controller
➀ ➀
ST
➀
Stop
➀
Start
➀
➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34
➂
➂ Fault Contact should be set to N.O.
3-16 Wiring
Figure 3.15 Typical Wiring Diagram for Single-Speed Reversing Applications
F
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀ Branch R SMC-Flex
Protection
Controller
Reversing Contactors ➀
➀
➀ ➀
OFF ➀
FOR REV
Stop
➀ F➀
R
➀
R
F
➀
R ➀
F
➀
➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex Aux #1
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➁ Refer to the controller nameplate to verify the rating of the control power input rating.
➂ No braking manuever allowed in wiring diagram.
Notes: (1) Minimum transition time for reversing direction is 1/2 second.
(2) Phase Reversal protection must be disabled in reversing applications.
Wiring 3-17
Figure 3.16 Typical Wiring Diagram for Two-speed Applications

Two-Speed Motor Starter ➀
L
L1/1 T1/2
3-Phase H ➁
L2/3 T2/4
Input Power H➁
L3/5 T3/6
M
H
➀ Branch
SMC-Flex
➀
Protection
Controller
➀ ➀
LOL ➀
Stop ➀ Low ➀
High ➀ H➀
HOL ➀
L
L ➀
L➀
H
H
➀
L➀
1 sec.
➀
H
1 sec.
➂
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex Aux #1
Bypass
23 24 25 26 27 28 29 30 31 32 33 34
TACH PTC Ground Fault Alarm Aux #2

➁ Two-speed, consequent pole installations.
➃ Overload must be disabled.
3-18 Wiring
Figure 3.17 Typical Wiring Diagram for SMC-Off-Bypass Control
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀ Branch ➀ SMC-Flex
Protection
Controller
➀
➀
BC
SMC Off Bypass

➀
X Bypass
Connector (BC) ➀
Stop ➀
X
Start ➀
➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34
TACH PTC Ground Aux #2

Fault Alarm
Contact Contact
Wiring 3-19
Figure 3.18 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control with no
Stopping Control
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
Controller
➀ ➀
H A ➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Fault Alarm
Contact Contact
3-20 Wiring
Figure 3.19 Typical Wiring Diagram for Hand-Off-Auto (PLC) Control with
Stopping Control
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
Controller
➀ ➀
H A ➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Fault Alarm
Contact Contact
Wiring 3-21
Soft Stop, Pump Control, and Figure 3.20 through Figure 3.23 show the different wiring for the Soft
SMB Smart Motor Braking Stop, Pump Control, and SMB Smart Motor Braking options.
Figure 3.20 Typical Wiring Diagram
Control Power
➂
Stop
➀
Start
Option Stop ➀
➀➁
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➁ Soft Stop, Pump Stop, or Brake.
Note: Refer to Chapter 3 for typical power circuits.

3-22 Wiring
Figure 3.21 Typical Retrofit Wiring Diagram
Control Power
➂ ➀➁
OL
M
➀
Stop
➀
Start
➀
Option Stop
➀➃
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➄
Contact Contact
➁ Overload protection should be disabled in the SMC-Flex controller.
➃ Soft Stop, Pump Stop, or Brake.
➄ Aux #2 should be set to N.O.

Wiring 3-23
Figure 3.22 Typical Wiring Diagram for Applications Requiring an Isolation

Contactor
Control Power
➁
IC
➀
Stop
➀
Start
Option Stop ➀
➀➂
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Input Input
➃
Fault Contact Contact Normal
➂ Soft Stop, Pump Stop, or Brake.
➃ Aux #2 should be set to N.O.

3-24 Wiring
Figure 3.23 Typical Wiring Diagram for Hand-Off-Auto (DPI) Control (Soft
Stop, Braking, and Pump Control Only)
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch SMC-Flex
Protection
Controller
➀ ➀
Control Power
100-240 VAC
H A ➀
X00
X00
00X
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

Wiring 3-25
Preset Slow Speed Figure 3.24 and Figure 3.25 show the different wiring for the Preset
Slow Speed.
Figure 3.24 Typical Wiring Diagram for the Preset Slow Speed
Control Power
➁
Stop
➀
Option Command Start

➀➂ ➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➁ Refer to the controller nameplate to verify the rating of the control power input voltage
➂ Slow Speed.

3-26 Wiring
Figure 3.25 Typical Slow Speed Wiring Diagram for Hand-Off-Auto (DPI)
Control
L1/1 T1/2
3-Phase
L2/3 T2/4 M
Input Power ➀
L3/5 T3/6
➀
➀ Branch
SMC-Flex
Protection
Controller
➀ ➀
Hand Start
Hand Stop ➀
H A
➀ ➀
Option Command
➀➁
➂
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34

➁ Slow Speed.
Wiring 3-27
Slow Speed with Braking Figure 3.26 shows the wiring for the Slow Speed with Braking option.
Figure 3.26 Typical Wiring Diagram for the Slow Speed with Braking with an
Isolation Contactor
Control Power
➁
IC
➀
Stop
➀
Brake
➀ Start
➀
Slow Speed
➀
11 12 13 14 15 16 17 18 19 20 21 22
SMC-Flex
Normal/Up-to-Speed/
Bypass
23 24 25 26 27 28 29 30 31 32 33 34


3-28 Wiring
Sequence of Operation Figure 3.27 through Figure 3.32 show the different operation
sequences for the Soft Stop, Preset Slow Speed, Pump Control, SMB
Smart Motor Braking, Accu-Stop, and Slow Speed with Braking
options.
Figure 3.27 Soft Stop Sequence of Operation
100%
Coast-to-rest
Soft Stop
Motor
Speed
Start Run Soft Stop
Time (seconds)
Push Buttons
Start
Closed
Open
Stop
Closed
Open
Soft Stop
Closed
Open
Auxiliary Contacts If Soft Stop Selected
Closed
Normal
Open
If Coast-to-rest Selected
Up-to-speed Closed
Open
ATTENTION The user is responsible for determining which

stopping mode is best suited to the application and
!
will meet applicable standards for operator safety on
a particular machine.
Wiring 3-29
Figure 3.28 Preset Slow Speed Sequence of Operation
100%
Coast-to-rest
Soft Stop
Motor
Speed
7 or 15%
Slow Speed Start Run Coast

Time (seconds)
Push Buttons
Start
Closed
Open
Stop
Closed
Open
Slow Speed
Closed
Open
Auxiliary Contacts
Normal Closed
Open
Up-to-speed Closed
Open
3-30 Wiring
Figure 3.29 Pump Control Sequence of Operation
100% Coast-to-rest
Motor
Speed
Pump Start Run Pump Stop
Time (seconds)
Push Buttons
Start
Closed
Open
Stop
Closed
Open
Pump Stop
Closed
Open
Auxiliary Contacts If Pump Stop Selected
Normal Closed
Open
If Coast-to-rest Selected
Up-to-speed Closed
Open

!
Wiring 3-31
Figure 3.30 SMB Smart Motor Braking Sequence of Operation
100%
Smart Motor Braking
Motor Coast-to-rest
Speed
Start Run Brake

Automatic Zero Speed
Time (seconds)
Shut-off
Push Buttons
Start
Closed
Open
Stop
Closed
Open
Smart Motor
Braking Closed
Open
Auxiliary Contacts If Brake Selected

e
Normal Closed
Open
If Coast-to-rest
s Selected
Up-to-speed Closed
Open

!
3-32 Wiring
Figure 3.31 Accu-Stop Sequence of Operation
100 %
Braking
Motor
Speed
Slow Speed
Braking
Coast-to-rest
Slow Speed
Slow Start Run Accu-Stop

Speed
Time (seconds)
Push Buttons
Start
Closed
Open
Stop
Closed
Open
➀ Accu-Stop
Closed
Open
Slow
Auxiliary Contacts Speed
Braking
Normal
If Coast-to-rest
Up-to-speed Selected
➀ When Accu-Stop push button is closed, start/stop function is disabled.

!
Wiring 3-33
Figure 3.32 Slow Speed with Braking Sequence of Operation
100%
Coast-to-Stop
Motor
Speed
Braking
Slow Speed Start Run Brake
Time (seconds)
Push Buttons
Start
Closed
Open
Stop
Closed
Open
Slow Speed
Closed
Open
Brake Closed
Open
Brake
Auxiliary Contacts
Normal Closed
Open
Up-to-speed Closed If Coast-to-rest selected

e
Open

!
will meet applicable standards for operator safety
on a particular machine.
3-34 Wiring
Notes
Chapter 4
Programming
Overview This chapter provides a basic understanding of the programming
keypad built into the SMC-Flex controller. This chapter also
describes programming the controller by modifying the parameters.
Keypad Description The keys found on the front of the SMC-Flex controller are described
below.
Escape Exit a menu, cancel a change to a parameter value, or

Esc acknowledge a fault/alarm.
Lang Select Select a digit, select a bit, or enter edit mode in a

parameter screen.
Sel
Will get to menu to change the language being displayed.
Up/Down Scroll through options increase/decrease a value, or

Arrows toggle a bit.
Enter Enter a menu, enter edit mode in a parameter screen, or

save a change to a parameter value.
Note: For ease of programming values, after using the Enter key to
edit, use the Sel key to jump to the digit that needs to be
modified, then use the arrow keys to scroll through the digits.
Programming Menu Parameters are organized in a three-level menu structure for

straightforward programming. Figure 4.1 details the programming
menu structure and the three-level hierarchy.
In order to change parameters, the controller must be in the STOP

mode, and the control voltage must be present.
4-2 Programming
Figure 4.1 Menu Structure Hierarchy
Power-up and
Status Display
Lang
Esc or Sel or or or
0
Select language
being displayed
OPERATION LEVEL
Choose Mode
➀
MAIN MENU
or
Device Memory
Parameter Select Storage Preferences Diagnostics
➁
Esc
0 0 0 0 0
Monitoring SMC-FLEX Reset to Defaults Change Password Alarms
Set Up Save to EEProm User Dspl Line Faults
Motor Protection Recall EEProm User Dspl Time Device Revision
Communications User Dspl Video
Utility Reset User Display
Linear LIst
➁
Esc
GROUP MENU
Parameter menu
continued in Figure 4.2
➀ The SMC-Flex controller does not support EEPROM, Link, Process, or Start-up modes.
➁ Steps back one level.
Programming 4-3
Figure 4.2 Parameter Menu Structure
➁ ➀➂
Parameter
Parameter
Esc
Motor
Monitoring Set Up Communications Utility Linear List
Protection
Metering Basic Overload Jam Comm Masks Language Linear List

