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SMC™ Dialog Plus Smart Motor Controller

Introduction Standards Compliance and Certifications Modes of Operation Cat. No. Explanation Product Selection
Options Accessories Specifications Approximate Dimensions
Modes of Operation

Modes of Operation

The SMC Dialog Plus controller provides the following modes of operation: Soft Start with selectable Kickstart, Current Limit Start, Dual Ramp Start, and Full Voltage Start.

Soft Start

This method has the most general application. The motor is raised to an initial torque value which is programmable from 0…90% of locked rotor torque. The motor voltage is gradually increased during the acceleration ramp time, which can be programmed from 0…30 seconds.

Soft Start with Selectable Kickstart

A kickstart, or boost, at the beginning of the voltage ramp is intended to provide a current pulse of 550% of full load current. The kickstart time is adjustable from 0.0…2.0 seconds. This allows the motor to develop additional torque at start for loads which may need a boost to get started.

Current Limit Start

This starting mode is used when it is necessary to limit the maximum starting current. The current limit can be programmed for 50…600% of full load current.

Dual Ramp Start

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

The acceleration ramp times can be programmed from 0…30 seconds. The initial torque values can be programmed from 0…90% of locked rotor torque. Note: Dual Ramp is only available with the standard controller.

Full Voltage Start

This mode is used for applications requiring across-the-line starting. The ramp time is less than 1/4 second.

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Description of Starting and Stopping Options

The following options are available in the SMC Dialog Plus controller. Only one option may be added to the standard unit.

Soft Stop¬ 

This option can be used on applications that require an extended coast to rest. It is designed for frictional loads that tend to stop suddenly when voltage is removed from the motor.

The voltage ramp down time can be programmed from 0…60 seconds. The load will stop when the motor voltage drops to a point where the load torque is greater than the motor torque.

Pump Control¬ 

This option is used to reduce 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 which 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.

Preset Slow Speed

This option can be used on applications that require a slow speed (for example, moving material into position).

The preset slow speed can be programmed for either 7% of base speed (low) or 15% of base speed (high) in the forward direction. It can also be set for 10% of base speed (low) or 20% of base speed (high) in the reverse direction without a reversing contactor.

SMB Smart Motor Braking¬ 

This option provides motor braking for applications that require the motor to stop faster than a coast to rest. Braking control, with automatic zero speed shut off, is fully integrated into the compact design of the SMC Dialog Plus controller. This design facilitates a clean, straightforward installation and eliminates the requirement for additional hardware such as braking contactors, resistors, timers, and speed sensors.
The microprocessor based braking system applies braking current to a standard squirrel cage induction motor. The strength of the braking current is programmable from 150…400% of full load current.

Accu-Stop¬ 

This option is used in applications requiring 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…400% of full load current. Slow Speed Current is programmable from 0…450% of full load current. Slow speed can be programmed for either 7% (low) or 15% (high).

Accu-Stop with Slow Speed at Start¬ 

The Accu-Stop option can also allow the motor to operate at a preset slow speed when Slow Speed Start is selected. This minimizes the jogging required to position a load. The start command will ramp the voltage from the preset slow speed to full speed. The operation of Accu-Stop is the same as explained previously.

Slow Speed with Braking¬ 

Slow Speed with Braking is used on applications that require slow speed (in the forward direction) for positioning or alignment and also require braking control to stop.

Slow speed adjustments are 7% (low) or 15% (high) of rated speed. Slow speed acceleration current is adjustable from 0…450%. Slow speed running current is adjustable from 0…450% of full load current. Braking current is adjustable from 0…400%.

¬ Not intended to be used as an emergency stop. Refer to the applicable standards for emergency stop requirements.


The following options are available in the SMC Dialog Plus controller. Only one option may be added to the standard unit.

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Description of Features

Electronic Motor Overload Protection

The SMC Dialog Plus controller incorporates, as standard, electronic motor overload protection. This overload protection is accomplished electronically with an I2t algorithm.
When coordinated with the proper short circuit protection, overload protection is intended to protect the motor, motor controller, and power wiring against overheating caused by excessive overcurrent. The SMC Dialog Plus controller meets applicable requirements as a motor overload protective device.
The controller’s overload protection is programmable, providing the user with flexibility. The overload trip class can be selected for class 10, 15, 20, or 30 protection. The trip current is programmed by entering the motor full-load current rating.
Thermal memory is included to accurately model motor operating temperature. Ambient insensitivity is inherent in the electronic design of the overload.
Note: The current sensing capability of the SMC Dialog Plus controller is disabled during bypass operation. The Bulletin 825 Converter Module and 150-NFS fanning strip are required for providing current feedback in these applications. Note: To achieve calibration, 70% motor load or greater is required at the motor shaft for 2 s. Calibration is required when a Bulletin 825 Converter Module is not used.

