PLEASE READ! IMPORTANT USER INFORMATION · 20 or 30 (2 DIPs) – Automatic or manual reset (1 DIP)...

PLEASE READ!

This manual is intended to guide qualified personnel in theinstallation and operation of this product.

Because of the variety of uses for this equipment and because ofthe differences between this solid-state equipment andelectromechanical equipment, the user of and those responsiblefor applying this equipment must satisfy themselves as to theacceptability of each application and use of the equipment. In noevent will Allen-Bradley Company be responsible or liable forindirect or consequential damages resulting from the use orapplication of this equipment.

The illustrations shown in this manual are intended solely toillustrate the text of this manual. Because of the many variablesand requirements associated with any particular installation, theAllen-Bradley Company cannot assume responsibility or liabilityfor actual use based upon the illustrative uses and applications.

No patent liability is assumed by Allen-Bradley Company withrespect to use of information, circuits or equipment described inthis text.

Reproduction of the content of this manual, in whole or in part,without written permission of the Allen-Bradley Company isprohibited.

IMPORTANT USER INFORMATION

The information in this manual is organized in numberedchapters. Read each chapter in sequence and perform procedureswhen you are instructed to do so. Do not proceed to the nextchapter until you have completed all procedures.

Throughout this manual we use notes to make you aware ofsafety considerations:

ATTENTION: Identifies information aboutpractices or circumstances that can lead to personalinjury or death, property damage or economic loss.

Attentions help you:

� identify a hazard

� avoid the hazard

� recognize the consequences

Important: Identifies information that is especially importantfor successful application and understanding of the product.

Table of Contents

i

Chapter 1 – IntroductionChapter Objectives 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Conventions 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number Code Explanation 1-2. . . . . . . . . . . . . . . . .

SMP-3 Overview 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functionality 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Communications Capabilities 1-3. . . . . . . . . . . . . . . . . . . . .

Chapter 2 – Before InstallationChapter Objectives 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Unpacking 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Precautions 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 – Installation and WiringChapter Objectives 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of SMP-3 Overload Relay To Contactor 3-2. . . . . Short Circuit Ratings 3-13. . . . . . . . . . . . . . . . . . . . . . . . . Typical Control Circuit Wiring Diagrams 3-17. . . . . . . . .

Configuring the SMP-3 Overload Relay 3-32. . . . . . . . . . . . . Setting Trip Class 3-32. . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Auto/Manual Reset 3-33. . . . . . . . . . . . . . . . . . . .

Selecting Ground Fault (GF), Jam/Stall, and Test Functionality 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Full Load Current (FLC) 3-35. . . . . . . . . . . . .

FLC Setting for Applications in USA and Canada 3-37. . . . . Motors with a Service Factor of 1.15 or greater 3-37. . . . Motors with Service Factor of less than 1.15 3-37. . . . . . Wye-Delta (YD) Applications (relay carrying motor phase current) 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLC Settings for Applications Outside USA and Canada 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Continuous Rated (MCR) Motors 3-37. . . . . . Star-Delta (YD) Applications (relay carrying motor phase current) 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 – Functional DescriptionChapter Objectives 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SMP-3 Inputs/Outputs 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration Dip Switches 4-1. . . . . . . . . . . . . . . . . . . Power Supply 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUT A and B 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trip Relay 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status LEDs 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SMP-3 Protection Features 4-3. . . . . . . . . . . . . . . . . . . . . . . Overload Protection 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . Trip Class. 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trip Curves. 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto/Man Reset. 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

ii

Phase Loss Protection 4-6. . . . . . . . . . . . . . . . . . . . . . . . Ground Fault Protection 4-6. . . . . . . . . . . . . . . . . . . . . . Jam/Stall Protection 4-7. . . . . . . . . . . . . . . . . . . . . . . . . .

SMP-3 Miscellaneous Features 4-7. . . . . . . . . . . . . . . . . . . . Test 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Reset 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communications 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Parameters 4-9. . . . . . . . . . . . . . . . . . . . Human Interface Adapter 4-13. . . . . . . . . . . . . . . . . . . . . Communication Interface Adapter 4-13. . . . . . . . . . . . . .

Chapter 5 – Human Interface ModuleChapter Objectives 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIM Description 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Panel Descriptions 5-2. . . . . . . . . . . . . . . . . . . . . . .

Control Panel Description 5-2. . . . . . . . . . . . . . . . . . . . . . . . SMP-3 HIM Control Panel Description 5-2. . . . . . . . . . . SMP-3 HIM LED Indicators 5-3. . . . . . . . . . . . . . . . . . . Drives HIM Control Panel Description 5-4. . . . . . . . . . . HIM Status Display 5-4. . . . . . . . . . . . . . . . . . . . . . . . . .

HIM Modes 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Mode 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program Mode 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Search Mode 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Status Mode 5-7. . . . . . . . . . . . . . . . . . . . . . . . .

HIM Installation and Removal 5-8. . . . . . . . . . . . . . . . . . . . . Installation 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Serial CommunicationCommunications Using Bulletin 1203 Communication Modules 6-1. . . . . . . . . . . . . . . . . . . . . . . . .

Logic Control Data 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . SMP-3 Status Data 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . Scale Factor Conversion 6-5. . . . . . . . . . . . . . . . . . . . . .

Sample Program Listing for Remote I/O to Serial Port Communication 6-6. . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 – Start UpChapter Objectives 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up Procedure 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Operations - Motor Connected 7-1. . . . . . . . . . . . . . .

Power Applied – Motor Connected 7-1. . . . . . . . . . . . . . . . .

Chapter 8 – ProgrammingChapter Objectives 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Logic Mask Parameter 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Illegal Logic Mask Settings 8-2. . . . . . . . . . . . . . . . . . . . . . . Mask Programming (Using the HIM in Program Mode) 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mask Programming (Using the HIM in Control Status Mode) 8-4. . . . . . . . . . . . . . . . . . . . . . . . .

iii

Chapter 9 – Troubleshooting and Fault InformationChapter Objectives 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED Diagnostics 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Troubleshooting Procedures 9-2. . . . . . . . . . . . . . . .

Fault Information 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIM Display. 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HIM Fault LED. 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SMP-3 Trip LED. 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Reset LED. 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . How to Clear a Fault 9-5. . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A – SpecificationsAppendix B – Smp-3 Accessories

1ChapterIntroduction

1-1

CHAPTER OBJECTIVES

This chapter provides an overview of this manual and brieflydescribes the SMP-3 overload relay, highlighting theavailable features and benefits.

MANUAL OVERVIEW

The purpose of this manual is to provide the user with thenecessary information to install, program, start up and maintainthe SMP-3 overload relay. To help ensure successfulinstallation and operation, the material presented in this manualmust be thoroughly read and understood before proceeding.Direct particular attention to the ATTENTION and Importantstatements.

Chapter 1 briefly describes this manual and the features of theSMP-3 overload relay.

Chapter 2 provides instructions regarding receiving, unpack-ing, inspecting, and storing the SMP-3 overload relay.

Chapter 3 describes how to mount, wire, and set the SMP-3overload relay. It also describes how to operate the SMP-3overload relay without a Human Interface Module.

Chapter 4 contains the functional specifications of the SMP-3overload relay.

Chapter 5 defines the display and control panel keys on theHuman Interface Module (HIM).

Chapter 6 provides the necessary information for the SMP-3setup using a PLC, SLC, or other logic controller. A sampleladder logic program is included to illustrate a possible SMP-3setup using a PLC.

Chapter 7 describes the steps to start up the SMP-3 overloadrelay. It includes a typical start-up routine that defines the ad-justments and checks to ensure proper operation.

Chapter 8 outlines the SMP-3 parameter information.

Chapter 9 defines the various SMP-3 fault codes, the corre-sponding corrective actions, and general troubleshooting in-formation.

Appendix A contains the general SMP-3 overload relay speci-fications.

Appendix B lists the accessories and their catalog numbers.

SMP, SMP-3, SLC, DeviceNet, and PanelView are trademarks and PLC is a registered trademark of the Allen-Bradley Company.

Chapter 1 – Introduction

1-2

MANUAL CONVENTIONS

To help differentiate parameter names and display text fromother text in this manual, the following conventions will beused:

� Parameter Names appear in bold.

� Display Text appear in ‘‘quotes”.

� Any reference to SMP-3 HIM refers to Bulletin 193–HIM1.

� Any reference to Drives HIM refers to Bulletin 1201 HIMs.

CATALOG NUMBER CODE EXPLANATION

193 – D 1C1

Bulletin Number

Current Rating(in Amps)

Contactor MountingSMP-3➊

D 0.7 – 2.5F 2.0 – 10H 8 – 37K 20 – 75L 20 – 90M 40 – 180N 70 – 304P 100 – 414R 140 – 608

1 A09 – A302 A38 – A453 A60 – A754 B1105 B1806 CT Mounted

Bulletin 193Bulletin 100

Contactor Size

Bulletin 592Contactor Size

T Size 00A Size 0 & 1C Size 2D Size 3E Size 4F Size 5G Size 6

–

70–304A100–414A140–608A40–180A

193193193193

NX15NX16NX17NX18

For customer field replacementof SMP-3 overload relay on currenttransformer mounted devices.

➊ A1 indicates an SMP-1 overload relay; B1 indicates an SMP-2 overload relay.

592


1-3

SMP-3 OVERVIEW

The SMP-3 overload relay is a solid-state electronic overloadrelay that is separately powered and microprocessor-based.

FUNCTIONALITY

The SMP-3 overload relay provides the following protectivefeatures:

� Overload protection

� Phase loss protection

� Ground fault protection

� Jam/stall protection

The SMP-3 overload relay also features:

� Two triac outputs (AC) for contactor control

� Manual reset button

� Test function

� Illegal FLC setting prevention

� Non-volatile operating memory protection

� Communication loss protection

� Ambient temperature compensation

� DIP switch selectable functions:

– Adjustable trip class 10, 15, 20 or 30 (2 DIPs)

– Automatic or manual reset (1 DIP)

– Ground fault protection (1 DIP)

– Jam/stall protection (1 DIP)

– Test function (1 DIP)

– 5:1 FLC setting range (8 DIPs)

� Status LEDs

– Trip (Red)

– OUT B (Yellow)

– OUT A (Yellow)

– Power (Green)

� Remote reset button (option)

� Communications

COMMUNICATIONS CAPABILITIES

The SMP-3 overload relay has communications capabilities.The embedded communications capabilities can be used tocontrol the SMP-3 overload relay or to obtain statusinformation from the SMP-3 overload relay:� Control Functionality

– Turn OUT A ON/OFF

– Turn OUT B ON/OFF– Reset/Clear Fault


1-4

� Status

– OUT A ON/OFF

– OUT B ON/OFF

– Fault code

– Protection parameter values:Parameter #1: Average Current

Parameter #2: FLC Setting

Parameter #3: Thermal Capacity Used

Parameter #4: Current Unbalance

– Additional parameter values (displayed on HIM only)

Parameter #5: SMP-3 Firmware Revision

Parameter #6: Device Port #

Parameter #7: Mask (0 = Disabled)

Parameter #8: Status

The SMP-3 overload relay can communicate the specifiedstatus and control data to and from the following HumanInterface and Communication Modules:

Device Communicated Information

OUT A and B control functions

SMP-3 Human InterfaceM H M

Display OUT A and B status ( HIM LEDs and HIMdisplay)

Module (HIM)Display fault status (HIM LED and HIM display)

Monitor all SMP-3 parameters

OUT A control function only

Drive Human InterfaceM H M

Display OUT A and B status (HIM display only)Drive Human InterfaceModule (HIM) Display fault status (HIM display only)

Monitor all SMP-3 parameters

OUT A and B control functions

Bulletin 1203 M

Display OUT A and B status (on programmable log-ic controller SIM LEDs [Cat. No. 1747-SIM] orPanelView display)Bulletin 1203

Communication Modules Display fault status (on programmable logic control-ler SIM LEDs [Cat. No. 1747-SIM] or PanelViewdisplay)

Monitor SMP-3 protection parameters

2ChapterBefore Installation

2-1

CHAPTER OBJECTIVES

This chapter describes the instructions regarding receiving,unpacking, inspecting, and storing your SMP-3 overload relay.For optimum performance of your SMP-3 relay, follow theseinstructions thoroughly.