Volts Phase A-B Motor Connection Overload Class Jam F Lvl Logic Mask Language All parameters
Volts Phase B-C Line Voltage Service Factor Jam F Dly Parameter Mgt ➃ Parameter Mgt ➃ Parameter Mgt ➃
Volts Phase C-A Starting Mode Motor FLC Jam A Lvl
Current Phase A Ramp Time Overload Reset Jam A Dly
DataLinks Motor Data
Current Phase B Initial Torque Overload A Lvl Parameter Mgt ➃
Current Phase C Cur Limit Lvl Parameter Mgt ➃ Data In A1 MotorFLC
Watt Meter Kickstart Time Data In A2 Motor ID
Stall
Kilowatt Hours Kickstart Lvl Data In B1 Parameter Mgt ➃
Underload
Elapsed Time Option 2 Input Stall Dly Data In B2
Meter Reset Stop Mode Underload F Lvl Parameter Mgt ➃ Data In C1
Power Factor Stop Time Underload F Dly Data In C2
Mtr Therm Usage Braking Current Underload A Lvl Data In D1
Ground Fault
Overload Class Underload A Dly Data In D2
Service Factor Parameter Mgt ➃ Gnd Flt Enable Data Out A1
Motor FLC Gnd Flt Lvl Data Out A2
Overload Reset Gnd Flt Dly Data Out B1
Undervoltage
Aux1 Config Gnd Flt Inh Time Data Out B2
Fault Contact Undervolt F Lvl Gnd Flt A Enable Data Out C1
Alarm Contact Undervolt F Dly Gnd Flt A Lvl Data Out C2
Aux2 Config Undervolt A Lvl Gnd Flt A Dly Data Out D1
Parameter Mgt ➃ Undervolt A Dly Data Out D2
Parameter Mgt ➃ Parameter Mgt ➃
PTC
Dual Ramp (Option
2 Input == Dual PTC Enable
Overvoltage
Ramp) Parameter Mgt ➃
Starting Mode 2 Overvolt F Lvl
Ramp Time 2 Overvolt F Dly
Phase Reversal
Initial Torque 2 Overvolt A Lvl
Cur Limit Lvl 2 Overvolt A Dly Phase Reversal
Kickstart Time 2 Parameter Mgt ➃ Parameter Mtg ➃
Kickstart Lvl 2
Parameter Mgt ➃
Unbalance Restart
Preset SS (Option 2 Unbalance F Lvl Starts Per Hour
Input = Preset SS) Unbalance F Dly Restart Attempts
Slow Speed Sel Unbalance A Lvl Restart Dly
Slow Speed Dir Unbalance A Dly Parameter Mgt ➃
Slow Speed Acc Parameter Mgt ➃
Slow Running Cur
Parameter Mgt ➃
(Option 2 Input =
Accu-Stop)
Braking Current
Slow Speed Sel
Slow Speed Dir
Slow Accel Cur
Slow Running Cu
Stopping Current
Parameter Mgt
➀ Depending upon SMC option selected, some parameters may not appear in product display.
➁ Steps back one level.
➂ For further information on parameters, see Appendix B.
➃ For further information on parameter management, see page 4-7.
4-4 Programming
Table 4.A Parameter Linear List
Parameter Parameter
Description Description Parameter No. Description
No. No.
1 Volts Phase A-B 40 Slow Speed Dir 79 PTC Enable
2 Volts Phase B-C 41 Slow Accel Cur 80 Phase Reversal
3 Volts Phase C-A 42 Slow Running Cur 81 Starts Per Hour
4 Current Phase A 43 Stopping Current 82 Restart Attempts
5 Current Phase B 44 Overload Class 83 Restart Delay
6 Current Phase C 45 Service Factor 84 Factory Use
7 Watt Meter 46 Motor FLC 85 Factory Use
8 Kilowatt Hours 47 Overload Reset 86 Factory Use
9 Elapsed Time 48 Factory Use 87 Logic Mask
10 Meter Reset 49 Factory Use 88 Data In A1
11 Power Factor 50 Overload A Lvl 89 Data In A2
12 Mtr Therm Usage 51 Underload F Lvl 90 Data In B1
13 Motor Speed 52 Underload F Dly 91 Data In B2
14 SMC Option 53 Underload A Lvl 92 Data In C1
15 Motor Connection 54 Underload A Dly 93 Data In C2
16 Line Voltage 55 Undervolt F Lvl 94 Data In D1
17 Starting Mode 56 Undervolt F Dly 95 Data In D2
18 Ramp Time 57 Undervolt A Lvl 96 Data Out A1
19 Initial Torque 58 Undervolt A Dly 97 Data Out A2
20 Cur Limit Level 59 Overvolt F Lvl 98 Data Out B1
21 Torque Limit 60 Overvolt F Dly 99 Data Out B2
22 Kickstart Time 61 Overvolt A Lvl 100 Data Out C1
23 Kickstart Level 62 Overvolt A Dly 101 Data Out C2
24 Option 2 Input 63 Unbalance F Lvl 102 Data Out D1
25 Starting Mode 2 64 Unbalance F Dly 103 Data Out D2
26 Ramp Time 2 65 Unbalance A Lvl 104 Motor ID
27 Initial Torque 2 66 Unbalance A Dly 105 CT Ratio
28 Cur Limit Level 2 67 Jam F Lvl 106 MV Ratio
29 Torque Limit 2 68 Jam F Dly 107 Aux1 Config
30 Kickstart Time 2 69 Jam A Lvl 108 Fault Contact
31 Kickstart Level2 70 Jam A Dly 109 Alarm Contact
32 Stop Mode 71 Stall Delay 110 Aux2 Config
33 Stop Time 72 Gnd Flt Enable 111 Language
34 Factory Use 73 Gnd Flt Level 112 Factory Use
35 Braking Current 74 Gnd Flt Delay 113 Factory Use
36 Factory Use 75 Gnd Flt Inh Time 114 Factory Use
37 Factory Use 76 Gnd Flt A Enable 115 Parameter Mgmt
38 Factory Use 77 Gnd Flt A Lvl 116 Backspin Timer
39 Slow Speed Sel 78 Gnd Flt A Dly
Programming 4-5
Password The SMC-Flex controller allows the user to limit access to the
programming system through password protection. This feature is
disabled with a factory-set default of 0. To modify the password or
login after a password is programmed, complete the procedure below.
Description Action Display
— — 0.0 Amps
0 Volt
0 %MTU
1. Press the ESC key to go from the Main Menu

Esc Diagnostics
status display to the Main menu. Parameter
2. Scroll with the Up/Down keys until the Main Menu

Preferences
Preferences option is highlighted. Diagnostics
3. Press the Enter key to access the Preferences:

Change Password
Preferences menu. User Dspy lines
4. Scroll with the Up/Down keys until the Preferences:

Change Password option is Change Password
User Dspy lines
highlighted.
5. Press the Enter key.
6. Press the Up/Down keys to enter the Prefs: Password

desired number. If you are modifying New Code: 83
Verify: 83
the password, make a note of it as
displayed. Use the Sel key to highlight
a single digit.
7. Verification of the new password is

required. Press the Enter key.
8. Press the Enter key after you have Preferences:

completed modifying the Change Password
User Dspy lines
password.➀➁
➀ After you have changed your password, go to Parameter Management and Save to User Store.
➁ To complete the programming process, re-enter the Main Menu mode to log out. This will eliminate
unauthorized access to the programming system.
Note: If you lose or forget the password, contact your local

Allen-Bradley distributor.
4-6 Programming
Parameter Management Before you begin programming, it’s important to understand how the
controller memory is:
• structured within the SMC-Flex controller
• used on power-up and during normal operation
Refer to Figure 4.3 and the explanations below.
Figure 4.3 Memory Block Diagram
EEPROM RAM ROM
Esc Sel
Random Access Memory (RAM)

This is the work area of the controller after it is powered up. When
you modify parameters in the Program mode, the new values are
stored in RAM. When power is applied to the controller, parameter
values stored in the EEPROM are copied to RAM. RAM is volatile
and the values stored in this area are lost when the controller
loses power.
Read-only Memory (ROM)

The SMC-Flex controller comes with factory default parameter
values. These settings are stored in non-volatile ROM and are
displayed the first time you enter the Program mode.
Electrically Erasable Programmable Read-only Memory

(EEPROM)
The SMC-Flex controller provides a non-volatile area for storing
user-modified parameter values in the EEPROM.
Programming 4-7
Using Parameter Management with DPI HIM

Memory Storage and Parameter Management perform the same
function of saving programmed settings.
Saving to EEPROM Memory Storage:

To ensure that the newly modified parameters Save EEPROM
Recall EEPROM
are not lost if control power is removed from the
controller, store the values into EEPROM.
Recalling from EEPROM Memory Storage:

Parameters stored in EEPROM can be manually Recall EEPROM
Reset to Defaults
brought to RAM by directing the controller to
recall the values stored in its EEPROM.
Recalling Defaults Memory Storage:

After parameter values have been modified and Reset to Defaults
Save EEPROM
saved to EEPROM, factory default settings can
still be re-initialized.
4-8 Programming
Parameter Modification All parameters are modified using the same method. The basic steps
to performing parameter modification are described below.
Notes: (1) Parameter values modified while the motor is operating
are not valid until the next time that operation occurs.
(2) If the password is set, parameters cannot be adjusted
without logging in.
(3) Use the Sel key to highlight a single digit.
Description Action Display ➁

— — 0.0 Amps
0 Volt
0 %MTU
1. Press the ESC key to go from the —

status display to the Main menu. Esc
2. Scroll with the Up/Down keys Main Menu

until the Parameter option is Parameter
Memory Storage
highlighted.
3. Press the Enter key to access the F GP : File
Monitoring
Parameter menu. Set Up
4. Scroll with the Up/Down keys F GP : File

until the option you want to use Set Up
Motor Protection
(Monitoring, Motor Protection,
etc.) is highlighted. For this
example, Set Up will be used.
5. Press Enter to select the Set Up —
group.
6. Scroll to Basic Set Up and press F GP : Group
Basic Set Up
Enter. ➀
7. Scroll to the Starting Mode F GP : Parameter
Starting Mode
parameter by using the Up/Down Ramp Time
keys, and press Enter.
8. Press Enter to select the option. F GP : P# 17
Scroll to the option of your Starting Mode
Current Lim
choice by using the Up/Down
keys. For this example, we will
choose Current Limit.
9. Press the Enter key to accept the —
new setting.
10. Scroll to the next parameter by F GP : P# 18
using the Down key. Continue Ramp Time
10 Secs
the process until all desired
settings are entered.
11. To save modifications to F GP : P# 115
memory, scroll to Parameter Parameter Mgmt
User Store
Mgmt, press Enter twice and
scroll to User Store. Press the
Enter key again to save the new
settings to EEPROM.
➀ The SMC Option advises the user if any control option (i.e., Pump Control) is resident. This parameter
is factory set and cannot be modified by the user.
➁ The display will indicate that the second line is now active by highlighting the first character. If the
LCD display does not provide a highlighted cursor, then the controller is in the Display mode.
Programming 4-9
Soft Start The following parameters are specifically used to adjust the voltage
ramp supplied to the motor.
Parameter Option
Starting Mode Soft Start

This must be programmed for Soft Start.
Ramp Time ➀ 0…30 s

This programs the time period that the controller will
ramp the output voltage up to full voltage from the
Initial Torque level programmed.
Initial Torque 0…90% locked rotor torque

The initial reduced output voltage level for the
voltage ramp to the motor is established and
adjusted with this parameter.
Kickstart Time 0.0…2.0 s

A boost of current is provided to the motor for the
programmed time period.
Kickstart Level 0…90% locked rotor torque

Adjusts the amount of current applied to the motor
during the kickstart time.
➀ If the controller senses that the motor has reached full speed before completing the Soft Start, it
will automatically switch to providing full voltage to the motor.
Current Limit Start To apply a current limit start to the motor, the following parameters
are provided for user adjustment:
Parameter Option
Starting Mode Current Limit

This must be programmed for Current Limit.
Ramp Time ➀ 0…30 s

hold the fixed, reduced output voltage before
switching to full voltage.
Current Limit Level 50…600% full load current

This parameter provides adjustability for the reduced
output voltage level provided to the motor.

Kickstart Level 0…90% locked rotor torque

Adjusts the amount of current applied to the motor
➀ If the controller senses that the motor has reached full speed before completing the current limit
start, it will automatically switch to providing full voltage to the motor.
4-10 Programming
Dual Ramp Start The SMC-Flex controller provides the user with the ability to select
between two Start settings. The parameters below are available in the
Set Up programming mode. To obtain Dual Ramp control, Ramp #1
is located in the Basic Set Up and Ramp #2 is located in the Option 2
Input (Dual Ramp).
Parameter Option
Set Up —
The user must select the Set Up programming mode to obtain
access to the Dual Ramp parameters.
Basic Set Up/Starting Mode —
Set Up as stated in previous pages.
Option 2 Input (Dual Ramp) ➀ —
This allows the user the option to choose between two Soft Start
profiles defined by:
1. Start Mode/Ramp Time/Initial Torque and
2. Start Mode 2/Ramp Time 2/Initial Torque 2.
When this feature is turned on, the ramp time/initial torque
combination is determined by a hard contact input to terminal 15.
When this input signal is low, ramp time/initial torque are selected.
When this input is high, ramp time 2/initial torque 2 are selected.
Once the Option 2 Input has been set to Dual Ramp, you must ESC
back to the Parameter (File) menu. Re-enter into the Set Up menu to
show both Basic Set Up and Dual Ramp.
Basic Set Up/Start Mode ➁ —
This selects the start mode for option #1.
Basic Set Up/Ramp Time 0…30 s
This programs the time period during which the controller will ramp
the output voltage up to full voltage for the first Start setup.
Basic Set Up/Initial Torque 0…90%
This parameter establishes and adjusts the initial reduced output locked rotor
voltage level for the first Soft Start setup. torque
Dual Ramp/Start Mode 2 ➁ —
This selects the start mode for option #2.
Dual Ramp/Ramp Time 2 0…30 s
This programs the time period during which the controller will ramp
the output voltage up to full voltage for the second Start setup.
Dual Ramp/Initial Torque 2 0…90%
The initial reduced output voltage level for the second Start setup is locked rotor
established and adjusted with this parameter. torque
➀ The Dual Ramp feaure is available on the standard controller.

➁ Kickstart can be programmed for both start modes.
Programming 4-11
Full Voltage Start The SMC-Flex controller may be programmed to provide a full
voltage start (output voltage to the motor reaches full voltage within
1/4 second) with the following programming:
Parameter Option
Starting Mode Full Voltage
This must be programmed for Full Voltage.
Linear Speed The SMC-Flex provides the user the ability to control the motor speed
during starting and stopping maneuvers. A tach input is required as
specified in Linear Speed Acceleration on page 1-6.
Parameter Option
Starting Mode Linear Speed
This must be programmed for Linear Speed.
Ramp Time 0…30 s
ramp from 0 speed to full speed.
Kickstart Level 0…90% locked rotor
Adjusts the amount of current applied to the motor torque
4-12 Programming
Programming Parameters The following table provides the option-specific parameters that are
provided with each control option. These parameters are in addition
to those already discussed in the Basic Set Up and Metering groups.
Diagrams supporting the options described below are shown later in
this chapter.
Option Parameter Range
Standard
Soft Stop SMC Option Standard
This parameter identifies the type of
control present and is not user
programmable.
Soft Stop Time 0…120 s

Allows the user to set the time
period for the soft stopping function.
Preset Slow SMC Option Standard

Speed This parameter identifies the type of
programmable.
Slow Speed Select Low: 7% – forward,

Allows the user to program the slow 10% – reverse
speed that best fits the application. High: 15% – forward,
20% – reverse
Slow Speed Direction Forward, Reverse

This parameter programs the slow
speed motor rotational direction.
Slow Accel Current 0…450% of full load

Allows the user to program the current
required current to accelerate the
motor to slow speed operation.
Slow Running Current 0…450% of full load

required current to operate the
motor at the slow speed setting.
Programming 4-13
Pump Control
Pump Control SMC Option Pump Control
programmable.
Pump Stop Time 0…120 s

Allows the user to set the time
period for the pump stopping
function.
Starting Mode Pump Start, Soft Start,

Allows the user to program the Current Limit Start
SMC-Flex controller for the type of
starting that best fits the application.
Braking Control
SMB Smart SMC Option Braking Control
Motor Braking This parameter identifies the type of
programmable.
Braking Current ➀ 0…400% of full load

intensity of the braking current
applied to the motor.
Accu-Stop SMC Option Braking Control

programmable.
Slow Speed Select Low:7%

Allows the user to program the slow High:15%
speed that best fits the application.