Stall Protection and Jam Detection

Motors can experience locked rotor currents and develop high torque levels in the event of a stall or a jam. These conditions can result in winding insulation breakdown or mechanical damage to the connected load. The SMC Dialog Plus controller provides both stall protection and jam detection for enhanced motor and system protection. Stall protection allows the user to program a maximum stall protection delay time from 0…10 s. The stall protection delay time is in addition to the programmed start time and begins only after the start time has timed out. If the controller senses that the motor is stalled, it will shut down after the delay period has expired.
Jam detection allows the user to determine the motor jam detection level as a percentage of the motor’s full load current rating. To prevent nuisance tripping, a jam detection delay time, from 0.0…10.0 s, can be programmed. This allows the user to select the time delay required before the SMC Dialog Plus controller will trip on a motor jam condition. The motor current must remain above the jam detection level during the delay time. Jam detection is active only after the motor has reached full speed.

Energy Saver

This is a standard feature with the SMC Dialog Plus controller. It is used to save energy on applications where the motor is lightly loaded or unloaded for long periods of time. The Energy Saver is a built-in feature of the controller. It does not require additional panel space or external wiring. It also does not require a complicated setup procedure.

Phase Rebalance

The SMC Dialog Plus controller incorporates, as standard, a dynamic Phase Rebalance feature. The controller compensates for voltage unbalance by automatically adjusting the voltage output to balance the 3-phase currents drawn by the motor. When phase rebalance is achieved, motor life may be extended and production can continue without interruption. Phase Rebalance is a built-in feature of the controller and does not require a complicated setup procedure.
Note: Phase Rebalance requires the use of the Bulletin 825 Converter Module and the Cat. No. 150-NFS fanning strip.
Note: The performance of the Phase Rebalance feature is dependent on the motor’s loading and characteristics. Severe imbalances cannot be corrected.

Underload Protection

Utilizing the underload protection of the SMC Dialog Plus controller, motor operation can be halted if a drop in current is sensed.
The SMC Dialog Plus controller provides an adjustable underload trip setting from 0…99% of the programmed motor full load current rating with an adjustable trip delay time of 0…99 s.

Undervoltage Protection

The SMC Dialog Plus controller’s undervoltage protection will halt motor operation if a drop in the incoming line voltage is detected.
The undervoltage trip level is adjustable as a percentage of the programmed line voltage, from 0…99%. To eliminate nuisance trips, a programmable undervoltage trip delay time of 0…99 s can also be programmed. The line voltage must remain below the undervoltage trip level during the programmed delay time.

Overvoltage Protection

If a rise in the incoming line voltage is detected, the SMC Dialog Plus controller’s overvoltage protection will halt motor operation.
The overvoltage trip level is adjustable as a percentage of the programmed line voltage, from 0…99%. To eliminate nuisance trips, a programmable overvoltage trip delay time of 0…99 s can also be programmed. The line voltage must remain above the overvoltage trip level during the programmed delay time.

Voltage Unbalance Protection

Voltage unbalance is detected by monitoring the 3-phase supply voltage magnitudes in conjunction with the rotational relationship of the three phases. The controller will halt motor operation when the calculated voltage unbalance reaches the user-programmed trip level.
The voltage unbalance trip level is programmable from 0…25% unbalance.

Excessive Starts Per Hour

The SMC Dialog Plus 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 during a short time period.

Metering

Power monitoring parameters include:


Note: The motor thermal capacity usage allows the user to monitor the amount of overload thermal capacity usage before the SMC Dialog Plus controller’s built-in electronic overload trips.
Note: In bypass configurations, the current sensing and power factor measurement capability of the SMC Dialog Plus controller is disabled. Three-phase current measurement, kW, kWH, and motor thermal capacity usage can still be maintained with the use of the Bulletin 825 Converter Module.
Note: The usage of an SMC Controller on a generator and line power requires the use of a Bulletin 825 Converter Module.

Built-in SCANport™ Communication

A serial interface port is provided as standard, which allows connection to a Bulletin 1201 Human Interface Module or a variety of Bulletin 1203 Communication Modules. This includes Allen-Bradley Remote I/O, DeviceNet network and RS-232/422/485-DF1.

LCD Display

The SMC Dialog Plus controller’s two-line 16-character backlit LCD display provides parameter identification using clear, informative text. Controller set up can be performed quickly and easily without the use of a reference manual. Parameters are arranged in an organized four-level menu structure for ease of programming and fast access to parameters.

Keypad Programming

Programming of parameters is accomplished through a five-button keypad on the front of the SMC Dialog Plus controller. The five buttons include up and down arrows, an Enter button, a Select button, and an Escape button. The user needs only to enter the correct sequence of keystrokes for programming the SMC Dialog Plus controller.

Auxiliary Contacts

Three hard contacts are furnished as standard with the SMC Dialog Plus controller. The first two contacts are programmable for Normal/Up-to-speed. The third is programmable for Normal/Fault.