RECEIVING

It is the responsibility of the user to thoroughly inspect theequipment before accepting the shipment delivery. Check theitem(s) received against the purchase order. If any items areobviously damaged, it is the responsibility of the user not toaccept delivery until the freight agent has noted the damage onthe freight bill. Should any concealed damage be found duringunpacking, it is again the responsibility of the user to notify thefreight agent. The shipping container must be left intact andthe freight agent should be requested to make a visualinspection of the equipment.

UNPACKING

Remove all packing material from around the SMP-3 overloadrelay.

INSPECTING

After unpacking, check the item(s) nameplate catalog numberagainst the purchase order. An explanation of the catalognumbering system for the SMP-3 overload relay is included asan aid for the nameplate interpretation. Refer to the followingpages to understand the nomenclature.

STORING

The SMP-3 overload relay should remain in its shippingcontainer prior to installation. If the equipment will not beused for a period of time, follow the instructions below tomaintain warranty coverage:

� Store in a clean, dry location.

� Store within an ambient temperature range of –40 °C to +85 °C.

� Store within a relative humidity range of 0% to 95%,non-condensing.

� Do not store where the device could be exposed to acorrosive atmosphere.

� Do not store in a construction area.

Chapter 2 – Before Installation

2-2

GENERAL PRECAUTIONS

In addition to the specific precautions listed throughout thismanual, the following general statements must be observed.

ATTENTION: The SMP-3 overload relaycontains ESD– (electrostatic discharge) sensitiveparts and assemblies. Static control precautionsare required when installing, testing, servicing, orrepairing this assembly. Component damage mayresult if ESD control procedures are not followed.If you are not familiar with static controlprocedures, refer to A-B publication 8000–4.5.2,“Guarding Against Electrostatic Damage,” or anyother applicable ESD protection handbook.

ATTENTION: An incorrectly applied orinstalled SMP-3 overload relay can result indamage to the components or reduction in productlife. Wiring or application errors, such asincorrectly setting the current to correspond to themotor full load current rating, incorrect orinadequate AC supply, or excessive ambienttemperatures may result in malfunction of theSMP-3 overload relay. Be sure to connect thegreen pigtail wire to a solid ground or earthconductor.

ATTENTION: Only personnel familiar with theSMP-3 overload relay and associated machineryshould plan to install, start-up, and maintain thesystem. Failure to comply may result in personalinjury and/or equipment damage.

3ChapterInstallation and Wiring

3-1

CHAPTER OBJECTIVES

Chapter 3 provides the information needed to properly installand wire the SMP-3 overload relay. All items must be read andunderstood before the actual installation begins.

ATTENTION: The following information ismerely a guide for proper installation. TheNational Electrical Code and any other governingregional or local code will overrule thisinformation. The Allen-Bradley Company cannotassume responsibility for the compliance orproper installation of the SMP-3 overload relay orassociated equipment. A hazard of personalinjury and/or equipment damage exists if codesare ignored during installation.

ATTENTION: The hard contact output includessurge suppression circuitry that will allow voltageto be present across terminals 30 and 40 when thecontact is open. The power supply must bedisconnected before performing any service.ATTENTION: The green ground wire of theSMP-3 overload relay must be connected toearth ground. (See page 3-13 for fasteningrequirements.)

ATTENTION: Outputs A and B are triac outputsthrough which leakage current may flow in theOff condition. This leakage current can behazardaous. The power supply must bedisconnected before performing any service.

Chapter 3 – Installation and Wiring

3-2

ASSEMBLY OF SMP-3 OVERLOAD RELAY TO CONTACTORThe following figures illustrate the steps necessary to assemblethe SMP-3 overload relay to a contactor.

Figure 3.1 Assembly of SMP-3 Overload Relay to Contactor (applicable to Cat. No. 193-C1_1 and Cat. No. 592-C1_T)

2.8 Nm25 lb-in

Note: A Cat. No. 193-C1_1 or Cat. No. 592-C1_T must bemounted to the contactor prior to fastening the contactor to apanel.


3-3

Figure 3.2 Assembly of SMP-3 Overload Relay to Contactor (applicable to Cat. No. 193-C1_2, 193-C1_3)


3-4

Figure 3.3 Bulletin 109 Starter Dimensions (with SMP-3 Overload Relay) ➊

H

J

GF

E

B

C

DA

K

➊ Refer to dimensions shown in Table 3A.


3-5

Table 3.A Bulletin 109 Starter Dimensions (with SMP-3 Overload Relay) ➊

Contactor Cat. No. A Width B Height C Depth D E F G H J ➋ K

100–A09, –A12 70(2-49/64)

165.8(6-17/32)

84(3-5/16)

117.1(4-5/8)

76.3(3)

60(2-3/8)

50(1-31/32)

35(1-25/64)

–15.7(–5/8)

45(1-13/16)

100–A18, –A24 70(2-49/64)

174.4(6-7/8)

92(3-5/8)

122.4(4-53/16)

87.1(3-7/16)

75(2-61/64)

60(2-3/8)

35(1-25/64)

–4.8(–13/64)

55(2-11/64)

100–A30 70(2-49/64)

193.4(7-19/64)

109(4-19/64)

118(4-21/32)

105.1(4-9/64)

90(3-35/64)

75(2-61/64)

40(1-9/16)

–7.4(–19/64)

55(2-11/64)

100–A38, –A45 90(3-35/64)

217.2(8-37/64)

125(4-59/64)

114.8(4-1/2)

124.1(4-57/64)

100(3-15/16)

NANA

55(2-5/32)

–6.8(–17/64)

75(2-61/64)

100–A60, –A75 90(3-35/64)

228.8(9-1/64)

142(5-19/32)

129(5-3/32)

131.9(5-13/64)

110(4-11/32)

NANA

80(3-5/32)

3.7(5/32)

93(3-21/32)

100–B110 119(4-11/16)

311(12-1/4)

155(6-7/64)

158.8(6-1/4)

176(6-15/16)

130(5-1/8)

NANA

100(3-15/16)

13.9(35/64)

119(4-11/16)

100–B180 119(4-11/16)

366(14-13/32)

190(7-31/64)

186(7-5/16)

211.3(8-5/16)

160(6-5/16)

NANA

110(4-21/64)

21.4(27/32)

134(5-9/32)

➊ Dimensions are shown in millimeters (inches). Dimensions are not intended formanufacturing purposes.

➋ Note that a (–) dimension indicates reset is located to right of contactor reference.


3-6

Figure 3.4 Bulletin 509 Starter Dimensions (with SMP-3 Overload Relay) ➊

A

B

E

H

F

D

G

CTo Top of Reset

➊ Refer to dimensions found in Table 3.B.


3-7

Table 3.B Bulletin 509 Starter Dimensions (with SMP-3 Overload Relay)

NEMASize

AWidth

BHeight

CReset Depth D E F

Dia. G H

0 – 1 90.4(3-9/16)

248.3(9-3/4)

117.7(4-5/8)

69.9(2-3/4)

234.4(9-1/4)

5.15(13/64)

41.8(1-21/32)

87(3-27/64)

2 100(3-5/16)

273.6(10-49/64)

117.7(4-5/8)

80(3-5/32)

260.2(10-1/4)

5.54(7/32)

41.8(1-41/64)

92.2(3-5/8)

3 155(6-1/8)

370(14-9/16)

151(5-5/16)

140(5-33/64)

220(8-21/32)

7.1(9/32)

45.6(1-13/16)

45.9(1-13/16)

4 178(7)

391(15-13/32)

190.3(7-1/2)

160(6-5/16)

250(9-27/32)

8.7(11/32)

45.6(6-5/16)

26.4(1-3/64)

5 187(7-3/8)

428(16-27/32)

223(8-25/32)

160(6-5/16)

380(14-31/32)

8.7(11/32)

75(2-61/64)

100(4)

6 337(13-17/64)

638(25-1/8)

291(11-29/64)

300(11-13/16)

450(17-23/32)

14.2(9/16)

6.8(17/64)

97(3-13/16)


3-8

Figure 3.5 Panel Mount Assembly Dimensions (Cat. No. 193–C1_1 used with Cat. No. 193-BPM4)70

(2.76)

6(24)

5(2)

61.7(2.43)

126(4.96)

3.69(.15)

122.1(4.81)

35mmDIN rail

87(3.43)


3-9

Figure 3.6 Panel Mount Assembly Instructions for Cat. No. 193-BPM4

1.8 N-m16 lb-in

12

3

4

Note: Must remove contactor adapter before assembling theSMP-3 overload relay and Cat. No. 193-BPM4.


3-10

Figure 3.7 Panel Mount Assembly Dimensions (Cat. No. 193-C1_3 used with Cat. No. 193-BPM5)

Á

90(3.54)

127(5.00)

5(.2)

81.8(3.22)

87.65(3.45)

144.5(5.69)

3.69(.15)

124.5(4.90)

35mmDIN rail

80(3.15)

115(4.53)

� 5.5(22)

4 - Holes

To Top of Reset

mm(inches)

6(,24)


3-11

Figure 3.8 Panel Mount Assembly Instructions for Cat. No. 193-BPM5

1

2 3

Note: Must remove contactor adapter before assembling theSMP-3 overload relay and Cat. No. 193-BPM5.