Stopping Current ➀ 0…400% of full load

applied to the motor from slow
speed operation.
4-14 Programming
Slow Speed SMC Option Braking Control

with Braking This parameter identifies the type of
programmable.
Slow Speed Select Low:7%

Allows the user to program the slow High:15%
speed that best fits the application.



➀ All braking/stopping current settings in the range of 1…100% will provide 100% braking current
to the motor.
Programming 4-15
Basic Set Up The Basic Set Up programming group provides a limited parameter
set, allowing quick start-up with minimal adjustment. If the user is
planning to implement some of the advanced features (e.g., Dual
Ramp, or Preset Slow Speed), then the Setup programming group
should be selected. It provides all the Basic Set Up parameter set plus
the advanced set.
Parameter Option
SMC Option Standard
Displays the type of controller. This is factory set and not adjustable.
Motor Connection Line or Delta
Displays the motor type to which the device is being connected.
Line Voltage
Displays the system line voltage to which the unit is connected.
Starting Mode Soft Start, Current
Allows the user to program the SMC-Flex controller for the type of starting that best fits the application. Limit, Full Voltage,
Linear Speed
Ramp Time 0…30 s
This sets the time period during which the controller will ramp the output voltage.
Initial Torque ➀ 0…90% of locked
The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter. rotor torque
Current Limit Level ➁ 50…600% FLC
The current limit level that is applied for the Ramp Time selected.
A boost current is provided to the motor for the programmed time period.
Kickstart Level 0…90% of locked
Adjusts the amount of current applied to the motor during kickstart. rotor torque
Option 2 Input Disable, Preset SS,
Allows the user to select a Dual Ramp or Preset Slow Speed (SS). Dual Ramp
Stop Mode Disable, Soft Stop,
Allows the user to program the SMC-Flex controller for the type of stopping that best fits the application. Linear Speed
Stop Time 0.0…120 s
This sets the time period which the controller will ramp the voltage during a stopping maneuver.
Aux1 Config Normal, Up-to-
N.O. contact is provided as standard with the SMC-Flex controller. This contact is located at terminals 19 and 20. Aux speed, External
Contacts 1 allows the user to configure the operation of the contacts. Bypass
Fault Contact N.O., N.C.
A fault auxiliary contact is provided between terminals 29 and 30. Fault Contact allows the user to program the operation of
the contact for a fault condition.
Alarm Contact N.O., N.C.
An alarm contact is provided between terminals 31 and 32. Alarm contact allows the user to program the operation of the
contact for an Alarm condition.
Aux2 Config N.O., N.C.
This parameter provides the user with the ability to program the “Normal” state of the second auxiliary contact. This
contact is located at terminals 33 and 34.
Parameter Mgmt ➂ Ready, User Store,
The newly programmed parameters’ values can be saved to memory, or the factory default parameter values can be User Recall, Load
recalled. Default
➀ Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter.
➁ Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level
parameter.
➂ The new programmed parameter values will not be stored to the EEPROM without the user’s direction
in Parameter Management: User Store.
4-16 Programming
Motor Protection While the Basic Set Up group allows the user to get started with a
minimum number of parameters to modify, the Motor Protection
group allows full access to the SMC-Flex controller’s powerful
parameter set. Following is a listing of the additional setup parameters
provided.
Note: The majority of parameters have a Fault and an Alarm
setting.
Parameter Option
Overload Trip Class, Service Factor, Motor FLC, Overload Reset,
Allows the user to select the operation of the overload: Overload Alarm Level
Underload ➁ Underload Fault Level, Underload Fault Delay, Underload
Determines the trip level as a percentage of the motor’s FLA, and the delay Alarm Level, Underload Alarm Delay
period.
Undervoltage ➀ Undervoltage Fault Level, Undervoltage Fault Delay,
Determines the trip level as a percentage of the line voltage and the delay period. Undervoltage Alarm Level, Undervoltage Alarm Delay
Overvoltage ➀ Overvoltage Fault Level, Overvoltage Fault Delay,
Determines the trip level as a percentage of line voltage and delay period. Overvoltage Alarm Level, Overvoltage Alarm Delay
Unbalance ➀ Unbalance Fault Level, Unbalance Fault Delay, Unbalance
Allows the user to set the current unbalance trip level and delay period. Alarm Level, Unbalance Alarm Delay
Jam ➁ Jam Fault Level, Jam Fault Delay, Jam Alarm Level, Jam
Determines the trip level as a percentage of motor full load current and delay period. Alarm Delay
Stall Stall Delay
Allows the user to set the stall delay time.
Ground Fault ➂ Ground Fault Enable, Ground Fault Level, Ground Fault
Allows the user to enable the ground fault level in amps, delay time, and inhibit Delay, Ground Fault Inhibit Time, Ground Fault Alarm Enable,
time. A separate 825-CBCT is required. Ground Fault Alarm Level, Ground Fault Alarm Delay
Motor PTC ➃ PTC Enable
Allows the user to connect a PTC to the SMC and enable a fault when it becomes
active.
Phase Reversal Phase Reversal
Determines the proper orientation of line connections to the SMC. If Enabled and
phases are out of sequence, a fault will be indicated.
Restarts Restarts Per Hour, Restart Attempts, Restart Delay
Allows the user to determine the maximum number of restarts per hour the unit
can experience, and delay time between consecutive starts.
➀ The delay time must be set to a value greater than zero when Undervoltage, Overvoltage, and
Unbalance are enabled.
➁ For Jam and Underload detection to function, the Motor FLC must be programmed in the Motor
Protection group. See Chapter 5 for instructions.
➂ See details in Ground Fault on page 1-15.
➃ See details in Thermistor/PTC Protection on page 1-16.
Programming 4-17
Example Settings Undervoltage ➀

With Line Voltage programmed for 480V and the Undervoltage level
programmed for 80%, the trip value is 384V.
Overvoltage ➀
With Line Voltage programmed for 240V and the Overvoltage level
programmed for 115%, the trip value is 276V.
Jam ➁➂
With Motor FLC programmed for 150 A and the Jam level
programmed for 400%, the trip value is 600 A.
Underload ➁
With Motor FLC programmed for 90 A and the Underload level
programmed for 60%, the trip value is 54 A.
➀ The average value of the three phase-to-phase voltages is utilized.

➁ The largest value of the three phase currents is utilized.
➂ Will self-protect.
Chapter 5
Motor Information
Overview The Basic Set Up and Overload programming group allows the user
to set parameters indicating to the controller the motor that is
connected. It is important to correctly input the data to achieve the
best performance from your controller.
ATTENTION For overload protection, it is critical that the data be

entered as it appears on the motor nameplate.
!
Motor Data Entry In the Program mode, enter the correct values into the Overload
group:
Parameter Option Display

Overload Class ➁➂ Disable, 10, F GP : P# 44
The factory default setting disables 15, 20, 30 Overload Class
Class ##
overload protection. To enable it, enter
the desired trip class in this parameter.
Service Factor ➁➂ 0.01…1.99 F GP : P# 45
Enter the value from the motor’s Service Factor
#.##
nameplate.
Motor FLC ➀➁➂ 1.0…1000 A F GP : P# 46
Enter the value from the motor’s Motor FLC
###.# Amps
nameplate.
Overload Reset ➁➂ Manual, Auto F GP : P# 47
Allows the user to select either a manual Overload Reset
Manual
or auto reset after an overload fault.
Motor Connection ➂ Line, Delta F GP : P# 15
Enter the type of motor being connected Motor Connection
Line
to the SMC-Flex; Line or Delta
Line Voltage ➀➂ 1…10,000V F GP : P# 16
Enter the system voltage in this Line Voltage
### Volt
parameter. This must be done to ensure
optimum motor performance and correct
operation of undervoltage and
overvoltage protection.
➀ Refer to the SMC-Flex controller nameplate for maximum ratings. Exceeding these could result in
damage to the controller.
➁ Found in Overload programming group. Only one location needs to be programmed.
➂ Found in Basic Set Up programming group.
Chapter 6
Metering
Overview While the SMC-Flex controller operates your motor, it also monitors
several different parameters, providing a full function metering①
package.
Viewing Metering Data To access the metering information, follow the procedure below.
— — ##.# Amps
### Volt
## %MTU
Main Menu
Esc Parameter
1. Press any of the following keys to Memory Storage
access the Main Menu.
2. Scroll with the Up/Down keys until Main Menu

Parameter
the Parameter option is shown. Memory Storage
3. Press the Enter key to select the —

Parameter option.
4. Scroll with the Up/Down keys until F GP : File

Monitoring
the Monitoring option is displayed. Set Up
5. Press the Enter key to access the —

Monitoring group.
6. Press the Enter key to access the F GP : Group

Metering
Metering group.
➀ Refer to Metering on page 1-19 or Figure 4.2 on page 4-3 for details on the metering functions.
6-2 Metering
7. Scroll through the Metering F GP : P# 1

parameters with the Up/Down keys to Volts Phase A-B
### Volt
access the desired information. Press
F GP : P# 2
the Enter key to view that parameter. Volts Phase B-C
### Volt
F GP : P# 3
Volts Phase C-A
### Volt
F GP : P# 4
Current Phase A
##.# Amps
F GP : P# 5
Current Phase B
##.# Amps
F GP : P# 6
Current Phase C
##.# Amps
F GP : P# 7
Watt Meter
##.# KW
F GP : P# 8
Kilowatt Hours
##.# KWH
F GP : P# 9
Elapsed Time
##.# Hour
F GP : P# 10
Meter Reset
No
F GP : P# 11
Power Factor
##.#
F GP : P# 12
Mtr Therm Usage
## %MTU
Chapter 7
Optional HIM Operation
Overview The SMC-Flex controller offers a variety of unique control options
that provide enhanced motor starting and stopping capabilities. (See
chapter 1 for brief descriptions of each option.)
Note: Only one option can reside in a controller.
Human Interface Module The control buttons available with the Bulletin 20-HIM LCD Human
interface modules are compatible with the SMC-Flex controller’s
control options. The following table details the functionality of each
button with regards to each option.
Notes: (1) The logic mask port must be enabled prior to initiating
control commands to the SMC-Flex controller. Refer to HIM
Control Enable on page 8-4 for instructions.
(2) The control terminals must be wired according to
Figure 3.11 on page 3-12 or Figure 3.18 on page 3-19.
Option Action Operation
Standard
Soft Stop The green start button, when pressed, will
Current Limit I commence motor acceleration to full speed.
Full Voltage
Linear Speed The red stop button, when pressed, will
O provide a coast stop, and/or reset a fault.
The jog button, when pressed, will initiate the

Jog programmed maneuver.
Preset Slow The green start button, when pressed, will

Speed I commence motor acceleration to full speed.
The red stop button, when pressed, will

O provide a coast stop and/or reset a fault.
The jog button is not active for Preset Slow

Jog Speed.
* Slow Speed cannot be operated via the HIM.
7-2 Optional HIM Operation
Option Action Operation
Pump Control
Pump Control The green start button, when pressed, will
I commence motor acceleration to full speed.

The jog button, when pressed, will initiate a

Jog pump stop maneuver.
Braking Control
Smart Motor Braking The green start button, when pressed, will

The jog button, when pressed, will initiate a

Jog brake stop.
Accu-Stop The green start button, when pressed, will


With a “stopped” status, the jog button,

Jog when pressed, will initiate slow speed motor
operation. From an “at speed” condition, the
jog button, when pressed, will initiate
braking to slow speed operation. The
controller will maintain slow speed operation
as long as the jog button is pressed.
Slow Speed with The green start button, when pressed, will
Braking I commence motor acceleration to full speed.

The jog button will initiate a brake stop.