3-12

Figure 3.9 Panel Mount Assembly Dimensions (Cat. No. 193-C1L7 and 193-C1M7)

119(4.69)

105(4.13)

141(5.55)

TO TOP OF RESET

6.8(.27)

11.8(.46)

Ø 5.6(.22)

4 - HOLES

90(3.54)

B

A

mm(inches)

REMOTERESET

COMM

RESET

Table 3.C Panel Mount Assembly Dimensions (Cat. No. 193-C1L7 and 193-C1M7)Cat. No. Current Range (Amperes) Dimension A Dimension B

193–C1L7 20–90 158(6.22)

46.2(1.82)

193–C1M7 40–180 188.3(7.41)

60.8(2.39)


3-13

Short Circuit Ratings

The SMP-3 overload relay is suitable for use on a circuitcapable of delivering not more than the RMS symmetricalamperes, 600 volts maximum, as listed in Table 3.D .

Table 3.D SMP-3 Short Circuit Ratings

Cat. No. Maximum AvailableAmperes

MaximumVoltage

193-C1_1, -C1_T 5,000A 600V

193-C1_2, _3, _A, _C, _4, _5,_D, _E,

10,000A 600V

193-C1N6 18,000A 600V

193-C1P6 30,000A 600V

193-C1R6 42,000A 600V

Select the motor branch circuit protection that complies withThe National Electrical Code and any other governing regionalor local codes.

Table 3.E Wire Size and Torque Specifications

Power Terminals Control Terminals

CatCurrentRa ge

Min. Wire Capacity Max. Wire Capacity Torque Min. Wire Capacity Max. Wire Capacity TorqueCat. No.

CurrentRange

(A) Metric(mm2) AWG Metric

(mm2) AWGLugNm

(Lb-in)

WireNm

(Lb-in)

Metric(mm2) AWG Metric

(mm2) AWG Nm(Lb-in)

193-C1_1592-C1_T

0.7-37 2.5 #14 10 #8 – 1.8(16)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

592-C1_A 0.7-75 2.5 #14 10 #8 – 2.3(20)

0.5 #22 (2) 2.5 (2) #14 0.8(7)


3-14

Table 3.E Wire Size and Torque Specifications (Continued)

CatPower Terminals Control Terminals

Cat. No.XXX= Current

Ra geMin. Wire Capacity Max. Wire Capacity Torque Min. Wire Capacity Max. Wire Capacity Torque

(XXX=592 or193)

CurrentRange

(A) Metric(mm2) AWG Metric

(mm2) AWGLugNm

(Lb-in)

WireNm

(Lb-in)

Metric(mm2) AWG Metric

(mm2) AWG Nm(Lb-in)

193-C1_2193-C1_3592-C1_C

0.7-75 2.5 #14 35 #2 – 4(35)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

193-C1_4592-C1_D

20-180 10 #8 50 #1/0 17(150)

17(150)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

193-C1_5592-C1_E

20-180 16 #6 120 #4/0 31(275)

31(275)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

193-C1N6592-C1NF592-C1NG

70-304 25 #4 240 500MCM 45(400)

42(375)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

193-C1P6592-C1PF592-C1PG

100-414 50 (2) #1/0 (2) 185 (2)350MCM

45(400)

31(275)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

193-C1R6592-C1RF592-C1RG

140-608 50 (2) #1/0 (2) 240 (2)500MCM

45(400)

31(275)

0.5 #22 (2) 2.5 (2) #14 0.8(7)

193-NX15 300:5 2.5 #14 10 #8 – 1.8 (16) 0.5 #22 (2) 2.5 (2) #14 0.8 (7)193-NX16 400:5 2.5 #14 10 #8 – 1.8 (16) 0.5 #22 (2) 2.5 (2) #14 0.8 (7)193-NX17 630:5 2.5 #14 10 #8 – 1.8 (16) 0.5 #22 (2) 2.5 (2) #14 0.8 (7)


3-15

Table 3.F specifies the srew size needed to secure the greenground wire of the SMP-3 overload relay to earth ground.

Table 3.F Ground Screw Specifications

Cat. No. Screw Type

Standard Metric

193-C1_1, 2, or 3592-C1_T, A, or C

No. 8 M4

193-C1_4 or 5592-C1_D or E

1/4” M6

Figure 3.10 SMP-3 Customer Interfaces

ConfigurationDIP Switches

FLC SettingDIP Switches

A2 Terminal

Manual Reset Button

Communication Port

Remote Reset Port

Status LEDs

Ground Wire

Table 3.G Control Terminal Block Designation

Terminal Description

10 Out A ➊

20 Out B ➊

30, 40 Normally Closed Contact ➋

50, 60 Power Supply (110-240V AC)

➊ Output A and B output the power supply voltage with respect to terminal 60.

➋ Contact is closed when the SMP-3 overload relay is reset and powered. Contact is open when the SMP-3 overload relay is unpowered.

Note: The SMP-3 ground wire must be connected to earthground.


3-16

Figure 3.11 Typical Motor Connections

Three Phase Full Voltage Single Phase Full Voltage

L1 L2 L3

S.C.P.D.

2T1

4T2

6T3

A1

A2

SMP-3

T1T2

T3

L3L2L1

T12 4 6

T2 T3

T1 T2

A1S.C.P.D.

A2

SMP-3


3-17

Typical Control Circuit Wiring Diagrams

ATTENTION: The ratings of the SMP-3 triacsand trip relay must not be exceeded. If the coilcurrent or voltage of the contactor exceeds thetriac or relay rating an interposing relay must beused.

ATTENTION: When power is applied toSMP-3 terminals “50” and “60,” the N.O. relayacross “30” and “40” closes.

ATTENTION: Additional control circuitprotection may be required. Refer to NationalElectrical Code.

ATTENTION: The green ground wire of theSMP-3 must be connected to earth ground.


3-18

Figure 3.12 SMP-3 Starter Wiring Diagram (with Triac Control)

ÌÌM

SMP-310

20

30

40

50

60

OUT A

OUT B

FUSETRIPRELAY

120/240VAC P/S

T1 T2 T3

L1 L2 L3

To 120V AC or240V AC Supply

Figure 3.13 SMP-3 Starter Wiring Schematic (with Triac Control)

ÌÌÌÌ

M

ÌÌÌÌ

SMP-350 60

30 40OUT ASMP-3 10

Control Circuit Fuses(When Used)

To 120/240V AC Supply

SMP-3

➊ Applicable to Cat. No. 193-C1_1, 2,3,4, and 5, 592-C1_T, A, C, D, and E.

➋ The coil voltage and supply voltage must be the same. (i.e.120V AC or 240V AC).

Note: Refer to page 3-17 for wiring ATTENTIONS.


3-19

Figure 3.14 SMP-3 Starter Wiring Diagram (with Push ButtonControl)

ÌÌÌÌ

M

SMP-310

2030

40

50

60

OUT A

OUT B

FUSETRIPRELAY

120/240VAC P/S

T1 T2 T3

L1 L2 L3


STARTÌÌÌÌSTOP

ÌÌ

Figure 3.15 SMP-3 Starter Wiring Schematic (with Push ButtonControl)

ÌÌÌÌ

M

ÌÌÌÌ

SMP-350 60

30 40



SMP-3

START

ÌÌÌÌ

STOPÌÌÌÌÌÌ

M

➊ Applicable to Cat. No. 193-C1_1, 2,3,4,and 5, 592-C1_T, A, C, D, and E.

➋ The coil voltage and supply voltage must be the same. (i.e.120V AC or 240V AC).



3-20

Figure 3.16 CT-Mounted SMP-3 Starter Wiring Diagram Figure 3.17 CT-Mounted SMP-3 Starter Wiring (with Triac Control) Schematic (with Triac Control)

OUT A

OUT B

SMP-310

20

30

40

50

60

FUSE

120/240VAC P/S

TRIPRELAY

T1 T2 T3

CT1 CT2 CT3

L1 L2 L3

T1 T2 T3

ÌÌÌÌ

M

ÌÌÌÌ

CR

Interposing Relay

A1A2

L1 L2 L3

To 120VAC Supply

ÌÌÌÌ

CR

ÌÌÌÌSMP-350 60

30 40OUT ASMP-3 10

To 120V AC Supply

SMP-3

ÌÌÌÌ

To Voltage Source

MCR

➊ Applicable to Cat. No. 193-C1_6, 592-C1_F and G.

➋ The supply voltage to the SMP-3 overload must be 120 V AC.



3-21

Figure 3.18 SMP-3 Reversing Starter Wiring Diagram Figure 3.19 SMP-3 Reversing Starter Wiring Schematic(with Triac Control) (with Triac Control)

OUT A

OUT B

ÌÌÌÌ

FOR

SMP-310

20

30

40

50

60

FUSE

TRIPRELAY

120/240VAC P/S

T1 T2 T3

L1 L2 L3

ÌÌÌÌ

REV


4030ÌÌÌÌ

FOR

ÌÌÌÌ

SMP-350 60

OUT ASMP-3 10



SMP-3

ÌÌÌÌ

REV

OUT BSMP-3 20

REV

FOR

➊ Applicable to Cat. No. 193-C1_1, 2,3,4,and 5, 592-C1_T,A, C, D, and E.

➋ The coil voltage and supply voltage must be the same.(i.e.120V AC or 240V AC).

Note: Refer to page 3-17 for wiringATTENTIONS.


3-22

Figure 3.20 SMP-3 Reversing Starter Wiring Diagram Figure 3.21 SMP-3 Reversing Starter Wiring Schematic(with Push Button Control) (with Push Button Control)

OUT A

OUT B

ÌÌÌÌFOR

SMP-310

20

30

40

50

60

FUSE

TRIPRELAY

120/240VAC P/S

T1 T2 T3

L1 L2 L3

ÌÌÌÌ

REV


STOP

ÌÌ

REV

ÌÌ

FOR

ÌÌ

ÌÌÌÌSMP-350 60

30 40


SMP-3

ÌÌÌÌ

REV

STOP

ÌÌ

REV

ÌÌÌ

FOR

ÌÌÌFOR

REVFOR

REVÌÌÌÌ

FOR

➊ Applicable to Cat. No. 193-C1_1, 2,3,4,and 5, 592-C1_T,A, C, D, and E.

➋ The coil voltage and supply voltage must be the same.(i.e.120V AC or 240V AC).



3-23

Figure 3.22 CT-Mounted SMP-3 Reversing Starter Wiring Diagram Figure 3.23 CT-Mounted SMP-3 Reversing Starter (with Triac Control) Wiring Schematic (with Triac Control)

OUT A

OUT B

ÌÌÌÌ

FOR

SMP-310

2030

40

5060

FUSETRIPRELAY

120/240VAC P/S

L1 L2 L3

ÌÌÌÌ

REV

To 120V AC Supply

ÌCRR

ÌÌÌÌ

CRF

T1 T2

CT1 CT2 CT3

L1 L2 L3

T1 T2 T3

T3

A1 A2

InterposingRelay

InterposingRelay

A2 A1

ÌÌÌÌÌÌÌÌÌ

SMP-350 60

30 40OUT ASMP-3 10

To 120V AC Supply

SMP-3OUT BSMP-3 20

CRR

CRF

ÌÌÌÌCRF

ÌÌÌÌ

CRR

ÌÌÌÌREV

ÌÌÌÌFOR

FOR

REVCRF

CRR

To Voltage Source


➋ The coil voltage and supply voltage must be 120V AC.



3-24

Figure 3.24 SMP-3 Multi-speed Starter Wiring Diagram (with Triac Control)

OUT A

OUT B

OUT A

OUT B

SMP-3 (Low)10

2030

40

50

60

FUSETRIPRELAY

120/240VAC P/S

T3

SMP-3 (High)10

2030

40

50

60

FUSETRIPRELAY

120/240V AC P/S

ÌÌÌÌ

High ÌÌÌÌ

Low

L1 L2 L3

T1 T2T11 T12 T13



3-25

Figure 3.25 SMP-3 Multi-speed Starter Wiring Schematic (with Triac Control)

ÌÌÌÌ

High

ÌÌÌÌ

SMP-3(Low)

50 60

30 40

OUT ASMP-3(High) 10



ÌÌÌÌ

Low

OUT BSMP-3(Low) 10

ÌÌÌÌ

SMP-3(High)

50 60

30 40

SMP-3(Low)

SMP-3(High)

Low

High

➊ Applicable to Cat. No. 193-C1_1, 2,3,4,and 5, 592-C1_T, A, C, D, and E.➋ The coil voltage and supply voltage must be the same. (i.e.120V AC or 240V AC).



3-26

Figure 3.26 SMP-3 Multi-speed Starter Wiring Diagram (with Push Button Control)

OUT B

OUT A

OUT B

OUT A

SMP-3 (Low)10

2030

40

50

60

FUSETRIPRELAY

120/240VAC P/S

T3

SMP-3 (High)10

2030

40

50

60

FUSETRIPRELAY

120/240VAC P/S

ÌÌÌÌHigh

ÌÌÌÌ

Low

L1 L2 L3

T1 T2T11 T12 T13


STOP

ÌÌ

H

ÌÌÌÌ

L

ÌÌÌÌ


3-27

Figure 3.27 SMP-3 Multi-speed Starter Wiring Schematic (with Push Button Control)

ÌÌÌÌ

SMP-3(Low)

50 60

30 40


To 120/240 V AC Supply

ÌÌÌÌ

SMP-3(High)

50 60

30 40

SMP-3(Low)

SMP-3(High)

Low

High

STOP

ÌÌÌÌ

HÌÌÌÌ

L

ÌÌH

ÌÌÌ

LÌÌÌÌÌÌ

High

Low

ÌÌÌÌ

High

ÌÌÌÌ

Low

➊ Applicable to Cat. No. 193-C1_1, 2,3,4,and 5, 592-C1_T, A, C, D, and E.➋ The coil voltage and supply voltage must be the same. (i.e.120V AC or 240V AC).



3-28

Figure 3.28 CT-Mounted SMP-3 Multi-speed Starter Wiring Diagram (with Triac Control)

ÌÌÌÌ

CRHÌÌÌÌ

CRLA1 A2

InterposingRelay

Interposing Relay

A2 A1

SMP-3 (Low)10

2030

405060

OUT A

OUT B

FUSETRIPRELAY

120/240VAC P/S

T1 T2

CT1 CT2 CT3

T1 T2 T3

T3

SMP-3 (High)10

2030

405060

OUT A

OUT B

FUSETRIPRELAY

120/240VAC P/S

T11 T12

CT1 CT2 CT3

T1 T2 T3

T13

ÌÌÌÌ

LowÌÌÌÌ

High

To 120V AC Supply

L1 L2 L3


3-29

Figure 3.29 CT-Mounted SMP-3 Multi-speed Starter Wiring Schematic (with Triac Control)

ÌÌÌÌÌÌÌÌÌ

High

ÌÌÌÌÌÌ

Low

Low

HighCRL

CRHÌÌÌÌ

CRH

ÌÌÌÌÌÌ

SMP-3(Low)

50 60

30 40

OUT ASMP-3(High) 10


To 120V AC Supply

ÌÌÌÌ

CRL

OUT ASMP-3(Low) 10

ÌÌÌÌ

SMP-3(High)

50 60

30 40

SMP-3(Low)

SMP-3(High)

CRL

CRH


To Voltage Source


➋ The supply voltage to the SMP-3 must be 120V AC.Note: Refer to page 3-17 for wiring ATTENTIONS.


3-30

Figure 3.30 Remote Reset Wiring Diagram

Bulletin 800T–NX131(Back View)

Bulletin 1202 Cable

L1 (+) L2 (–)

P2P1 P1 (Black Wire)

P2 (Brown Wire)

L

Contact A(NO)

Jumper A Jumper B

Table 3.H Remote Reset Cable Selections

Catalog Number “L” Dimension

1202–RRC1 1 Meter (3.28 Ft.)

1202–RRC3 3 Meters (9.84 Ft.)

1202–RRC6 6 Meters (19.69 Ft.)

1. Connect a jumper wire (A) from the L1(+) terminal to one ofthe N.O. contact terminals on the Bulletin 800T–NX131, asshown above. Connect a second jumper (B) from L2(–)terminal to the other N.O. contact terminal. Use .50 mm(AWG 22) minimum wire for the jumpers.

2. Connect the black wire of the Bulletin 1202 cable to the P1terminals as shown above on the Bulletin 800T–NX1311 andthe brown wire of the Bulletin 1202 cable to the P2 terminalsof the Bulletin 800T–NX131.


3-31

Figure 3.31 Communication Adapter Mounting Distances and the Cable Connections

A

N1

2

Maximum DistanceA + B ≤ 10 MetersA + C ≤ 10 MetersB + C ≤ 10 Meters

A

B

C

Adapter 1

Adapter 1

Adapter 2

Splitter

Bulletin 1202 Cable

Bulletin 1203–SG2

Pull back connector to dis-connect cable from adapterdevice or port 1 connection.

Male–Male Cable ➊

Male–MaleCable ➊



Port 1

➊ Use Cables 1202-CXX. See Appendix B.

Port 1

Maximum DistanceA ≤ 10 Meters


3-32

CONFIGURING THE SMP-3 OVERLOAD RELAY

The SMP-3 overload relay contains 14 DIP switches forconfiguring the trip characteristics of the SMP-3 overload relay.These DIP switches are located on the front of the device underthe anti-tamper shield. These DIP switches are used to set thetrip class, manual or automatic reset mode, ground faultdetection, jam detection, test, and the full load current of theSMP-3 overload relay as shown below:.

Setting Trip Class – The trip class can be set to class 10, 15, 20,or 30. The trip class number (10, 15, 20, 30) defines the maxi-mum time, in seconds, at which the relay will trip when carry-ing 600% of the rated current. For the SMP-3 overload relay,the rated current is 1.2 times the full load current (FLC) set-ting.

Figure 3.32 SMP-3 DIP Switches

FLC SettingTrip ClassAuto/Man

Ground FaultJamTest

}

ON

OFF

Trip ClassDIPSwitch

• •Class 10 – Place both Trip Class DIP switches in the “OFF” postion. (Class 10 is used for motor loads with low inertiaand for hermetically sealed motors with short locked rotor times that require the maximum protection.)

•• Class 15 – Place the most significant trip class DIP switch in the “OFF” position and the least significant in the “ON”

position. (Class 15 is used when the motor is not able to accelerate the load with a class 10 setting and the maximumprotection is needed.)

••

Class 20 – Place the most significant trip class DIP switch in the “ON” position and the least significant in the “OFF”position. (Class 20 is standard overload protection for general applications.)

• • Class 30 – Place both trip class DIP switches in the “ON” postion. (Class 30 is used for motors that need to start highinertia loads and require long acceleration times.)


3-33

Setting Auto/Manual Reset – The Auto/Man reset DIP switch is used to establish the “overload” reset mode of the SMP-3.

Auto/Man DIP Switch

•Auto

Automatic Reset – The SMP-3 overload relay is set to automatic reset mode by placing the Man/AutoDIP switch in the “ON” or “Auto” postion. In the “Auto” reset mode, an overload fault on the SMP-3overload relay will automatically be reset after the appropriate reset delay time (See Reset Delay Timesin Chapter 4).

•Man

Manual Reset – The SMP-3 overload relay is set to manual reset mode by placing the Man/Auto DIPswitch in the “OFF” or “Man” position. In manual reset mode, an overload fault on the SMP-3 over-load relay can be manually reset by pressing the SMP-3 “RESET” button, the remote reset push button(connected to the “REMOTE RESET” port on the SMP-3 overload relay), or the reset button on theHuman Interface Module (connected to the “COMM” port on the SMP-3 overload relay). However, anoverload fault can not be manually reset on the SMP-3 overload relay until the appropriate reset delaytime has expired. (See Reset Delay Times in Chapter 4).

ATTENTION: Do not use the automatic resetmode in applications where unexpected orautomatic restart of the motor can cause injury topersons or damage equipment.

Note: The Auto/Man setting only affects the reset mode of theSMP-3 overload relay after an overload fault. All other faultsmust be manually reset. Only an overload fault is autoresettable.


3-34

Selecting Ground Fault (GF), Jam/Stall, and Test Functionality

DIP Switch Setting

•ON

Ground Fault (GF) – The ground fault feature of the SMP-3 overload relay is enabled by placing theGF DIP switch in the “ON” position. When the ground fault is enabled, the SMP-3 overload relay willtrip if an equipment ground fault of� 50% of the full load current setting exists for 0.5 second, afterthe SMP-3 overload relay has been operating with � 30% of the full load current setting for at leastone trip class time period.

Note 1: The ground fault protection can only be used in three-phase applications. For single phaseapplications the ground fault DIP switch must be in the OFF position.

Note 2: With wye-delta motor applications, the trip threshold is equal or greater than 25% of the of theFull Load Current setting.)

• OFFJam/Stall – The Jam/Stall feature of the SMP-3 overload relay is enabled by placing the Jam/Stall DIPswitch in the “ON” position. When the jam/stall switch is enabled, the SMP-3 overload relay will tripif �400% of the full load current setting exists for 0.5 seconds, after the SMP-3 overload relay hasbeen operating with ≥30% of the full load current setting for more than one trip class period of time.

TEST – The trip functionality of the SMP-3 overload relay can be tested by placing the test DIPswitch in the “ON” postion. When the test DIP switch is moved to the “OFF” position, the SMP-3overload relay will remain in the “Test Fault“ condition until manually reset.


3-35

Setting the Full Load Current (FLC)The full load current is set with the eight FLC DIP switches.Above each DIP switch on the front of the SMP-3 overloadrelay a number identifies the current associated with thatparticular DIP switch. The total FLC setting is the sum of allthe currents for the DIP switches set in to ON position.

The rated current (the current above which the SMP-3 overloadrelay will ultimately trip) is 120% of the full load currentsetting. The current range and the minimum settings are listedbelow.

ATTENTION: The current measurement isbased on the average value of the peaks of asinusoidal current within a frequency of 50 to 60Hz. Overload and other protection is based on thehigh phase. Any non-sinusoidal current willdeviate from the true RMS current value beingread. Operation at frequencies other than 50 to 60Hz or non-sinusoidal currents can comprise theprotection characteristics of the SMP-3 overloadrelay.