Jog * Slow Speed cannot be operated via the
HIM.
ATTENTION The Bulletin 20-HIM LCD Human interface

module’s stop push button is not intended to be used
!
as an emergency stop. Refer to applicable standards
Chapter 8
Communications
Overview The SMC-Flex provides advanced communications capabilities that
allow it to be started and stopped from multiple sources as well as
provide diagnostic information through the use of communication
interfaces. The SMC-Flex uses the DPI method of communication,
therefore all standard DPI communication interfaces used by other
devices (i.e., PowerFlex Drives) can be used in the SMC-Flex.
Standard DPI communications cards are available for various

protocols including DeviceNet, ControlNet, Remote I/O, ModBus,
and Profibus DP. Other modules may be available in the future. For
specific programming examples, configuration, or programming
information, refer to the user manual for the communication interface
being used. A list of available interfaces is located below.
Table 8.A
Protocol Type Cat. No. User Manual
DeviceNet 20-COMM-D 20COMM-UM002➊-EN-P

ControlNet 20-COMM-C 20COMM-UM003➊-EN-P
Remote I/O 20-COMM-R 20COMM-UM004➊-EN-P
Profibus 20-COMM-P 20COMM-UM006➊-EN-P
RS-485 20-COMM-S 20COMM-UM005➊-EN-P
InterBus 20-COMM-I 20COMM-UM007➊-EN-P
EtherNet/IP 20-COMM-E 20COMM-UM010➊-EN-P
➊ Denotes revision level of user manual. Example: Publication 20COMM-UM002C-EN-P is at

revision C.
Communication Ports The SMC supports three DPI ports for communication. Ports 2 and 3
are supported through the serial connection on the side of the device
and are typically used to interface with a Human Interface Module
(HIM). Port 2 is the default connection with port 3 available by
installing a splitter on port 2. Port 5 is supported by connecting one of
the modules listed above to the internal DPI comm card connection.
Human Interface Module The SMC-FLEX controller can be programmed with the built-in
keypad and LCD display or with the optional Bulletin 20-HIM LCD
human interface modules. Parameters are organized in a three-level
menu structure and divided into programming groups.
8-2 Communications
Keypad Description
The functions of each programming key are described below.
Table 8.B Keypad Descriptions

Escape Exit a menu, cancel a change to a parameter value, or
Esc acknowledge a fault/alarm.
Select Select a digit, select a bit, or enter edit mode in a

Sel parameter screen.
Up/Down Scroll through options increase/decrease a value, or

Arrows toggle a bit.
Enter Enter a menu, enter edit mode in a parameter screen,

or save a change to a parameter value.
Note: If a human interface module is disconnected from the

SMC-Flex controller while the Logic Mask is set to 1, a
“Coms Loss” will occur.
Note: For ease of programming values, after using the Enter key to
edit, use the Sel key to jump to the digit that needs to be
modified, then use the arrow keys to scroll through the digits.
The Bulletin 20-HIM LCD interface modules may be used to

program and control the SMC-Flex controller. The human interface
modules have two sections: a display panel and a control panel. The
display panel duplicates the 3-line, 16-character backlit LCD display
and programming keypad found on front of the SMC-Flex controller.
Refer to Chapter 4 for a description of the programming keys; refer to
Appendix D for a listing of human interface module catalog numbers
that are compatible with the controller.
Note: Bulletin 20-HIM Rev3.002 or later must be utilized with the

SMC-Flex.
Note: Extension cables are available up to a maximum of 10 m in

total length.
Note: A maximum of two HIM modules can be installed.

Communications 8-3
The control panel provides the operator interface to the controller.
Start
The green start button, when pressed, will begin motor
I operation. (Proper setup of the HIM port is required.)
Stop
The red stop button, when pressed, will halt motor
O
operation and/or reset a fault.
Jog
Jog
The jog button is active only when a control option is
present. Pressing the jog button will initiate the option
maneuver (for example: Pump Stop).
ATTENTION The Bulletin 20-HIM interface module’s stop push

button is not intended to be used as an emergency
!
stop. Refer to the applicable standards for
ATTENTION The external HIM has a similar programming

operation to the built-in programmer, but note that
!
differences do exist.
All other controls available with the various human interface modules
are non-functional with the SMC-Flex controller.
8-4 Communications
Connecting the Human Interface Module to the Controller

Figure 8.1 shows the connection of the SMC-Flex controller to a
human interface module. Table 8.C provides a description of each
port.
See Figure 3.11 on page 3-12 for the control wiring diagram that
enables start-stop control from a human interface module.
Figure 8.1 SMC-Flex Controller with Human Interface Module

Port 5 — DPI
Communications
Port 2
Ports 2 and 3 when two

HIMs are connected with
a splitter
Table 8.C Description of Ports
Port # Description
1 Unused — not available for use
2 First 20-HIM connected to SMC-Flex
3 Second 20-HIM connected to SMC-Flex
5 DPI Communication Board port
HIM Control Enable

To enable motor control from a connected human interface module,
follow the procedure below with the connected human interface
module’s programming keys.
The Bulletin 20-HIM LCD human interface modules with control

panels can start and stop the SMC-FLEX controller. However, the
factory default settings disable control commands other than Stop
through the serial communication port.
To enable motor control from a connected human interface module or

communication module, you must take the following programming
steps:
Communications 8-5
Series A
1. Disconnect the HIM and allow to power down.
2. Reconnect the HIM. On Initializing screen, the bottom right cor-
ner of LCD shows Port X. Note this port number.
3. Go to Logic Mask, found as follows:

Main Menu: Parameter/Communications/Comm Mask/Logic
Mask
4. Set b0X equal to 1 (where X is the port number noted in step 2).
5. Go to Parameter Management and save as User Store.
Important: The Logic Mask must be set to 0 prior to disconnecting
a human interface module from the SMC-FLEX
controller. If not, the unit will fault on a “Coms Loss”.
If enabling control from the built-in SMC-Flex programmer, the

Logic Mask must be set as follows:
Table 8.D Logic Mask Requirements
Mask Code Description

0 No external DPI devices are enabled
8-6 Communications
4 Only one HIM on port 2 is enabled

12 Two HIMs are enabled on ports 2 and 3
32 Only the DPI communication cared on port 5 is enabled
36 One HIM on port 2 and the DPI communication card on port 5 in
enabled
44 Two HIMs on ports 2 and 3 and the DPI communication card on
port 5 is enabled
Control Enable The Logic Mask parameter (Parameter 87) allows the user to
configure whether a communication device (HIM or network
connection) can perform control commands such as starting. Each
communication port can be enabled or disabled as required. When a
given device is enabled through the logic mask that device is allowed
to execute control commands. In addition, disconnecting any device
with the logic mask enabled will result in a communication fault
unless the communication fault is disabled. When a given device is
disabled through the logic mask that device cannot execute control
commands, but can still be used for monitoring. A device that is
disabled through the logic mask can be disconnected without causing
a fault.
IMPORTANT Stop commands override all start commands and can

be initiated from the hardwired inputs or any port
regardless of the logic mask.
Loss of Communication and The loss of communication fault will follow the functionality as
Network Faults defined in the DPI specification. There will be separate faults for each
device. Since three DPI ports are supported there will be three faults
that can be generated.
DPI provides a separate network fault for each port. This fault can be
generated directly by the peripheral and is separate from the
Communications Loss fault (which is actually generated by the
SMC-Flex itself).
SMC-Flex Specific Information The SMC is can be used with all LCD applicable DPI interface.
Regardless of the type of interface being used, the information below
can be used to configure the rest of the system.
Communications 8-7
Default Input/Output Configuration The default configuration for I/O is 4 bytes in and 4 bytes out (TX =
4 bytes, RX = 4 bytes) and is arranged according to the following
table.
Table 8.E
Produced Data (Status) Consumed Data (Control)
Word 0 Logic Status Logic Command
Word 1 Feedback ➊ Reference ➋
➊ The feedback word is always Current in Phase A

➋ The reference word is not used with the SMC-Flex, however the space must be reseverd
Variable Input/Output The SMC-Flex supports 16-bit DataLinks. Therefore, the device can
Configuration be configured to return additional information. The I/O message size
depends on how many DataLinks are enabled. The following table
summarizes the I/O data sizes.
Table 8.F
Logic Status/ Reference/ DataLinks

Rx Tx
Command FeedBack
Size Size A B C D
(16-bit) (16-bit)
4 4 x x
8 8 x x x
12 12 x x x x
16 16 x x x x x
20 20 x x x x x x
To configure DataLinks, refer to Configuring DataLinks on page 8-9.

8-8 Communications
SMC — Flex Bit Identification
Table 8.G Logic Status Word
Bit #
Status Description
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
X Enabled 1 — Control Power Applied
0 — No Control Power
X Running 1 — Power Applied to Motor
0 — Power not Applied to Motor
X Phasing 1 — ABC Phasing
0 — CBA Phasing
X Phasing 1 — 3-phase is valid
Active 0 — No valid 3-phase detected
X Starting 1 — Performing a Start Maneuver
(Accel) 0 — Not Performing a Start Maneuver
X Stopping 1 — Performing a Stop Maneuver
(Decel) 0 — Not Performing a Stop Maneuver
X Alarm 1 — Alarm Present
0 — No Alarm Present
X Fault 1 — Fault Condition Exists
0 — No Fault Condition
X At Speed 1 — Full Voltage Applied
0 — Not Full Voltage Applied
X Start/ 1 — Start/Isolation Contactor Enabled
Isolation 0 — Start/Isolation Contactor Disabled
X Bypass 1 — Bypass Contactor Enabled
0 — Bypass Contactor Disabled
X Ready 1 — Ready
0 — Not Ready
— — Bits 12…15 — Not Used
Table 8.H Logic Command Word (Control)
Bit #
Status Description
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
X Stop 1 — Stop/Inhibit
0 — No Action
X Start 1 — Start
0 — No Action
X Option #1 1 — Stop Maneuver/Inhibit
Input 0 — No Action
X Clear 1 — Clear Faults
Faults 0 — No Action
X Option #2 1 — Perform Option 2 function
Input 0 — No Action
— — Bits 5…15 — Not Used
Communications 8-9
Reference/Feedback The SMC-Flex does not offer the analog Reference feature. The
analog Feedback feature is supported and will provide Parameter 1,
Current in Phase A, automatically as the feedback word.
Parameter Information A complete listing of the SMC-Flex parameters is located in

Appendix B.
Scale Factors for PLC The parameter values stored and produced by the SMC-Flex through
Communication communication are unscaled numbers. When reading or writing
values from a PLC image table, it is important to apply the proper
scaling factor, which is based on the number of decimal places.
Read Example
Parameter 11; Power Factor — The stored value is 85. Since this
value has two decimal places, the value should be divided by 100.
The correctly read value is 0.85.
Write Example
Parameter 46; Motor FLC — The value which is to be written to
the SMC is 75 A. Since this value has one decimal place, the value
should be multiplied by 10. The correctly written value is 750.
Display Text Unit Equivalents Some parameters have text descriptions when viewed from a HIM or
through a communication software program such as RSNetworx.
When receiving or sending information from a PLC each text
description has a numerical equivalent. Table 8.I has an example of
Parameter 44, Overload Class, and the appropriate relationship
between the text descriptor and the equivalent value. This relationship
is identical for other similar parameters located in Appendix B.
Table 8.I
Text Descriptor Numerical Equivalent
Disabled 0
Class 10 1
Class 15 2
Class 20 3
Class 30 4
Configuring DataLinks DataLinks are supported in the SMC-Flex. A DataLink is a

mechanism used by most drives to transfer data to and from the
controller without using an Explicit Message. The SMC-Flex
supports 16-bit DataLinks, therefore the device can be configured to
return up to four additional pieces of information without the need for
an explicit message.
8-10 Communications
Rules for Using DataLinks

• Each set of DataLink parameters in an SMC-Flex can be used by
only one adapter. If more than one adapter is connected, multiple
adapters must not try to use the same DataLink.
• Parameter settings in the SMC determine the data passed through
the DataLink mechanism.
• When you use a DataLink to change a value, the value is not
written to the Non-Volatile Storage (NVS). The value is stored in
volatile memory and lost when the drive loses power.
Parameters 88…103 are used to configure the DataLinks. For
additional information regarding DataLinks, refer to the user manual
for the communication interface being used.
Note: Node addressing of the DPI communication card can be

programmed via software or a hand-held DPI HIM. The on-
board HIM cannot be used to address the communication
card.
Updating Firmware The latest version of firmware and instructions for the SMC-Flex can
be obtained from www.ab.com.
Chapter 9
Diagnostics
Overview This chapter describes the fault diagnostics of the SMC-Flex
controller. Further, this section describes the conditions that cause
various faults to occur.
Protection Programming
Many of the protective features available with the SMC-Flex
controller can be enabled and adjusted through the programming
parameters provided. For further details on programming, refer to the
Motor Protection section in Chapter 4, Programming.
Fault Display The SMC-Flex controller comes equipped with a built-in three-line,
16-character LCD. The LCD displays the unit has faulted on the first
line, the fault number on the second line, and the fault code on the
third line.
Figure 9.1 Fault Display
Faulted
Fault # 1
Line Loss A
Note: The fault display will remain active as long as control power
is applied. If control power is cycled, the fault will be cleared,
the controller will re-initialize, and the display will show a
status of “Stopped.”
Note: You can hit Esc to get to another programming/diagnostic

list, but the SMC-Flex will still be in a faulted state.
Important: Resetting a fault will not correct the cause of the fault
condition. Corrective action must be taken before
resetting the fault.
9-2 Diagnostics
Clear Fault You can clear a fault using any of several methods:
• Program the SMC-Flex controller for a Clear Fault, which can be
found in Main Menu/Diagnostics/Faults.
• If a human interface module is connected to the controller, press
the Stop button.
Note: A stop signal from HIM will always stop the motor and clear
the fault regardless of Logic Mask.
• Cycle control power to the SMC-Flex controller.