3-36

Table 3.I FLC DIP Switch Designations and Minimum Settings

Cataloger ➊

CurrentRange

LC

FLC SwitchDesignations

MinimumSetting

A pereNumber ➊ (FLCRange) SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

(Amperes)➋ ➌

xxx–C1Dx (0.7–2.5A) 1.00 0.70 0.40 0.20 0.10 .05 .03 .02 0.70xxx–C1Fx (2–10A) 5.0 2.0 1.0 1.0 0.5 0.2 0.2 0.1 2.0xxx–C1Hx (8–37A) 15.0 10.0 5.0 4.0 2.0 1.0 0.5 0.2 8.0xxx–C1Kx (20–75A) 30 20 10 5 5 2 2 1 20xxx–C1Lx (20–90A) 40 25 10 5 5 2 2 1 20xxx–C1Mx (40–180A) 75 50 25 10 10 5 3 2 40xxx–C1Nx (70–304A) 150 75 40 20 10 5 2 2 70xxx–C1Px (100–414A) 200 100 50 25 20 10 5 4 100xxx–C1Rx (140–608A) 300 150 80 40 20 10 5 3 140

➊ The X indicates a variable character in the Catalog Number.➋ If theSMP-3 FLC is set below the minimum allowable setting shown, the SMP-3

overload relay will fault on a Min FLC SET fault, fault code #6.

➌ If the FLC setting is set below the minimum allowable setting, the SMP-3 overloadrelay will default to using and reporting the minimum FLC setting shown in Table 3I.


3-37

FLC SETTING FOR APPLICATIONS IN USA AND CANADA

Motors with a Service Factor of 1.15 or greater: set the full loadcurrent to the nearest value of the motor current taken from themotor nameplate.

Motors with Service Factor of less than 1.15: set the full loadcurrent to the nearest value of 90% of the motor current takenfrom the motor nameplate.

Wye-Delta (Y∆) Applications (relay carrying motor phase current):Follow the applicable service factor instruction, except dividethe motor nameplate full load current amperes by 1.73.

FLC SETTINGS FOR APPLICATIONS OUTSIDE USA ANDCANADA

Maximum Continuous Rated (MCR) Motors: Set the full loadcurrent to the nearest value of the motor current taken from themotor nameplate.

Star-Delta (Y∆) Applications (relay carrying motor phase current):Follow the above MCR instructions, except divide the motornameplate full load current amperes by 1.73.


3-38

4ChapterFunctional Description

4-1

CHAPTER OBJECTIVES

This chapter describes the functionality and features of theSMP-3 overload relay.

SMP-3 INPUTS/OUTPUTS

Configuration Dip Switches

The SMP-3 overload relay contains 14 configuration DIPSwitches. The six left-most DIP switches are used to configurethe trip class (2), establish the Auto/Man Reset Mode (1),enable/disable Ground Fault (1), enable/disable Jam/Stall (1),and to induce a Test Trip (1). The eight right-most DIPswitches are used to establish the SMP-3 FLC setting. SeeChapter 3 for further details on configuring the SMP-3.

Note: The SMP-3 overload relay continually monitors the DIPswitches for configuration changes, thus enabling the user tomake configuration changes on-the-fly.

Note: If the FLC setting is set lower than the minimumallowable setting for longer than five seconds, the SMP-3 willtrip on an “Illegal FLC Set” fault (F6).

Power SupplyThe SMP-3 overload relay contains a 120/240V AC universalinput power supply across control terminals 50 and 60 (SeeChapter 3 for control terminal block designations, wire size,and tightening torque information). The SMP-3 will notfunction if the correct control voltage is not applied to theseterminals (See Appendix A for control voltage specifications).

OUT A and BThe SMP-3 overload relay contains two triacs, OUT A andOUT B, that are located across terminals 10 and 50 (OUT A)and 20 and 50 (OUT B), with a user-replaceable fuse commonto both outputs. Since the outputs were intended to providecoil control capability, the triacs within each SMP-3 overloadrelay were designed to control the 120 or 240V AC coil of thelargest contactor which that SMP-3 can be mounted to (SeeAppendix A for OUT A and B ratings and recommendedfusing).When power is first applied to the SMP-3 overload relay, OUTA and OUT B will remain in their OFF condition. A user canonly turn OUT A or OUT B ON through the use of acommunication adapter. Once turned ON, OUT A and OUT Bwill remain ON until they are turned OFF, the SMP-3 isde-energized, or until the SMP-3 overload relay faults. Similarto the Trip Relay, the SMP-3 overload relay will turn both OUTA and OUT B OFF when a fault occurs. Unlike the Trip Relay,however, OUT A and B will remain OFF after the fault iscleared; OUT A and B will not turn ON until commanded todo so.

Chapter 4 – Functional Description

4-2

ATTENTION: Noise suppression circuitryacross OUT A and OUT B inside the SMP-3overload relay allows leakage current to flowwhen the output is in the off-state. See AppendixA for leakage current.

Trip Relay

The SMP-3 overload relay contains a Normally Open trip relayacross terminals 30 and 40 (See Appendix A for Trip Relayratings and recommended fusing). When power is applied to anunfaulted SMP-3 overload relay, the trip relay will close.However, when power is applied to a faulted SMP-3, the triprelay will remain open until the fault is reset.

Once the trip relay is closed, it will remain closed until theSMP-3 overload relay is de-energized or until a fault occurs. Ifa fault does occurs, the trip relay will open. The trip relay willremain open until the fault is reset. Once the fault is reset, thetrip relay will again close.

ATTENTION: Noise suppression circuitryacross the Trip Relay can result in leakage currentflowing through the relay circuit while it is in theopen state. See Appendix A for leakage current.

Status LEDs

The SMP-3 overload relay contains four LEDs to display thestatus of the SMP-3 overload relay. The description of eachLED is as follows:

LED Color Description

Power Green ON when power is applied to terminals 50 and 60 OFF when power is removed from terminals 50 and 60

AC OUT A Yellow ON when the triac output at terminal 10 is turned ONOFF when the triac output at terminal 10 is turned OFF

AC OUT B Yellow ON when the triac output at terminal 20 is turned ON OFF when the triac output at terminal 20 is turned OFF

Trip Red FLASH a specific fault code when the SMP-3 overloadrelay is tripped OFF when the fault is cleared

ATTENTION: The yellow status LEDs forOUT A and OUT B indicate that the SMP-3overload relay’s micro-controller attempted toturn the triac ON or OFF. It is not an indicationthat it did, in fact, turn it ON or OFF.

When a fault occurs, the SMP-3’s Trip LED and Remote ResetLED (Allen-Bradley Cat. No. 800T-NX1311) will flash aspecific fault code. The code consists of flashing a specificnumber of times, pausing, then repeating the same number offlashes. Table 9A on page 9-6 shows the number of flashesassociated with each type of SMP-3 fault.


4-3

SMP-3 PROTECTION FEATURES

The SMP-3 overload relay provides four primary forms ofmotor protection: Overload, Phase Loss, Ground Fault, andJam/Stall Protection.

Overload Protection

Overload protection is an embedded feature of the SMP-3overload relay. The SMP-3 overload relay provides overloadprotection by monitoring the maximum phase of motor current,and then using that data to calculate the overload’s thermalcapacity utilized. The SMP-3 overload relay will trip on anoverload fault (F2) if the following condition exists:

% Thermal Capacity Utilized (%TCU) > 100%

Trip Class. The SMP-3 overload relay offers adjustable tripclass settings of 10, 15, 20, and 30 (See Chapter 3 for “Settingthe Trip Class” instructions). The time it takes for the SMP-3overload relay to reach 100% TCU, at a specific over-currentlevel, is dependent upon this trip class setting.

Typically, the trip class number (10, 15, 20, or 30) defines themaximum time in seconds in which the overload relay will tripwhen carrying 600% of rated current. For the SMP-3 overloadrelay, the rated current is 1.2 times the full load current (FLC)set with the eight FLC DIP switches.

Trip Curves. The following figures illustrate the SMP-3 over-load relay’s time-current characteristics for each trip class.

Figure 4.1 SMP-3 Trip Curves – Class 10

0.1

1.0

10.0

100.0

1000.0

1 10Multiples of Full Load Current

2 3 987654

Appr

oxim

ate

Trip

Tim

e (s

ec.)

Approximate trip timefor 3-phase balanced condi-tion from cold start.

Approximate trip timefor 3-phase balanced condi-tion from hot start.


4-4




1.0

10.0

100.0

1000.0

10000.0

1 102 3 987654

Multiples of Full Load Current

Appr

oxim

ate

Trip

Tim

e (s

ec.)




Multiples of Full Load CurrentAp

prox

imat

e Tr

ip T

ime

(sec

.)

1.0

10.0

100.0

1000.0

10000.0

1 102 3 987654


4-5




Multiples of Full Load Current

Appr

oxim

ate

Trip

Tim

e (s

ec.)

1.0

10.0

100.0

1000.0

10000.0

1 102 3 987654

The following figure illustrates the time-current characteristicsof the SMP-3 overload relay after the auto-reset time hasexpired and the SMP-3 overload relay is reset.

Figure 4.5 SMP-3Trip Curve after Auto Restart

1000%100%0

1

10

100

1000

100000

Percent Full Load Current Setting

Seco

nds

Class 10

Class 15

Class 20

Class 30

Auto Reset Times:Class 10 = 90sClass 15 = 135sClass 20 = 180sClass 30 = 270s


4-6

Auto/Man Reset. The Auto/Man configuration DIP switch isused to select the overload reset mode of the SMP-3 overloadrelay. If Auto Reset (automatic reset) mode is selected, theSMP-3 overload relay will automatically reset after an overloadfault after the appropriate reset delay time has expired.

Class Reset Delay Time(seconds)

10 90

15 135

20 180

30 270

If Man Reset (manual reset) mode is selected, the SMP-3overload relay must be manually reset after an overload fault.The user, however, can not manually reset an overload faultuntil the appropriate reset delay time has expired. (See Chapter9 for instructions on “How to Clear a Fault”)

Note: The Auto/Man Reset configuration only affects the resetmode of an overload fault. All other faults must be manuallyreset.

Note: An overload fault can never be reset until theappropriate reset delay time has expired.

Phase Loss Protection

Phase Loss protection is an embedded feature of the SMP-3overload relay. The SMP-3 overload relay provides phase lossprotection by monitoring the average current through theSMP-3 overload relay and the current unbalance between eachphase. The SMP-3 overload relay will trip on a phase loss fault(F3) if the following conditions exist:

% Current Unbalance (%CU) > 50% for onesecond continuously

Note: The Phase Loss protection is inhibited until the SMP-3overload relay operates with sufficient current ( ≥ 30% of theFLC Setting).

Ground Fault Protection

Ground fault protection is enabled or disabled by placing theGround Fault configuration DIP switch in the ON or OFFposition, respectively. When ground fault protection isenabled, the SMP-3 overload relay will sense an equipmentground fault condition and trip on a ground fault (F4) if thefollowing conditions exist:

Ground Fault Level ≥ 50% of the FLC Setting for0.5 seconds continuously

Note: The ground fault protection is inhibited until the SMP-3overload relay has been operating with sufficient current (≥30% of the FLC Setting) for at least one trip class duration.


4-7

Note: In Wye-Delta motor applications, the trip threshold is ≥25% of the FLA Setting

The ground fault protection feature of the SMP-3 overloadrelay can only be used in three-phase applications. The groundfault configuration DIP switch must be placed in the OFFposition for single-phase applications.

Jam/Stall Protection

Jam/Stall protection is enabled or disabled by placing theJam/Stall configuration DIP switch in the ON or OFF position,respectively. When Jam/Stall protection is enabled, the SMP-3overload relay will monitor the average current motor currentand trip on a Jam/Stall (F5) if the following conditions exist:

Average Current > 400% of the FLA Setting for0.5 seconds continuously

Note: The Jam/Stall protection is inhibited until the SMP-3overload relay has been operating with sufficient current (≥ 30% of the FLC Setting) for at least one trip class duration.

SMP-3 MISCELLANEOUS FEATURES

Test

The SMP-3 overload relay provides a TEST DIP switch to al-low a user to test the tripping ability of the SMP-3 overloadrelay. When the TEST switch is placed in the ON position thefollowing events will occur:

� The SMP-3 overload relay will trip on a TEST fault

� The SMP-3 TRIP LED will flash a 1-flash fault code

� The Trip Relay across terminals 30 & 40 will open

When some of the additional features of the SMP-3 overloadrelay are being utilized, the following events may also occur:

� OUT A and OUT B will turn OFF

� The HIM will display “TEST/TRIP” and fault code “F1”

� The Remote Reset LED will flash a 1-flash fault code

Once the tripping ability of the SMP-3 overload relay has beenverified, the TEST DIP switch must be placed in the OFFposition before the TEST fault can be reset.

Reset

The SMP-3 overload relay contains a blue RESET button thatcan be used to manually reset SMP-3 faults. Refer to Chapter 9for more information regarding when and how to clear faults.


4-8

Remote Reset

The SMP-3 provides a REMOTE RESET port to which aremote reset push-button (Allen-Bradley Cat. No.800T-NX1311) can be connected to using a Bulletin 1202Remote Reset Cable (See Remote Reset Wiring Diagram andCable Selection in Chapter 3 for more information).

Once connected, the remote reset push button duplicates thefunctionality of the SMP-3 RESET button and TRIP LED. TheLED on the remote reset push button will flash the same faultcode as the SMP-3’s TRIP LED, and the push button can bepressed to reset a SMP-3 fault.

Communications

The SMP-3 overload relay provides a COMM port to which aCommunication Module and/or Human Interface Module canbe connected to using a Bulletin 1202 Communication Cable(See Appendix B for a complete listing of communicationadapters and cables). Since the SMP-3 overload relay onlyprovides one communication port, a communication splitter(1203-SGA) must be used to communicate to two adapters atthe same time. The splitter expands the SMP-3’s COMM port(port 1) into two ports (port 1 and port 2).

Note: The SMP-3’s COMM port can not be expanded to morethan two ports. The SMP-3 will only support port 1 and port 2.


4-9

Communication Parameters. The following is list of the parameters that the SMP-3 overload relay can communicate toan adapter.

[Average Current]

This parameter is the average value of thethree-phase current passing through the SMP-3overload relay. The accuracy of the average currentreported to a communication adapter is ± 5%

Parameter # 1

Parameter Type Read Only

Units Amps

[FLC Setting]

This parameter is the actual Full Load Current (FLC)setting established by the eight FLC DIP switches.

Parameter # 2


Units Amps

[Thermal Capacity Utilized]

This parameter indicates the amount of the overloadrelay’s thermal capacity which has be utilized. Thevalue is based on the maximum phase of current andthe time it is present.

Parameter # 3


Units Percent

[Current Unbalance]

This parameter indicates the level of unbalancebetween the three phases of current. The value isbased upon the magnitude unbalance between thethree phases.

Parameter # 4


Units Percent


4-10

Communication Parameters. (cont.)

[Firmware Revision]

The firmware revision number identifies the releaseof the logic code that is controlling the SMP-3overload relay. If contacting the factor regarding aproblem, be prepared to provide this number.

Parameter # 5


Units None

[Device Port #]

This parameter identifies the port that the adapterbeing used to monitor the parameter is connected to.The SMP-3 overload relay only supports port 1 andport 2, identified by a “1” in the second or thirdposition from the right, respectively.

Parameter # 6


Units Byte

BitP rt er ett g E p a at

7 6 5 4 3 2 1 0Port Number Setting Explanation

X Not Used — —

X Port 1 1 Connected

X Port 2 1 Connected

X Not Used — —

X Not Used — —

X Not Used — —

X Not Used — —

X Not Used — —


4-11

Communication Parameters. (cont.)

[Mask]

The mask parameter can be used to program oridentify the communication adapter devices that areenabled and/or disabled. Refer to Chapter 8 forLogic Mask Programming instructions

Parameter # 7

Parameter Type Read/Write

Units Byte

Factory Default 00000110

Settings 1 Permit Control (enabled)0 Deny Control (disabled)

BitA apter er ett g E p a at

7 6 5 4 3 2 1 0Adapter Number Setting Explanation

X Not Used — —

X Adapter 1 10

Enabled (Unmasked)Disabled (Masked)

X Adapter 2 10

Enabled (Unmasked)Disabled (Masked)

X Not Used — —

X Not Used — —

X Not Used — —

X Not Used — —

X Not Used — —

[Status]

This parameter is a 16 bit common status messageinterpreted by the HIM and transmitted by all serialport master devices. The message status contentsfor the SMP-3 overload relay are defined in Table4.A.

Parameter # 8


Units


4-12

Table 4.A SMP Status Word DefinitionBit Bit SMP

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0Bit

DescriptionSMP

Setting

X Reserved Fixed = 1







X Fault 0 = No Fault1 = Fault





X Output A 1 = On0 = Off

X Output B 1 = On0 = Off




4-13

Human Interface Module Adapter. The Human InterfaceModules were designed to allow users to locally program, mon-itor, and/or control master devices (such as SMP-3 overloadrelays, Drives, or SMCs). The SMP-3 overload relay can com-municate directly to a Drive HIM (1201-HA_) or a SMP-3 HIM(193-HIM1). However, since the SMP-3 HIM was designedspecifically for the SMP-3 overload relay, it provides morefunctionality than the Drive HIM when used with the SMP-3.For example, the SMP-3 HIM can control both OUT A andOUT B, while the Drive HIM can only control OUT A. SeeChapter 5 for more Human Interface Module information.

Communication Module Adapter. The SMP-3 overload relaycommunicates to its adapters (slaves) via SCANport, an Allen-Bradley proprietary serial communication protocol. The pur-pose of the Communication Module is to convert the SMP-3’sSCANport protocol to the desired logic controller protocol,such as R I/O or DeviceNet . See Chapter 6 for more Com-munication Module information.


4-14

5ChapterHuman Interface Module

5-1

CHAPTER OBJECTIVES

Chapter 5 describes the various controls and indicators foundon the SMP-3 Human Interface Module (HIM) and the DriveHIM.

HIM DESCRIPTION

Each HIM shown has two panels: a display panel and a controlpanel. The display panel enables the user to:

� program the SMP-3 overload relay

� view operating parameters

The control panel enables the user to:

� control output A

� control output B

� reset the SMP-3 overload relay

Figure 5.1 SMP-3 HIM

ESC SEL

START/RESET DISABLED

OUT A OUT B

FAULT

RESET

OUT A&BOUT A OUT B

Figure 5.2 Drive HIM

JOG

ESC SEL

ESC

SEL

RESET

Chapter 5 – Human Interface Module

5-2

DISPLAY PANEL DESCRIPTIONS

Note: The following display panel descriptions apply to boththe SMP-3 HIM and the Drives HIM.

EscapeUse this key to cause the programming system to goback one level in the menu structure.

SelectUse this key to indicate which line of the displayshould be active. The first character of the active linewill flash.

Up/Down ArrowsUse these keys to increment and decrement a value orscroll through the parameter list.

EnterPress this key to select a parameter or enter aparameter value into memory. After you have entereda parameter into memory, the top line of the displaywill automatically become active, allowing you tochoose another parameter (or group).

CONTROL PANEL DESCRIPTION

SMP-3 HIM Control Panel Description

Note: The Reset, Out A ON, Out B ON keys of any HIM canbe masked out (See Chapter 8). The OFF keys, however cannot be masked out. All OFF keys are always functional.

ResetPress this key to reset a SMP-3 overload relay fault ifit is clearable. This operation is edge-sensitive andtrip-free, that is, holding the key down will notprevent the SMP-3 overload relay fromtripping/faulting. This functionality can be maskedout.

OUT A

Out A ONPress this green key to energize output A (terminal10). This functionality can be masked out.

Press this red key to de-energize output A (terminal10).


5-3

OUT B

Out B ONPress this green key to energize output B (terminal20). This functionality can be masked out.

Press this red key to de-energize output B (terminal20).

OUT A&B

Press this red key to simultaneously de-energizeoutputs A and B (terminals 10 and 20, respectively).

SMP-3 HIM LED Indicators

FaultThis LED is illuminated when the HIM is connectedto a faulted SMP-3 overload relay.

Start/Reset DisabledThis LED is illuminated when the control buttons onthe HIM (OUT A and OUT B, ON, and Reset) aremasked-out (disabled). This LED is de-energizedwhen the controls of the HIM are active (enabled).An adapter may only be disconnected from theSMP-3 overload relay if it is masked out (Start/Resetare disabled). Therefore, this LED also indicateswhen the HIM may be disconnected from the SMP-3overload relay. IF the LED is energized, the HIMmay be disconnected from the SMP-3 overload relaywithout causing the SMP-3 overload relay to fault.

Note: The OUT A, OUT B, and OUT A and B OFF buttonsare always functional.

Note: Setting the Logic Mask to “1” or “0” will turn off or onthis LED, respectively (See Chapter 8).

Out AThis LED is illuminated when output A atterminal 10 is energized.

Out BThis LED is illuminated when output B atterminal 20 is energized.


5-4

Drives HIM Control Panel Description

Press this green key to energize output A (terminal10). This functionality can be masked out.

Press this red key to turn off both output A and B.

Pressing the same red key to reset the SMP-3overload relay when a fault exists.

Note: OUT B can not be energized with a Drive HIM.

HIM STATUS DISPLAY

The HIM contains a 2-line, 16-position alpha-numeric display.The top line is the text line while the bottom line is the valueline:

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

Text LineValue Line

When a HIM is connected to a SMP-3 overload relay, the HIMdisplay will display a series of start-up screens (as indicated inChapter 7). Eventually, it will display a default status display.