Important: An overload fault cannot be reset until the Motor
Thermal Usage, parameter 12, value is below 75%. See
Protection and Diagnostics on page 1-11 for further
details.
Fault Buffer The SMC-Flex controller stores in memory the five most recent
faults. Display the fault buffer by selecting the View Faults Queue
and scrolling through the fault buffer parameters. The information is
stored as fault codes and fault descriptions. A fault code cross-
reference is provided in Table 9.A.
Diagnostics 9-3
Fault Codes
Table 9.A provides a complete cross-reference of the available fault
codes and corresponding fault descriptions.
Table 9.A Fault Code Cross-reference
Fault Code Fault Code
Line Loss A 1 Jam 24
Line Loss B 2 Stall 25
Line Loss C 3 Phase Reversal 26
Shorted SCR A 4 Coms Loss P2 27
Shorted SCR B 5 Coms Loss P3 28
Shorted SCR C 6 Coms Loss P5 29
Open Gate A 7 Network P2 30
Open Gate B 8 Network P3 31
Open Gate C 9 Network P5 32
PTC Pwr Pole 10 Ground Fault 33
SCR Overtemp 11 Excess Starts 34
Motor PTC 12 Power Loss A 35
Open Bypass A 13 Power Loss B 36
Open Bypass B 14 Power Loss C 37
Open Bypass C 15 Hall ID 38
No Load A 16 NVS Error 39
No Load B 17 No Load 40
No Load C 18 Line Loss A 41 ➀
Line Imbalance 19 Line Loss B 42 ➀
Overvoltage 20 Line Loss C 43 ➀
Undervoltage 21 V24 Loss 45
Overload 22 V Control Loss 46
Underload 23 System Faults 128…209
➀ See Table 9.B for definition.
Fault and Alarm Auxiliary Contact The fault and alarm auxiliary contacts are located at terminals 29/30
and 31/32 respectively. These contacts can be programmed as either
N.O. or N.C. Parameter setup can be found in the Parameter/Motor
Protection group when modifying parameters in the Program Mode.
9-4 Diagnostics
Fault Definitions Table 9.B shows the fault definitions for the SMC-Flex.
Table 9.B Fault Definitions

Fault Description
Line Loss F1, F2, F3 The SMC-Flex can determine if a line connection has been lost, and will indicate this accordingly.
Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the SMC-Flex.
Open Gate Open gate indicates that an abnormal condition that causes faulty firing (e.g., open SCR gate) has been sensed during
the start sequence. The SMC-Flex controller will attempt to start the motor a total of three times before the controller
shuts down.
Power Pole PTC and SCR The power pole temperature in each phase is monitored. If the temperature rises above the predetermined level, the
Overtemperature unit will fault to protect the power pole. A reset can be performed once the temperature falls below this level.
Motor PTC A motor PTC can be connected to terminals 23 and 24. If the PTC parameter is enabled and the PTC trips, the
SMC-Flex will trip and indicate a Motor PTC fault.
Open Bypass Power pole bypass contacts are monitored for proper operation. In the event that a contact closure is not sensed, the
SMC-Flex will indicate an Open Bypass fault.
No Load The SMC-Flex can determine if a load connection has been lost, and No Load fault will be indicated.
Line Unbalance ➀ Voltage unbalance is detected by monitoring the three phase supply voltages. The formula used to calculate the
percentage voltage unbalance is as follows:
Vu = 100 (Vd / Va)
Vu: Percent voltage unbalance
Vd: Maximum voltage deviation from the average voltage
Va: Average voltage
The controller will shut down when the calculated voltage unbalance reaches the user-programmed trip percentages.
Overvoltage and Overvoltage and undervoltage protection are user-defined as a percentage of the programmed line voltage. The
Undervoltage Protection ➀ SMC-Flex controller continuously monitors the three supply phases. The calculated average is then compared to the
programmed trip level.
Underload ➁ Underload protection is available for undercurrent monitoring. The controller will shut down when the motor current
drops below the trip level. This trip level, a percentage of the motor’s full load current rating, can be programmed.
Overload Protection Overload protection is enabled in the Motor Protection group by programming the:
• Overload class
• Overload reset
• Motor FLC
• Service factor
• Refer to Chapter 5 for more information on Motor Protection.
Phase Reversal Phase reversal is indicated when the incoming power to the SMC-Flex controller is in any sequence other than ABC.
This pre-start protective feature can be disabled.
Coms Loss The SMC-Flex controller disables control through the DPI communication port as the factory default. To enable control,
the Logic Mask found in the Communication programming group must be set to “4.”
If a Bulletin 20-HIM LCD Human interface module is disconnected from the SMC-Flex controller when control is
enabled, a Comm Fault will occur.
Network Network faults are faults generated on the network external to the SMC-Flex, and are annunciated on the LCD display.
Ground Fault Ground faults are based on feedback from the user supplied 825 CT detecting ground fault currents. Ground fault
parameters of level and time delay must be programmed for proper operation.
Excess Starts/Hour Excess starts/hour is displayed when the number of starts in a one hour period exceeds the value programmed.
Power Loss Power loss indicates that an input power phase is not present. The controller’s LCD display will identify the missing
phase.
If all three phases are absent when a start command is issued, the LCD will display “Starting” without motor rotation.
Line Loss F41, F42, F43 During expected SCR gate periods, the power pole voltage and currents are monitored. If the SCR conduction is
discontinuous, a fault is indicated.
➀ Phase loss, overvoltage, and undervoltage protection are disabled during braking operation.
➁ Jam detection and underload protection are disabled during slow speed and braking operation.
Chapter 10
Troubleshooting
Introduction For safety of maintenance personnel as well as others who might be
exposed to electrical hazards associated with maintenance activities,
follow the local safety related work practices (for example, the NFPA
70E, Part II in the United States). Maintenance personnel must be
trained in the safety practices, procedures, and requirements that
pertain to their respective job assignments.
ATTENTION Hazardous voltage is present in the motor circuit

even when the SMC-Flex controller is off. To avoid
!
shock hazard, disconnect main power before
working on the controller, motor, and control
devices such as Start-Stop push buttons. Procedures
that require parts of the equipment to be energized
during troubleshooting, testing, etc., must be
performed by properly qualified personnel, using
appropriate local safety work practices and
precautionary measures.
ATTENTION Disconnect the controller from the motor before

measuring insulation resistance (IR) of the motor
!
windings. Voltages used for insulation resistance
testing can cause SCR failure. Do not make any
measurements on the controller with an IR tester
(megger).
Note: The time it takes for the motor to come up to speed may be
more or less than the time programmed, depending on the
frictional and inertial characteristics of the connected load.
Note: Depending on the application, the Braking options (SMB

Motor Braking, Accu-Stop, and Slow Speed) may cause
some vibration or noise during the stopping cycle. This may
be minimized by lowering the braking current adjustment. If
this is a concern in your application, please consult the
factory before implementing these options.
10-2 Troubleshooting
The following flowchart is provided to aid in quick troubleshooting.
Figure 10.1 Troubleshooting Flowchart
YES
Fault Displayed?
NO
Define Nature
of Trouble
Motor will not start — Motor rotates

but does not Motor stops while Miscellaneous
no output voltage to
accelerate to full running situations
motor
speed
See See See See See

See10.A
Table See
Table 10.B See10.C
Table See10.D
Table See10.E
Table
Table 10.A
on page Table 10.B
on page Table 10.C
on page Table 10.D
on page Table 10.E
on page
10-3 10-4 10-4 10-4 10-5
Table 10.A SMC Fault Display Explanation
Display Fault Code Possible Causes Possible Solutions

Line Loss ➀ 1, 2, 3 • Missing supply phase • Check for open line (i.e., blown fuse)
(with phase • Motor not connected properly • Check for open load lead
indication) • Consult the factory
Shorted SCR 4, 5, & 6 • Shorted Power Module • Check for shorted SCR, replace power module if
necessary
Open Gate 7, 8, & 9 • Open gate circuitry • Perform resistance check; replace power module if
(with phase necessary
indication) • Loose gate lead • Check gate lead connections to the control module
PTC Power Pole 10 & 11 • Controller ventilation blocked • Check for proper ventilation
• Controller duty cycle exceeded • Check application duty cycle
• Fan failure • Replace fan
• Ambient temperature limit exceeded • Wait for controller to cool or provide external cooling
SCR Overtemp • Failed thermistor • Replace power module
• Failed control module • Replace control module
Motor PTC 12 • Motor ventilation blocked • Check for proper ventilation
• Motor duty cycle exceeded • Check application duty cycle
• Wait for motor to cool or provide external cooling
• PTC open or shorted • Check resistance of PTC
Troubleshooting 10-3
Table 10.A SMC Fault Display Explanation (Continued)
Display Fault Code Possible Causes Possible Solutions

Open Bypass 13, 14, & 15 • Control voltage is low • Check control voltage power supply
• Inoperable power module bypass • Replace power module
• Check control module TB2…TB4 and TB5…TB7 for
secureness
• Check Aux 1 configuration is not set to External
Bypass
No Load 16, 17, 18, & • Loss of load side power wiring • Check all load side power connections and motor
40 windings
Line Unbalance 19 • Supply unbalance is greater than the • Check power system and correct if necessary
user-programmed value • Extend the delay time to match the application
• The delay time is too short for the requirements
application
Overvoltage 20 • Supply voltage is greater than user- • Check power system and correct if necessary
programmed value • Correct the user-programmed value
Undervoltage 21 • Supply voltage is less than user- • Check power system and correct if necessary
programmed value • Correct the user-programmed value
• The delay time is too short for the • Extend the delay time to match the application
application requirements
Overload 22 • Motor overloaded • Check motor overload condition
• Overload parameters are not matched • Check programmed values for overload class and
to the motor motor FLC
Underload 23 • Broken motor shaft • Repair or replace motor
• Broken belts, toolbits, etc. • Check machine
• Pump cavitation • Check pump system
Jam 24 • Motor current has exceeded the user • Correct source of jam
programmed jam level. • Check programmed time value
Stall 25 • Motor has not reached full speed by • Correct source of stall
the end of the programmed ramp time
Phase Reversal 26 • Incoming supply voltage is not in the • Check power wiring
expected ABC sequence
Coms Loss 27, 28, & 29 • Communication disconnection at the • Check for a communication cable disconnection to
serial port the SMC-Flex controller
Network 30, 31, & 32 • DPI network loss • Reconnect for each DPI connected device
Ground Fault 33 • Ground fault current level has • Check power system and motor; correct if
exceeded programmed value necessary
• Check programmed ground fault levels to match
application requirements
Excess Starts/Hr. 34 • Number of starts in a one hour period • Wait an appropriate amount of time to restart
has exceeded the value programmed • Turn off the Starts/Hr. feature
Power Loss ➀ 35, 36, • Missing supply phase (as indicated) • Check for open line (i.e., blown line fuse)
(with phase & 37
indication)
Hall ID 38 • Incorrect power module has been • Check power module and replace
installed
NVS Error 39 • Data entry error • Check user data and perform a User Store function
• Replace control module
Line Loss 41, 42, 43 • Line distortion • Check supply voltage for capability to start/stop
• High impedance connection motor
• Check for loose connections on line side or motor
side of power wires
➀ Prestart fault indication.

Table 10.B Motor Will Not Start — No Output Voltage to the Motor
Display Possible Cause Possible Solutions

Fault displayed • See fault description • See Table 10.A
addressing fault
conditions
Display is blank • Control voltage is • Check control wiring and
absent correct if necessary
• Cycle control power
Stopped • Pilot devices • Check wiring
0.0 Amps • SMC Enable input is • Check wiring
open at terminal 13
• Input terminals are not • Check wiring
wired correctly
• Start-Stop control has • Follow the instructions on
not been enabled for page 8-4…8-5 to enable
the human interface control capability
module
• Control voltage • Check control voltage
Starting • Two or three power • Check power system
phases are missing
Table 10.C Motor Rotates (but does not accelerate to full speed)

addressing fault
conditions
Starting • Mechanical problems • Check for binding or
external loading and
correct
• Check motor
• Inadequate Current • Adjust the Current Limit
Limit setting Level to a higher setting
Table 10.D Motor Stops While Running

addressing fault
conditions
Display is blank • Control voltage is • Check control wiring and
absent correct if necessary
Stopped • Pilot devices • Check control wiring and
0.0 Amps correct if necessary
Starting • Two or three power • Check power system
phases are missing
Troubleshooting 10-5
Table 10.E Miscellaneous Situations
Situation Possible Cause Possible Solutions

Motor current and • Motor • Verify type of motor as a standard
voltage fluctuates squirrel cage induction motor
with steady load • Erratic Load • Check load conditions
Erratic operation • Loose • Shut off all power to controller and
connections check for loose connections
Accelerates too fast • Starting time • Increase starting time
• Initial torque • Lower initial torque setting
• Current limit • Decrease current limit setting
setting
• Kickstart • Lower kickstart time or turn off
Accelerates too • Starting time • Decrease starting time
slow • Initial torque • Increase initial torque setting
• Current limit • Increase current limit setting
setting
• Kickstart • Increase kickstart time or turn off
Fan does not • Wiring • Check wiring and correct if
operate necessary
• Failed fan(s) • Replace fan module
Motor stops too • Time setting • Verify the programmed stopping
quickly with time and correct if necessary
Soft Stop option
Motor stops too • Stopping time • Verify the programmed stopping
slowly with setting time and correct if necessary
Soft Stop option • Misapplication • The Soft Stop option is intended to
extend the stopping time for loads
that stop suddenly when power is
removed from the motor.
Fluid surges with • Misapplication • Soft Stop ramps voltage down over
pumps still occur a set period of time. In the case of
with the Soft Stop pumps, the voltage may drop too
option rapidly to prevent surges. A closed
loop system such as Pump Control
would be more appropriately
suited.
• Refer to Publication 150-911
Motor overheats • Duty cycle • Preset Slow Speed and Accu-Stop
options: Extended operation at slow
speeds reduces motor cooling
efficiency. Consult motor
manufacturer for motor limitations.
• Smart Motor Braking option:
Check duty cycle. Consult motor
manufacturer for motor limitations.
Motor short circuit • Winding fault • Identify fault and correct.
• Check for shorted SCR; replace if
necessary.
• Ensure power terminals are secure.
Power Module Check If a power module needs to be checked, use the applicable procedure
that follows.
ATTENTION To avoid shock hazard, disconnect main power

before working on the controller, motor, or control
!
devices such as Start/Stop push buttons.
ATTENTION Make sure that wires are properly marked and

programmed parameter values are recorded.
!
Shorted SCR Test
1. Using an ohmmeter, measure the resistance between the line and
load terminals of each phase on the controller. (L1-T1, L2-T2, &
L3-T3)
The resistance should be greater than 10,000 ohms.
Appendix A
Specifications
Functional Design Specifications
Standard Features
Installation Power Wiring Standard squirrel-cage induction motor or a Wye-Delta, six-lead motor.
Control Wiring 2- and 3-wire control for a wide variety of applications.
Setup Keypad Front keypad and backlit LCD display.
Software Parameter values can be downloaded to the SMC-Flex Controller with DriveTools
programming software and the Cat. No. 20-COMM… DPI communication module.
Communications One DPI provided for connection to optional human interface and communication modules.
Starting Modes • Soft Start
• Current Limit Start
• Dual Ramp
• Full Voltage
• Linear Speed Acceleration
• Preset Slow Speed
• Soft Stop
Protection and Diagnostics Power loss, line fault, voltage unbalance, excessive starts/hour, phase reversal, undervoltage,
overvoltage, controller temp, stall, jam, open gate, overload, underload, communication fault.
Metering A, V, kW, kWH, elapsed time, power factor, motor thermal capacity usage.
Alarm Contact Overload, underload, undervoltage, overvoltage, unbalance, jam, stall, and ground fault
Status Indication Stopped, starting, stopping, at speed, alarm, and fault.
Auxiliary Contacts Contact programmable as normal/up-to-speed/external bypass; one programmable for fault,
one programmable for alarm, and one programmable for N.O./N.C. normal.
Optional Features
Pump Control Helps reduce fluid surges in centrifugal pumping systems during starting and stopping period.
Starting time is adjustable from 0…30 seconds. Stopping time is adjustable from 0…120
seconds.
Braking Control SMB Smart Motor Braking Provides motor braking without additional equipment for applications that require the motor to
stop quickly. Braking current is adjustable from 0…400% of the motor’s full load current
rating.
Accu-Stop Provides controlled position stopping. During stopping, braking torque is applied to the motor
until it reaches preset slow speed (7% or 15% of rated speed) and holds the motor at this
speed until a stop command is given. Braking torque is then applied until the motor reaches
zero speed.
Braking current is programmable from 0…450% of full load current.
Slow Speed with Braking Used on applications that require slow speed (in the forward direction) for positioning or
alignment and also require braking control to stop.
A-2 Specifications
Wiring Diagram Figure A.1 Wiring Diagram
L1/1 T1/2
3-Phase
L2/3 T2/4 M
➀
Input Power
L3/5 T3/6
SMC-Flex Controller
➀
➀ Branch
Protection
➀ ➀
➀
Fan
Stop ➀
Option Input #1 ➀
Start
Option Input #2 ➀ ➀
11 12 13 14 15 16 17 18 19 20 21 22
}
SMC-Flex
Control Terminals Aux #1 Not Used
Normal/Up-to-Speed/External Bypass
Internal
Auxillary
23 24 25 26 27 28 29 30 31 32 33 34
Contacts
}
}
}

Electrical Ratings
UL/CSA/NEMA IEC
Power Circuit
Rated Operation Voltage 200…480V AC 200…415V
200…600V AC 200…500V
(–15%, +10%)
Rated Insulation Voltage N/A 500V
Rated Impulse Voltage N/A 6000V
Dielectric Withstand 2200V AC 2500V
Repetitive Peak Inverse Voltage Rating 200…480V AC: 200…415V: 1400V
1400V 200…500V: 1600V
200…600V AC:
1600V
Operating Frequency 50/60 Hz 50/60 Hz
Utilization Category MG 1 AC-53B:3.0-50:1750
Protection Against Electrical Shock N/A IP00 (open device)/
Optional IP20
DV/DT Protection RC Snubber Network
Transient Protection Metal Oxide Varistors:
220 Joules
Specifications A-3
UL/CSA/NEMA IEC
Short Circuit Protection
SCPD Performance Type 1
SCPD List Max. Max. Max. Max.
Available Fuse Available Circuit
Fault (A) Fault Breaker (A)
Line Device Operational Current 5 10 kA 35 10 kA 35
Rating (A) 25 10 kA 150 10 kA 150
43 10 kA 300 10 kA 300
60 10 kA 400 10 kA 300
85 10 kA 400 10 kA 400
108 30 kA 400 30 kA 300
135 30 kA 500 30 kA 400
201 30 kA 600 30 kA 600
251 30 kA 700 30 kA 700
317 42 kA 800 30 kA 800
361 42 kA 1000 30 kA 1000
480 42 kA 1200 30 kA 1200
Delta Device Operational Current 8.7 10 kA 35 10 kA 35
Rating (A) 43 10 kA 150 10 kA 150
74 10 kA 300 10 kA 300
104 10 kA 400 10 kA 300
147 10 kA 400 10 kA 400
187 30 kA 500 30 kA 500
234 30 kA 700 30 kA 700
348 30 kA 1000 30 kA 1000
435 42 kA 1200 30 kA 1200
549 42 kA 1600 30 kA 1600
625 42 kA 1600 30 kA 1600
831 42 kA 1600 30 kA 1600
Control Circuit
Rated Operational Voltage 100…240V AC 100…240V
24V AC/24V DC 24V ~/24V DC
Rated Insulation Voltage N/A 240V
Rated Impulse Voltage N/A 3000V
Dielectric Withstand 1600V AC 2000V
Operating Frequency 50/60 Hz 50/60 Hz
Protection Against Electric Shock N/A IP20
Power Requirements
Control Module 75 VA
Heatsink Fan(s) (A) ➀ 50 VA
Vibration
Operational 1G
Non-Operational 2.5 G
➀ For devices rated 5…480 A, heatsink fans can be powered by either 110/120V AC or 220/240V AC.
A-4 Specifications
UL/CSA/NEMA IEC
Steady State Heat Dissipation (W)
Controller Rating (A) 5 95
25 95
43 106
60 122
85 155
108 167
135 176
201 200
251 218
317 225
361 245
480 290
Auxiliary Contacts
• 19/20 (Normal/Up-to-Speed/External Bypass) • 31/32 (Alarm)
• 29/30 (Fault) • 33/34 (Normal)
Type of Control Circuit Electromagnetic relay
Number of Contacts 1
Type of Contacts N.O.
Type of Current AC
Rated Operational Current 3 A @ 120V AC, 1.5 A @ 240V AC
Conventional Thermal Current Ith 5A
Make/Break VA 3600/360
Utilization Category AC-15
PTC Input Ratings
Response Resistance 3400 Ω ±150 Ω
Reset Resistance 1600 Ω ±100 Ω
Short-Circuit Trip Resistance 25 Ω ±10 Ω
Max. Voltage at PTC Terminals (RPTC = 4 k) < 7.5V
Max. Voltage at PTC Terminals (RPTC = open) 30V
Max. No. of Sensors 6
Max. Cold Resistance of PTC Sensor Chain 1500 Ω
Response Time 800 ms
Tach Input 0…5V DC. 4.5V DC = 100% Speed
Environmental
Operating Temperature Range 0…50°C (32…122°F) (open)
0…40°C (32…104°F) (enclosed)
Storage and Transportation Temperature –20…+75°C
Range
Altitude 2000 m (6560 ft)
Humidity 5…95% (non-condensing)
Pollution Degree 2
Specifications A-5
Mechanical
Resistance to Operational 1.0 G Peak,
Vibration 0.15 mm (0.006 in.) displacement
Non-Operational 2.5 G,
0.38 mm (0.015 in.) displacement
Resistance to Operational 5.5 G
Shock Non-Operational 25 G
Construction Power Poles 5…85 A Heatsink thyristor modular design
108…480 A Heatsink hockey puck thyristor modular
design
Control Modules Thermoset and Thermoplastic Moldings
Metal Parts Plated Brass, Copper, or Painted Steel
Terminals Power 5…85 A Cable size — 2.5…85 mm2
Terminals (#14…3/0 AWG)
Tightening torque — 14.7 N•m
(130 lb.-in.)
Wire strip length — 18…20 mm
(0.22…0.34 in.)
108…251 A Two M10 x 1.5 diameter holes per
power pole
317…480 A Two M12 x 1.5 diameter holes per
power pole
Power Terminal Markings NEMA, CENELEC EN50 012
Control Terminals M 3 screw clamp:
clamping yoke connection
Other
EMC Emission Conducted Radio Frequency Class A
Levels Emissions
Radiated Emissions Class A
EMC Immunity Electrostatic Discharge 8 kV Air Discharge
Levels Radio Frequency Per EN/IEC 60947-4-2
Electromagnetic Field
Fast Transient Per EN/IEC 60947-4-2
Surge Transient Per EN/IEC 60947-4-2
Overload Current Range Line Delta
Characteristics 5 1…5 1.7…9
25 5…25 8.6…43
43 8.6…43 14.8…75
60 12…60 20.8…104
85 17…85 29.4…147
108 54…108 94…187
135 68…135 117…234
201 100…201 174…348
251 125…251 218…435
317 158…317 275…549
361 180…361 313…625
480 240…480 415…831
Trip Classes 10, 15, 20, and 30
Trip Current Rating 117% of Motor FLC
Number of Poles 3
Approvals Open Type Controllers CE Marked Per Low Voltage Directive
73/23/EEC, 93/68/EEC
UL Listed (File No. E96956)
CSA Certified (Class No. 3211-06)
A-6 Specifications
Approximate Dimensions and Open Type Controllers

Shipping Weights Dimensions are in millimeters (inches). Dimensions are not intended
for manufacturing purposes.
Controller
Height Width Depth Weight
Rating (A)
5…85 321 150 203 5.7 kg
(12.6) (5.9) (8.0) (12.6 lb.)
108…251 560 225 253.8 30.4 kg
(22.05) (8.86) (9.99) (67 lb.)
317…480 600 290 276.5 45.8 kg
(23.62) (11.42) (10.89) (101 lb.)
Enclosed Type Line-Connected Controllers

Factory-installed options may affect enclosure size requirements.
Exact dimensions can be obtained after order entry. Consult your

local Allen-Bradley distributor.
A C
IP65 (Type 4/12)

Controller
Rating (A) Disconnect Rating
B Height A Width C Depth
(A)
Non-Combination Controller
5 — 610 (24) 406 (16) 229 (9)
25 — 610 (24) 406 (16) 229 (9)
43 — 610 (24) 406 (16) 229 (9)
60 — 610 (24) 406 (16) 229 (9)
85 — 610 (24) 406 (16) 229 (9)
108 — 762 (30) 610 (24) 305 (12)
135 — 762 (30) 610 (24) 305 (12)
201 — 965 (38) 762 (30) 356 (14)
251 — 965 (38) 762 (30) 356 (14)
317 — 1295 (51) 914 (36) 356 (14)
361 — 1295 (51) 914 (36) 356 (14)
480 — 1295 (51) 914 (36) 356 (14)
Specifications A-7
IP65 (Type 4/12)

Controller
Rating (A) Disconnect Rating
B Height A Width C Depth
(A)
Combination Controllers with Fusible Disconnect
5 30 A/J 610 (24) 406 (16) 229 (9)
25 30 A/J 610 (24) 406 (16) 229 (9)
43 60 A/J 610 (24) 406 (16) 229 (9)
60 100 A/J 610 (24) 406 (16) 229 (9)
85 100 A/J 610 (24) 406 (16) 229 (9)
108 200 A/J 965 (38) 762 (30) 356 (14)
135 200 A/J 965 (38) 762 (30) 356 (14)
201 400 A/J 965 (38) 762 (30) 356 (14)
251 400 A/J 965 (38) 762 (30) 356 (14)
317 600 A/J 1524 (60) 965 (38) 356 (14)
361 600 A/J 1524 (60) 965 (38) 356 (14)
480 ➀ 600 A/J 1524 (60) 965 (38) 356 (14)
480 ➁ 800 A/J 2286 (90) 508 (20) 508 (20)
Combination Controllers with Circuit Breaker
5 15 A 610 (24) 406 (16) 229 (9)
25 30 A 610 (24) 406 (16) 229 (9)
43 80 A 610 (24) 406 (16) 229 (9)
60 100 A 610 (24) 406 (16) 229 (9)
85 125 A 610 (24) 406 (16) 229 (9)
108 175 A/175 A Plug 965 (38) 762 (30) 356 (14)
135 225 A/225 A Plug 965 (38) 762 (30) 356 (14)
201 300 A/300 A Plug 965 (38) 762 (30) 356 (14)
251 400 A/400 A Plug 965 (38) 762 (30) 356 (14)
317 600 A/600 A Plug 1295 (51) 914 (36) 356 (14)
361 600 A/600 A Plug 1295 (51) 914 (36) 356 (14)
480 800 A/800 A Plug 1295 (51) 914 (36) 356 (14)
➀ Use this row for 460V -58 and 575V -59.
➁ Use this row for 460V -59 and 575V -60 and -61.
Enclosed Type Delta-Connected Controllers
Controller IP65 (Type 4/12)