There are two styles of status displays for the SMP-3 overloadrelay: an OUT A/B status and a fault status display. If theHIM is connected to an unfaulted SMP-3 overload relay thatdisplay will indicate the status of outputs A and B and theaverage current through the SMP-3 overload relay:

A=OFF B=ON0.0 AMPS

A=OFF B=ON0.0 AMPS

A=ON B=ON0.0 AMPS

A=OFF B=OFF0.0 AMPS

A user can always view the status display by pressing escapeuntil it is displayed.

If the SMP-3 overload relay faults while the HIM is connectedto it, the HIM display will automatically default to one of theeight fault status displays. the fault status display will indicatethe fault cause and fault code. The fault code (i.e. F2)corresponds to the number of flashes (i.e. “2”) on the SMP-3Trip LED.


5-5

Note: Earlier versions of the HIM may require the user topress ESC (Escape key) to return to the fault default statusdisplay.

OverloadF2

Trip/TestF1

Phase LossF3

Ground FaultF4

Jam/StallF5

Illegal FLC SetF6

Non Vol Mem FaultF7

Comm FaultF8

HIM MODES

The SMP-3 HIM supports four modes: display, program,search, and control status mode.

The menu structures are dictated by the master device. So adrive HIM used with a SMP-3 overload relay will provide thesame menu scheme and modes as a SMP-3 HIM used with aSMP-3 overload relay. (Assuming both have the same coderelease).

Note: Earlier versions of HIMs may only support the displayand program modes.

Display Mode

When selected, the Display Mode allows you to view all eightof the SMP-3 communication parameters. However, in Displaymode the SEL key is disabled to prevent the parameters frombeing modified.

The SMP-3 parameters can be viewed by using the followingsteps:


5-6

ACTION DESCRIPTION HIM DISPLAY

or

ESC SEL

To Select Mode

1. Press any key to go from the Status Display to the Choose Modemenu.

2. Press the up/down keys to toggle to “Display” in the display.

3. Press Enter to go to the Display menu. (If this is the first time thatthe display mode is entered since the last power-up, the display willstart with parameter 1. Otherwise the display will start with the lastparameter displayed). The parameter number is located on the rightside of the value line.

4. Press Up for the next display parameter.

A=OXX B=OXXX.X AMPS

Choose ModeDisplay

Average CurrentX.X AMPS 1

FLC SettingX.X AMPS 2

Thermal Cap UsedX%TCU 3

Current UnbalX%CU 4

(Firmware Rev?)X.xx 5

DEVICE PORT#00000XX0 6

MASK (0–DISABLE)00000XX0 7

STATUSXXXXXXXXXXXXXX 8


5-7

Program Mode

When selected, the program mode is used to view the SMP-3communication parameters or program the SMP-3 Logic Maskparameter. The difference between Program and Display Modeis that in Program Mode the first character of the text lineflashes to indicate that the parameter value can modified.Refer to Chapter 8 for instructions on programming.

Search Mode

When selected, the search mode will indicate whichprogrammable parameters are not at default settings. SinceLogic Mask is the only programmable parameter, it is the onlyparameter that is verified.

Control Status Mode

When selected, the Control Status mode allows you to quicklymask out/disable the HIM.

When using this mode, the HIM will automatically program thecontrol bit of the Logic Mask which represents the HIM. Referto Chapter 8 for details about programming the Logic Mask inControl Status Mode.

Note: Only the HIM can be masked out using the ControlStatus Mode.

Note: The start/reset Disabled LED will be energized when theSMP-3 is masked out regardless of the mode used to performthe masking.


5-8

HIM INSTALLATION AND REMOVAL

Installation

The HIM can be used as a hand-held terminal or it can bemounted on the front of an enclosure. The HIM connects to theSMP-3 overload relay via a SCANport cable plugged into the“COMM” port on the front of the SMP-3 overload relay.Communication with any HIM that is plugged in to the SMP-3overload relay is established when the SMP-3 overload relay isenergized.

The SMP-3 overload relay has one SCANport communicationport. This can be expanded to a maximum of two ports with asplitter (Cat. No. 1202–SG2). Only one splitter may be usedand the total current draw of the two adapters must not exceed200mA.

Removal

The HIM can be disconnected from the SMP-3 overload relayin one of two ways:

A. Turn off outputs A and B (if ON), de-energize the SMP-3overload relay, disconnect the HIM cable from the SMP-3overload relay, and re-energize the SMP-3 overload relay.

B. Remove the HIM from the SMP-3 overload relay while theSMP-3 overload relay is energized by masking out theLogic Mask bit that identifies the adapter address of theHIM. Refer to Chapter 8 for Logic Mask programminginstructions.

IMPORTANT: When the Logic Mask bit for an adapter ischanged from “1” to “0,” it disables all command functions forthe adapter except for the stop commands.

IMPORTANT: If any unmasked communication adapter isdisconnected from the SMP-3 overload relay while the SMP-3overload relay is energized, the SMP-3 overload relay willissue a “Comm Fault.”

6ChapterSerial Communication

6-1

COMMUNICATIONS USING BULLETIN 1203 COMMUNICATION MODULES

The SMP-3 overload relay can communicate its parameter datato a PLC, SLC, or other logic controller by using an optionalBulletin 1203 communications module. The amount ofinformation that is transferred between the SMP-3 overloadrelay and the logic controller is determined by the DIP switchsettings on the communication module.

The suggested DIP switch settings for an SMP-3 overload relayand 1203-GD1 (used to communicate with a PLC) applicationis shown in Table 6.A. DIP switch settings for othercommunications modules will be similar. Refer to theappropriate communication module user manual for details.

Table 6.A 1203-GD1 Communication Module Configuration (whenused with SMP-3 overload relay)

SW3DIP # Type of Data Transferred

RackSpace

(in words)

Recom-mendedSetting

ReferenceInformation

1 Block transfer of data(not recommended)

1 off

2 Logic Control and SMP-3overload relay Status data

1 onSeeTable 6.B and 6.C

3 Analog reference 1 on

4 Parameter data viaDatalink A (not supported)

2 off

5 Parameter data viaDatalink B (not supported)

2 off

6 Parameter data viaDatalink C (not supported)

2 off

7 Parameter data viaDatalink D (not supported)

2 off

8 Unused — off

Chapter 6 – Serial Communication

6-2

Logic Control DataThe information in Table 6.B illustrates the logic control data that is sent to the SMP-3 overload relay through the logic controlleroutput image table. When using the Bulletin 1203-GD1 communication module, this information is sent to the SMP-3 overloadrelay when SW3 dip 2 on the 1203-GD1 module is ON.

Table 6.B SMP-3 Logic Control Data

Bittat ett xp a at

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0Status Setting Explanation

X Turn Out A off 1 Turn Out A off

X Turn Out B off 1 Turn Out B off

X Clear Fault 1 Clear Fault

X Turn Out A on 1 Turn Out A on

X Turn Out B on 1 Turn Out B on

X X X X X X X X Not Used X XXX

X X X Analog Parameter Selection➀

001010011100

Average CurrentThermal Capacity UtilizedFull Load Current SettingCurrent Unbalance

➀ These three bits are used to specify/request the analog reference parameter theSMP-3 overload relay should send back with the SMP-3 Status Data.

Note: The Turn Triac Off, Turn Triac On, and Clear Faultsignals are edge sensitive.


6-3

SMP-3 Status DataThe information in Table 6.C illustrates the SMP-3 overloadrelay status data that is sent to the logic controller input imagetable from the SMP-3 overload relay. When using the Bulletin1203-GD1 communication module, this data will be sent to thePLC from the SMP-3 overload relay when SW3 dip 2 on the1203-GD1 module is ON.


6-4

Table 6.C SMP-3 Status DataBit

tat ett xp a at15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Status Setting Explanation

X Out A 01

offon

X Out B 01

offon

X Control Status 01

Control DisabledControl Enabled

X ConnectionIndication

X Fixed (Help detect if connected)

X Not Used X XXXX X X Analog Feedback

Designator000001010011100

Default (Average Current)Average CurrentThermal Capacity UtilizedFull Load Current SettingCurrent Unbalance

X X X X X X X X Fault Code 0000 00000000 00010000 00100000 00110000 01000000 01010000 01100000 01110000 1000

No FaultTrip/TestOverload FaultPhase Loss FaultGround FaultJam/Stall FaultIllegal FLC Set FaultNon-Vol Memory FaultComm Loss Fault

Note: The next 16 bit word following the 16 bit Status Dataword is the unscaled analog value of the parameter selected bybits 13–15 in the Logic Control Data word.


6-5

Scale Factor Conversion

When reading the average current parameter data in the logiccontroller’s input table, divide these values by the scalingvalues shown in Table 6.D to determine the “display units.”

Table 6.D Average Current and FLC Setting Scaling

Current Range(FLC Range) Scaling Factor ➀

0.7–2.5 A 100x value

2–10 A 10x value

8–37 A 10x value

20–75 A 1x value

20–90 A 1x value

40–180 A 1x value

70–304 A 1x value

100–414 A 1x value

140–608 A 1x value

➀ The value received will be scaled by the number shown. To recover the actualvalue, divide the received value by the scaling factor shown.


6-6

SAMPLE PROGRAM LISTING FOR REMOTE I/O TO SERIAL PORT COMMUNICATION

The diagram shown below reflects the memory configuration used in the sample ladder logic program shown in the remainingportion of this chapter.

Figure 6.1 Typical SMP-3 R/IO Communication Block Diagram

Logic Control Data

SMP-3 Status DataAnalog Parameter Value

PLC-5

PanelView

Gateway ➀

➁

ContactorSMP-3

➀ Logic Control Data ( Table 6.B) from logic controller’s output image table. ➁ SMP-3 Status Data (Table 6.C) to logic controller’s input image table.