Rating (A) B Height A Width C Depth
Non-Combination Controller
5 610 (24) 406 (16) 229 (9)
25 610 (24) 406 (16) 229 (9)
43 610 (24) 406 (16) 229 (9)
60 610 (24) 406 (16) 229 (9)
85 610 (24) 406 (16) 229 (9)
108 762 (30) 610 (24) 305 (12)
234 762 (30) 610 (24) 305 (12)
348 965 (38) 762 (30) 356 (14)
435 965 (38) 762 (30) 356 (14)
549 1524 (60) 914 (36) 356 (14)
625 1524 (60) 914 (36) 356 (14)
831 2286 (90) 635 (25) 508 (20)
A-8 Specifications
Notes
Appendix B
Parameter Information
Table B.1 Parameter List
Parameter Parameter Min./ Default User

Group Units
Description Number Max. Settings Settings
Metering Volts Phase A-B 1 V
Metering Volts Phase B-C 2 V
Metering Volts Phase C-A 3 V
Metering Current Phase A 4 A
Metering Current Phase B 5 A
Metering Current Phase C 6 A
Metering Watt Meter 7 KW/MW
Metering Kilowatt Hours 8 KWH/MWH
Metering Elapsed Time 9 Hours
Metering Meter Reset 10 Ready Ready
ETM Reset
KWH Reset
Metering Power Factor 11 0.00…0.99
Metering Mtr Therm Usage 12 % 0…100
Metering Motor Speed 13 % 0…100
Basic Set Up SMC Option 14 Standard
Brake
Pump Control
Basic Set Up Motor Connection 15 Line/Delta Line
Basic Set Up Line Voltage 16 V 0…10000 480
Basic Set Up Starting Mode 17 Full Voltage Soft Start
Current Limit
Soft Start Linear Speed
Pump Start
Basic Set Up Ramp Time 18 SEC 0…30 10
Basic Set Up Initial Torque 19 %LRT 0…90 70
Basic Set Up Cur Limit Level 20 %FLC 50…600 350
Basic Set Up Torque Limit 21 %LRT 0…100 90
Basic Set Up Kickstart Time 22 SEC 0.0…2.0 0.0
Basic Set Up Kickstart Level 23 %LRT 0…90 0
Basic Set Up Option 2 Input 24 Disable Disable
Dual Ramp
Preset SS
Dual Ramp Starting Mode 2 25 Full Voltage Soft Start
Current Limit
Soft Start
Linear Speed
Dual Ramp Ramp Time 2 26 SEC 0…30 10
Dual Ramp Initial Torque 2 27 %LRT 0…90 70
Dual Ramp Cur Limit Level 2 28 %FLC 50…600 350
Dual Ramp Torque Limit 2 29 %LRT 0…100 90
B-2 Parameter Information
Table B.1 Parameter List (Continued)

Group Units
Dual Ramp Kickstart Time 2 30 SEC 0.0…2.0 0.0
Dual Ramp Kickstart Level2 31 %LRT 0…90 0
Basic Set Up Stop Mode 32 Disable Disable
Soft Stop
Linear Speed
SMB
Accu-Stop
Basic Set Up Stop Time 33 SEC 0…120 0
Basic Set Up/ Accu-Stop Braking Current 35 %FLC 0…400 0
Preset SS/ Accu-Stop Slow Speed Sel 39 SS Low SS High
SS High
Preset SS/ Accu-Stop Slow Speed Dir 40 SS FWD SS FWD
SS REV
Preset SS/ Accu-Stop Slow Accel Cur 41 %FLC 0…450 0
Preset SS/ Accu-Stop Slow Running Cur 42 %FLC 0…450 0
Accu-Stop Stopping Current 43 %FLC 0…400 0
Basic Set Up/ Overload Overload Class 44 Disable Disable
Class 10
Class 15
Class 20
Class 30
Basic Set Up/ Overload Service Factor 45 0.01…1.99 1.15
Basic Set Up/ Overload Motor FLC 46 A 1.0…1000.0 1.0
Basic Set Up/ Overload Overload Reset 47 Manual Manual
Auto
Overload Overload A Lvl 50 %MTU 0…100 0
Underload Underload F Lvl 51 %FLC 0…99 0
Underload Underload F Dly 52 SEC 0…99 0
Underload Underload A Lvl 53 %FLC 0…99 0
Underload Underload A Dly 54 SEC 0…99 0
Undervoltage Undervolt F Lvl 55 %V 0…99 0
Undervoltage Undervolt F Dly 56 SEC 0…99 0
Undervoltage Undervolt A Lvl 57 %V 0…99 0
Undervoltage Undervolt A Dly 58 SEC 0…99 0
Overvoltage Overvolt F Lvl 59 %V 0…199 0
Overvoltage Overvolt F Dly 60 SEC 0…99 0
Overvoltage Overvolt A Lvl 61 %V 0…199 0
Overvoltage Overvolt A Dly 62 SEC 0…99 0
Unbalance Unbalance F Lvl 63 % 0…25 0
Unbalance Unbalance F Dly 64 SEC 0…99 0
Unbalance Unbalance A Lvl 65 % 0…25 0
Unbalance Unbalance A Dly 66 SEC 0…99 0
Jam Jam F Lvl 67 %FLC 0…1000 0
Jam Jam F Dly 68 SEC 0…99 0
Jam Jam A Lvl 69 %FLC 0…1000 0
Jam Jam A Dly 70 SEC 0…99 0
Parameter Information B-3

Group Units
Stall Stall Delay 71 SEC 0.0…10.0 0
Ground Fault Gnd Flt Enable 72 Disable Disable
Enable
Ground Fault Gnd Flt Level 73 A 1.0…5.0 2.5
Ground Fault Gnd Flt Delay 74 SEC 0.1…250.0 0.5
Ground Fault Gnd Flt Inh Time 75 SEC 2…25 10
Ground Fault Gnd Flt A Enable 76 Disable Disable
Enable
Ground Fault Gnd Flt A Lvl 77 A 1.0…5.0 2.0
Ground Fault Gnd Flt A Dly 78 SEC 0…250 10
PTC PTC Enable 79 Disable Disable
Enable
Phase Reversal Phase Reversal 80 Disable Disable
Enable
Restart Starts Per Hour 81 0…99
Restart Restart Attempts 82 0…5 2
Restart Restart Delay 83 SEC 0…60 0
Comm Masks Logic Mask 87 8-bit binary
DataLinks Data In A1 88
DataLinks Data In A2 89
DataLinks Data In B1 90
DataLinks Data In B2 91
DataLinks Data In C1 92
DataLinks Data In C2 93
DataLinks Data In D1 94
DataLinks Data In D2 95
DataLinks Data Out A1 96
DataLinks Data Out A2 97
DataLinks Data Out B1 98
DataLinks Data Out B2 99
DataLinks Data Out C1 100
DataLinks Data Out C2 101
DataLinks Data Out D1 102
DataLinks Data Out D2 103
Motor Data Motor ID 104 0…65535 0
Motor Data CT Ratio 105 1…1500
Motor Data MV Ratio 106 1…10000
Basic Set Up Aux1 Config 107 Normal Normal
Up To Speed
External Bypass
Basic Set Up Fault Contact 108 NO NO
NC
Basic Set Up Alarm Contact 109 NO NO
NC
B-4 Parameter Information

Group Units
Basic Set Up Aux2 Config 110 NO NO
NC
Language Language 111 English English
French
Spanish
German
Portuguese
Mandarin
All Parameter Mgmt 115 Ready Ready
User Recall
User Store
Factory Default
Basic Set Up Backspin Timer 116 SEC 0…999 0
Appendix C
Renewal Parts
Description SMC Rating Input Control Voltage Part No. ➀
Control Modules Standard All 120…240V AC 41391-454-01-S1FX
Pump Control All 41391-454-01-B1FX
Braking Control 5…85 A 41391-454-01-D1AX
108…251 A 41391-454-01-D1BX
317…480 A 41391-454-01-D1CX
Standard All 24V AC/DC 41391-454-02-S2FX
Pump Control All 41391-454-02-B2FX
Braking Control 5…85 A 41391-454-02-D2AX
108…251 A 41391-454-02-D2BX
317…480 A 41391-454-02-D2CX
Description SMC Rating Line Voltage Part No. ➀
Power Poles 5A 200…480V 150-FPP5B ➁➂
25 A 200…480V 150-FPP25B ➁➂
43 A 200…480V 150-FPP43B ➁➂
60 A 200…480V 150-FPP60B ➁➂
85 A 200…480V 150-FPP85B ➁➂
108 A 200…480V 41391-800-01 ➃
135 A 200…480V 41391-800-03 ➃
201 A 200…480V 41391-800-05 ➃
251 A 200…480V 41391-800-07 ➃
317 A 200…480V 41391-800-09 ➃
361 A 200…480V 41391-800-11 ➃
480 A 200…480V 41391-800-13 ➃
5A 200…600V 150-FPP5C ➁➂
25 A 200…600V 150-FPP25C ➁➂
43 A 200…600V 150-FPP43C ➁➂
60 A 200…600V 150-FPP60C ➁➂
85 A 200…600V 150-FPP85C ➁➂
108 A 200…600V 41391-800-02 ➃
135 A 200…600V 41391-800-04 ➃
201 A 200…600V 41391-800-06 ➃
251 A 200…600V 41391-800-08 ➃
317 A 200…600V 41391-800-10 ➃
361 A 200…600V 41391-800-12 ➃
480 A 200…600V 41391-800-14 ➃
Heatsink Fans 5…85 A All 41391-801-03 ➁
108…251 A All 41391-801-01
317…480 A All 41391-801-02
Base Plate 108…251 A All 41391-803-01
317…480 A All 41391-803-02
➀ One piece provided per part number.

➁ 5…85 A power pole structure does not include heatsink fan.
➂ Three-phase power pole structure provided per part no.
➃ One-phase power pole provided per part no.
Appendix D
Accessories
Description Description/Used With Cat. No.
Protective Modules 5…85 A, 480V 150-F84
108…480 A, 480V 150-F84L
5…85 A, 600V 150-F86
108…480 A, 600V 150-F86L
Terminal Lugs 108…251 A 199-LF1
317…480 A 199-LG1
IEC Terminal Covers 108…251 A 150-TC2
317…480 A 150-TC3
HIM Hand-Held ➀ 20-HIM-A2
20-HIM-A3
20-HIM-A4
20-HIM-A5
Door-Mounted 20-HIM-C3
20-HIM-C3S
20-HIM-C5
20-HIM-C5S
Extension Cables 1202-H03
1202-H10
1202-H30
1202-H90
Splitter Cable 1203-S03
Communication DeviceNet 20-COMM-D
Modules ControlNet 20-COMM-C
Remote I/O 20-COMM-R
Profibus 20-COMM-P
RS 485 20-COMM-S
InterBus 20-COMM-I
EtherNet 20-COMM-E
➀ Requires a 20-HIM-H10 cable.

Appendix E
Renewal Part Cross Reference
Orderable Control Module
SMC Line Input
Description Allen-Bradley Internal Cat. No.
Rating Voltage Voltage
Renewal Part No. Label ➀
Standard All — 100…240V 41391-454-01-S1FX 150-FS1FX
All — 24V 41391-454-02-S2FX 150-FS2FX
Pump Control All — 100…240V 41391-454-01-B1FX 150-FB1FX
All — 24V 41391-454-02-B2FX 150-FB2FX
Control Brake Control 5…85 A — 100…240V 41391-454-01-D1AX 150-FD1AX
Module 5…85 A — 24V 41391-454-02-D2AX 150-FD2AX
108…251 A — 100…240V 41391-454-01-D1BX 150-FD1BX
108…251 A — 24V 41391-454-02-D2BX 150-FD2BX
317…480 A — 100…240V 41391-454-01-D1CX 150-FD1CX
317…480 A — 24V 41391-454-02-D2CX 150-FD2CX
Originally Ordered Internal Control Orderable Power

Control Type Control Voltage Line Voltage Amperes Series
AB Cat. No. Module Label ➀ Poles
Standard 100…240V 200…480V AC 5 150-F5NBD A 150-FS1FX 150-FPP5B
25 150-F25NBD A 150-FS1FX 150-FPP25B
43 150-F43NBD A 150-FS1FX 150-FPP43B
60 150-F60NBD A 150-FS1FX 150-FPP60B
85 150-F85NBD A 150-FS1FX 150-FPP85B
200…600V AC 5 150-F5NCD A 150-FS1FX 150-FPP5C
25 150-F25NCD A 150-FS1FX 150-FPP25C
43 150-F43NCD A 150-FS1FX 150-FPP43C
60 150-F60NCD A 150-FS1FX 150-FPP60C
85 150-F85NCD A 150-FS1FX 150-FPP85C
24V AC/DC 200…480V AC 5 150-F5NBR A 150-FS2FX 150-FPP5B
25 150-F25NBR A 150-FS2FX 150-FPP25B
43 150-F43NBR A 150-FS2FX 150-FPP43B
60 150-F60NBR A 150-FS2FX 150-FPP60B
85 150-F85NBR A 150-FS2FX 150-FPP85B
200…600V AC 5 150-F5NCR A 150-FS2FX 150-FPP5C
25 150-F25NCR A 150-FS2FX 150-FPP25C
43 150-F43NCR A 150-FS2FX 150-FPP43C
60 150-F60NCR A 150-FS2FX 150-FPP60C
85 150-F85NCR A 150-FS2FX 150-FPP85C
➀ These are not orderable cat. nos. If a control module needs to be ordered, reference the control
module renewal part no. found in Appendix C.
E-2 Renewal Part Cross Reference
Originally Ordered Internal Control Orderable Power

Control Type Control Voltage Line Voltage Amperes Series
AB Cat. No. Module Label ➀ Poles
Pump Control 100…240V 200…480V AC 5 150-F5NBDB A 150-FB1FX 150-FPP5B
25 150-F25NBDB A 150-FB1FX 150-FPP25B
43 150-F43NBDB A 150-FB1FX 150-FPP43B
60 150-F60NBDB A 150-FB1FX 150-FPP60B
85 150-F85NBDB A 150-FB1FX 150-FPP85B
200…600V AC 5 150-F5NCDB A 150-FB1FX 150-FPP5C
25 150-F25NCDB A 150-FB1FX 150-FPP25C
43 150-F43NCDB A 150-FB1FX 150-FPP43C
60 150-F60NCDB A 150-FB1FX 150-FPP60C
85 150-F85NCDB A 150-FB1FX 150-FPP85C
24V AC/DC 200…480V AC 5 150-F5NBRB A 150-FB2FX 150-FPP5B
25 150-F25NBRB A 150-FB2FX 150-FPP25B
43 150-F43NBRB A 150-FB2FX 150-FPP43B
60 150-F60NBRB A 150-FB2FX 150-FPP60B
85 150-F85NBRB A 150-FB2FX 150-FPP85B
200…600V AC 5 150-F5NCRB A 150-FB2FX 150-FPP5C
25 150-F25NCRB A 150-FB2FX 150-FPP25C
43 150-F43NCRB A 150-FB2FX 150-FPP43C
60 150-F60NCRB A 150-FB2FX 150-FPP60C
85 150-F85NCRB A 150-FB2FX 150-FPP85C
Braking 100…240V 200…480V AC 5 150-F5NBDD A 150-FD1AX 150-FPP5B
Control 25 150-F25NBDD A 150-FD1AX 150-FPP25B
43 150-F43NBDD A 150-FD1AX 150-FPP43B
60 150-F60NBDD A 150-FD1AX 150-FPP60B
85 150-F85NBDD A 150-FD1AX 150-FPP85B
200…600V AC 5 150-F5NCDD A 150-FD1AX 150-FPP5C
25 150-F25NCDD A 150-FD1AX 150-FPP25C
43 150-F43NCDD A 150-FD1AX 150-FPP43C
60 150-F60NCDD A 150-FD1AX 150-FPP60C
85 150-F85NCDD A 150-FD1AX 150-FPP85C
24V AC/DC 200…480V AC 5 150-F5NBRD A 150-FD2AX 150-FPP5B
25 150-F25NBRD A 150-FD2AX 150-FPP25B
43 150-F43NBRD A 150-FD2AX 150-FPP43B
60 150-F60NBRD A 150-FD2AX 150-FPP60B
85 150-F85NBRD A 150-FD2AX 150-FPP85B
200…600V AC 5 150-F5NCRD A 150-FD2AX 150-FPP5C
25 150-F25NCRD A 150-FD2AX 150-FPP25C
43 150-F43NCRD A 150-FD2AX 150-FPP43C
60 150-F60NCRD A 150-FD2AX 150-FPP60C
85 150-F85NCRD A 150-FD2AX 150-FPP85C
➀ These are not orderable cat. nos. If a control module needs to be ordered, reference the control
module renewal part no. found in Appendix C.
Glossary
AC Alternating current.
AC Contactor An alternating current (AC) contactor is designed for the specific purpose of
establishing or interrupting an AC power circuit.
Ambient Temperature Ambient temperature is the temperature of air, water, or a surrounding medium
where equipment is operated or stored.
American Wire Gauge A standard system used for designing the size of electrical conductors. Gauge
(AWG) numbers have an inverse relationship to size; larger numbers have a smaller cross
sectional area. However, a single-strand conductor has a larger cross-sectional
area than a multi-strand conductor of the same gauge so that they have the same
current-carrying specification.
Block Transfer Block Transfer is the method used by a PLC™ to transfer data that does not require
continuous updates. To perform this function, the module provides a status word to
the PLC during normal discrete transfer scan. This status word occupies the first
module group in the PLC I/O image table for the designated rack. The status word
is then used by the PLC program to control the BTW and BTR functions of the
PLC.
BTR A PLC Block Transfer Read instruction.
BTW A PLC Block Transfer Write instruction.
Buffer 1. In software terms, a register or group of registers used for temporary storage of
data to compensate for transmission rate differences between the transmitter
and receiving device.
2. In hardware terms, an isolating circuit used to avoid the reaction of one circuit
with another.
Contactor, Reversing A method of reversing motor rotation by the use of two separate contactors, one of
which produces rotation in one direction and the other produces rotation in the
opposite direction. The contactors are electrically (and mechanically) interlocked
so that both cannot be energized at the same time.
COP This instruction copies data from one location into another. It uses no status bits. If
you need an enable bit, program a parallel output using a storage address.
Cursor The intensified or blinking element in a video display. A means for indication
where data entry or editing occurs.
Cycle 1. A sequence of operations that is repeated regularly.
2. The time it takes for one sequence of operations to occur.

Glossary-II
DH-485 Link Data Highway 485 link. An Allen-Bradley token-passing baseband link for a local
area network based on the RS-485 standard.
Disable To inhibit logic from being activated.
Duty Cycle The relationship between the operating and rest times or repeatable operation at
different loads.
Enable To allow an action or acceptance of data by applying an appropriate signal to the

appropriate input.
Fault Any malfunction that interferes with normal system operation.
G File G File configuration is based on the devices that you have on the RIO link. G File
configuration consists of setting logical device starting addresses and the logical
device image size of each physical device/adapter with which the scanner
communicates.
Gate The control element of an SCR (silicon controlled rectifier) commonly referred to
as a thyristor. When a small positive voltage is applied to the gate momentarily, the
SCR will conduct current (when the anode is positive with respect to the cathode
of the SCR). Current conduction will continue even after the gate signal is
removed.
Jogging Jogging is a means of accomplishing momentary motor movement by repetitive

closure of a circuit using a single push button or contact element.
Jumper A short conductor with which you connect two points.
LCD Liquid crystal display, which is a reflective visual readout device commonly used
in digital watches and laptop computers.
Locked Rotor Torque The minimum torque that a motor will develop at rest for all angular positions of
the rotor (with rated voltage applied at rated frequency).
Mode A selected method of operation. Example: run, test, or program.
Normally Closed Contacts A set of contacts on a relay or switch that are closed when the relay is de-energized
or the switch is de-activated. They are open when the relay is energized or the
switch is activated.
Normally Open Contacts A set of contacts on a relay or switch that are open when the relay is de-energized
or the switch is de-activated. They are closed when the relay is energized or the
switch is activated.
PLC® Controller 1. An Allen-Bradley programmable controller.
2. An Allen-Bradley programmable controller with a name that includes the

letters PLC. See Programmable Controller.
Glossary-III
Port On a communication link, the logic circuitry or software at a station that determines
its communication parameters for a particular communication channel.
Power Factor A measurement of the time phase difference between the voltage and current in an
AC circuit. It is represented by the cosine of the angle of this phase difference.
Power factor is the ratio of Real Power (kW) to total kVA or the ratio of actual
power (W) to apparent power (volt-amperes).
Preset Speed Preset speed refers to one or more fixed speeds at which the drive will operate.
Programmable Controller A solid-state system that has a user-programmable memory for storage of
instructions to implement specific functions such as I/O control, logic, timing,
counting, report generation, communication, arithmetic, and data file
manipulation. A controller consists of a central processor, input/output interface,
and memory. A controller is designed as an industrial control system.
Protocol A set of conventions governing the format and timing of data between
communication devices.
Remote I/O I/O connected to a processor across a serial link. With a serial link, remote I/O can
be located long distances from the processor.
RS-232-C An EIA standard that specifies electrical, mechanical, and functional

characteristics for serial binary communication circuits in a point-to-point link.
RS-422 An EIA standard that specifies electrical characteristics of balanced-voltage digital

interface circuits in a point-to-point link.
RS-485 An EIA standard that specifies electrical characteristics of balanced-voltage digital

interface circuits in a multi-point link.
Scrolling The vertical movement of data on a display screen caused by the dropping of one
line of displayed data for each new line added at the opposite end.
Serial Pertaining to time-sequential transmission of, storage of, or logic operations on

data, using the same facilities for successive parts.
Service Factor (S-F) When used on a motor nameplate, a number which indicates how much above the
nameplate rating a motor can be loaded without causing serious degradation (i.e.,
a motor with 1.15 S-F can produce 15% greater torque than one with 1.0 S-F) to
adjust measured loads in an attempt to compensate for conditions which are
difficult to measure or define.
Silicon Controlled Rectifier A solid-state switch, sometimes referred to as a thyristor. The SCR has an anode,
(SCR) cathode and control element called the gate. The device provides controlled
rectification since it can be turned on at will. The SCR can rapidly switch large
currents at high voltages. They are small in size and low in weight.
SLC Controller An Allen-Bradley programmable controller with a name that includes the letters
SLC. See Programmable Controller.
Glossary-IV
Status The condition at a particular time of any numerous entities within a system. These
conditions may be represented by values in a status line.
Surge Protection The process of absorbing and clipping voltage transients on an incoming AC line
or control circuit. MOVs (Metal Oxide Varistors) and specially designed R-C
networks are usually used to accomplish this.
Toggle To switch alternately between two possible selections.
Transient A momentary deviation in an electrical or mechanical system.
UL Underwriters Laboratories (a third-party safety certification agency).

Back Cover
Publication 150-UM008C-EN-P - May 2004 2 PN 40055-218-01 (3)

Supersedes Publication 150-UM008B-EN-P - January 2003 © 2004 Rockwell International Corporation. Printed in the U.S.A.

SMC Flex User Manual

Uploaded by

Copyright:

Available Formats

SMC Flex User Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SMC Flex User Manual

Uploaded by

Copyright:

Available Formats

SMC-Flex™

The illustrations, charts, sample programs and layout examples shown in

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,

Reproduction of the contents of this copyrighted publication, in whole or

Throughout this manual we use notes to make you aware of safety

Identifies information about practices or circumstances

Attention statements help you to:

IMPORTANT Identifies information that is critical for successful

This product is tested to meet the Council Directive 89/336/EC

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage,

This equipment is classified as open equipment and must be mounted in an

Chapter 2 Receiving .......................................................................................2-1

Chapter 3 Terminal Locations .........................................................................3-1

Chapter 4 Overview ....................................................................................... 4-1

Chapter 5 Overview ....................................................................................... 5-1

Chapter 6 Overview ....................................................................................... 6-1

Chapter 7 Overview ....................................................................................... 7-1

Chapter 8 Overview ........................................................................................8-1

Chapter 9 Overview ........................................................................................9-1

Chapter 10 Introduction ..................................................................................10-1

Appendix A Functional Design Specifications ................................................... A-1

Chapter 2 Figure 2.1 Dimensions: 5…85 A Controllers ...............................2-5

Chapter 3 Figure 3.1 Wiring Terminal Locations (5…85 A) .........................3-1

Figure 3.10 Typical Wiring Diagram for Dual Ramp

Chapter 4 Figure 4.1 Menu Structure Hierarchy ......................................... 4-2

Chapter 9 Figure 9.1 Fault Display ..............................................................9-1

Chapter 10 Figure 10.1 Troubleshooting Flowchart .......................................10-2

Appendix A Figure A.1 Wiring Diagram ..........................................................A-2

• Selection Guide — Publication 150-SG008_①-EN-P

• Application Guide — Publication 150-AT002_①-EN-P

Description The SMC-Flex™ controller offers a full range of starting modes as

Operation The SMC-Flex controller can operate three-phase squirrel-cage

Modes of Operation (Standard) Soft Start ①

Figure 1.1 Soft Start

➀ Kickstart is also available with Soft Start.

Figure 1.2 Selectable Kickstart

Start Run Soft Stop

Current Limit Start ➀

Figure 1.3 Current Limit Start

➀ Kickstart is also available with Current Limit Start.

Dual Ramp Start ➀

Figure 1.4 Dual Ramp Start

➀ Dual Ramp Start is available only with the standard controller.

Full Voltage Start

Figure 1.5 Full Voltage Start

Preset Slow Speed

Time (seconds) Start Run

ATTENTION Slow speed running is not intended for continuous

Linear Speed Acceleration ➀

Figure 1.7 Linear Speed Acceleration

Start Run Stop

➀ Kickstart is also available with Linear Speed Acceleration.

ATTENTION Linear Stop is not intended to be used as an

Figure 1.8 Soft Stop

Start Run Soft Stop

ATTENTION Soft Stop is not intended to be used as an emergency

Important: The options listed in this section are mutually exclusive

Modes of Operation Pump Control Option ➀