6-7

The following section outputs the OUT A status, OUT B status, and Control status of the SMP-3 overload relay to a local rack andPanelview address.Rung 2:0Output OutA Status, OutB Status, and Control Status from SMP (Rack 2,Word 0,Bit 0–2)to Local Rack indicators (Rack 0, Word 1, Bits 0–2)| +BTD–––––––––––––––+ |+–––––––––––––––––––––––––––––––––––––––––––––––––––––––––+BIT FIELD DISTRIB +–+| |Source I:020| || | 36| || |Source bit 0| || |Destination O:001| || | 4| || |Destination bit 0| || |Length 3| || +––––––––––––––––––+ |Rung 2:1Output SMP Status (Rack 2,Word 0, Bit 0–2) to PanelView (Rack 1,Word 0)| +BTD–––––––––––––––+ |+–––––––––––––––––––––––––––––––––––––––––––––––––––––––––+BIT FIELD DISTRIB +–+| |Source I:020| || | 36| || |Source bit 0| || |Destination O:010| || | 36| || |Destination bit 0| || |Length 3| || +––––––––––––––––––+ |


6-8

The following section determines the value of the selected analog parameter sent from the SMP-3, and sends that value to thecorresponding destination of a Panelview. The Panelview destination is determined by the analog feedback designator from theSMP (Rack 2, Word 0, Bits 5–7).Rung 2:2Average Current to Rack 3,Word 0| I:020 I:020 I:020 +MOV–––––––––––––––+ |+––]/[–––]/[–––] [––––––––––––––––––––––––––––––––––––––––+MOVE +–+| 07 06 05 |Source I:021| || | 0| || |Destination O:030| || | 0| || +––––––––––––––––––+ |Rung 2:3Thermal Capacity Utilized to Rack 3,Word 1| I:020 I:020 I:020 +MOV–––––––––––––––+ |+––]/[–––] [–––]/[––––––––––––––––––––––––––––––––––––––––+MOVE +–+| 07 06 05 |Source I:021| || | 0| || |Destination O:031| || | 0| || +––––––––––––––––––+ |Rung 2:4Full Load Current Setting to Rack 3,Word 2| I:020 I:020 I:020 +MOV–––––––––––––––+ |+––]/[–––] [–––] [––––––––––––––––––––––––––––––––––––––––+MOVE +–+| 07 06 05 |Source I:021| || | 0| || |Destination O:032| || | 20| || +––––––––––––––––––+ |


6-9

Rung 2:5Current Unbalance to Rack 3,Word 3| I:020 I:020 I:020 +MOV–––––––––––––––+ |+––] [–––]/[–––]/[––––––––––––––––––––––––––––––––––––––––+MOVE +–+| 07 06 05 |Source I:021| || | 0| || |Destination O:033| || | 0| || +––––––––––––––––––+ |

The following section displays the SMP-3 fault status on the panelview.Rung 2:6Copy Fault status bits from SMP Status (Rack 2,Word 0, Bits 8–15)to buffer N31:1 bits 0–7 for comparison purposes.| +BTD–––––––––––––––+ |+–––––––––––––––––––––––––––––––––––––––––––––––––––––––––+BIT FIELD DISTRIB +–+| |Source I:020| || | 36| || |Source bit 8| || |Destination N31:1| || | 0| || |Destination bit 0| || |Length 8| || +––––––––––––––––––+ |Rung 2:7If any fault bit is set, energize generic fault indicator on Local Rack (Rack 0,Word 1,Bit 7)| +GRT–––––––––––––––+ O:001 |+–+GREATER THAN +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Source A N31:1| 07 || | 0| || |Source B 0| || | | || +––––––––––––––––––+ |


6-10

Set appropriate fault bit in word sent to Panelview (Rack 1, Word 0, Bit 8–15)based on fault code from SMP (Rack 2, Word 0, Bit 8–15 copied to N31:1)Rung 2:8| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 10 || |N31:1 = 1 | || +––––––––––––––––––+ |Rung 2:9| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 11 || |N31:1 = 2 | || +––––––––––––––––––+ |Rung 2:10| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 12 || |N31:1 = 3 | || +––––––––––––––––––+ |Rung 2:11| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 13 || |N31:1 = 4 | || +––––––––––––––––––+ |Rung 2:12| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 14 || |N31:1 = 5 | || +––––––––––––––––––+ |


6-11

Rung 2:13| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 15 || |N31:1 = 6 | || +––––––––––––––––––+ |Rung 2:14| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 16 || |N31:1 = 7 | || +––––––––––––––––––+ |Rung 2:15| +CMP–––––––––––––––+ O:010 |+–+COMPARE +––––––––––––––––––––––––––––––––––––––––––––––––––––( )––+| |Expression | 17 || |N31:1 = 8 | || +––––––––––––––––––+ |


6-12

The following section of code transfers commands from the local rack control switches to the SMP-3 overload relay. Thesecommands control OUT A and OUT B, reset faults, and establish the analog parameter that is to accompany the status word fromthe SMP-3 overload relay.Rung 2:16Output Local Rack Control Switches (Rack 0,Word 1,Bit 0–4) to SMP (Rack 2,Word 0, Bit 0–4).

Bit 0 – Output A OffBit 1 – Output B OffBit 2 – ResetBit 3 – Output A ONBit 4 – Output B ON

| +BTD–––––––––––––––+ |+–––––––––––––––––––––––––––––––––––––––––––––––––––––––––+BIT FIELD DISTRIB +–+| |Source I:001| || | 24| || |Source bit 0| || |Destination O:020| || | 24| || |Destination bit 0| || |Length 5| || +––––––––––––––––––+ |


6-13

The following section of code allows the analog parameter to be manually or automatically selected. The mode of operation isselected with Rack 0, Word 1, Bit 3: Set = automatic mode

Clear = manual mode

In manual mode the analog parameter is selected via Rack 0, Word 1, Bit 5, 6, 7. In automatic mode the analog parameter isselected via the code.Rung 2:17Manual Parameter SelectionOutput Local Rack analog parameter selection (Rack 0, Word 1, Bit 5,6,7) to SMP Control Word (Rack 2,Word 0,Bits13,14,15)

Bit 13,14,15 – 000 or 001 = Average Current010 = Thermal Capacity Utilized011 = FLC Setting100 = Current Unbalance

| I:010 +BTD–––––––––––––––+ |+––]/[––––––––––––––––––––––––––––––––––––––––––––––––––––+BIT FIELD DISTRIB +–+| 03 |Source I:001| || | 24| || |Source bit 5| || |Destination O:020| || | 24| || |Destination bit 13| || |Length 3| || +––––––––––––––––––+ |

Rung 2:18Auto Parameter SelectionReset parameter Selection to Average Current (1) after Current Unbalance (4)| I:010 +GRT–––––––––––––––+ +MOV–––––––––––––––+ |+––] [––+GREATER THAN +––––––––––––––––––––––––––––––+MOVE +–+| 03 |Source A N31:3| |Source 1| || | 3| | | || |Source B 4| |Destination N31:3| || | | | 3| || +––––––––––––––––––+ +––––––––––––––––––+ |


6-14

Rung 2:19Auto Parameter SelectionStart 30ms Timer to determine when to increment to next parameter| I:010 +TON–––––––––––––––+ |+––] [–––––––––––––––––––––––––––––––––––––––––––––––+TIMER ON DELAY +–(EN)–+| 03 |Timer T4:0| || |Time base 0.01+–(DN) || |Preset 30| || |Accum 0| || +––––––––––––––––––+ |Rung 2:20Auto Parameter SelectionAfter 30ms select next parameter| I:010 T4:0 +ADD–––––––––––––––+ |+––] [–––] [––––––––––––––––––––––––––––––––––––––––––––––+ADD +–+| 03 DN |Source A 1| || | | || |Source B N31:3| || | 3| || |Destination N31:3| || | 3| || +––––––––––––––––––+ |Rung 2:21Auto Parameter SelectionAfter 30ms, reset timer| I:010 T4:0 T4:0 |+––] [–––] [–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––(RES)–+| 03 DN |


6-15

Rung 2:22Auto Parameter SelectionOutput automatic parameter selection (N31:1, bit 0–2) to SMP command word (Rack2,word 0, bit 13–15)| I:010 +BTD–––––––––––––––+ |+––] [––––––––––––––––––––––––––––––––––––––––––––––––––––+BIT FIELD DISTRIB +–+| 03 |Source N31:3| || | 3| || |Source bit 0| || |Destination O:020| || | 24| || |Destination bit 13| || |Length 3| || +––––––––––––––––––+ || |+––––––––––––––––––––––––––––––––[END OF FILE]–––––––––––––––––––––––––––––––––+| |


6-16

7ChapterStart Up

7-1

CHAPTER OBJECTIVES

This chapter describes the steps necessary to ensure properstart-up of the SMP-3 overload relay. The informationcontained in the previous chapters must be read and understoodbefore proceeding.

IMPORTANT: Before start-up, the SMP-3 overload relayshould be configured and wired per the descriptions provided inChapter 3. The only programmable parameter of the SMP-3 isthe Logic Mask parameter. Refer to Chapter 8 forprogramming instructions to alter the default value (unmasked)of the logic mask parameter.

IMPO RTANT: Refer to Chapter 9 for fault code information.

ATTENTION: To avoid electric shock hazard ordamage to equipment, only qualified personnelshould perform the following procedure.Thoroughly read and understand the procedurebefore beginning. If an event does occur whileperforming this procedure, DO NOT PROCEED.Remove power by opening the branch disconnectdevice and correct the malfunction beforecontinuing.

START-UP PROCEDURE

The following start-up procedure is written for SMP-3applications with Human Interface Modules. For applicationwithout HIMs, disregard steps 5 and 6.

INITIAL OPERATIONS - MOTOR CONNECTED

❏ 1. Verify that the AC line power at the disconnect device iswithin the rated value for the SMP-3 overload relay.

❏ 2. Disconnect and lockout all incoming power to the SMP-3overload relay, including incoming AC power toterminals L1, L2, and L3. Verify that the wiring isconnected to the proper terminals, with the proper wiregauge and type of wire and that the proper short circuitprotection is used.

❏ 3. Verify that the SMP-3 outputs are in a de-energized statebefore applying power.

POWER APPLIED – MOTOR CONNECTED

❏ 4. When power is first applied to the SMP-3 overload relay,the green “Power” LED will turn ON. Also, an audibleclick will sound indicating that the trip relay has closed.

❏ 5. In addition, when power is applied to the SMP-3overload relay, the following information will bemomentarily displayed on the HIM:

Chapter 7 – Start Up

7-2

A. The HIM ID# and firmwareversion number

HIM ID #Version X.XX

B. Communication status HIM ID #Connecting...

HIM ID #Connected

C. Series letter of SMP-3overload relay

SMP-3Series X

D. Status of outputs A and B (this display will remain untilchanges are made or a faultoccurs.)

A=OFF B=OFF0.0 AMPS

Note: The HIM may be plugged into SMP-3 overload relay atany time after being powered up and communication with theHIM will be established.

❏ 6. If the HIM and SMP-3 overload relay are notcommunicating properly, “COMM FLT” may bedisplayed. If this occurs, remove the HIM from theSMP-3 overload relay, reconnect the HIM to the SMP-3overload relay and reset the fault on the SMP-3 overloadrelay. If this does not correct the problem or anotherfault message is displayed, record the information andremove all power. Determine and correct the fault sourcebefore proceeding. Refer to Chapter 9 fortroubleshooting and fault information.

Comm FaultF8

❏ 7. Verify the trip functionality of the SMP-3 overload relayby placing the TEST DIP switch in the “ON” position.Verify the SMP-3 overload relay has interrupted themotor current and is indicating a “Test” fault, F1 (oneflash on fault LED). Turn the TEST DIP switch to the“OFF” position and reset the fault.

❏ 8. If the green power LED does not turn on, the trip relaydoes not function properly, or the red TRIP LED flashes,refer to Chapter 9 for troubleshooting techniques.

8ChapterProgramming

8-1

CHAPTER OBJECTIVESChapter 8 describes the programming procedure for the SMP-3overload relay. The Logic Mask is the only SMP-3programmable parameter.

LOGIC MASK PARAMETER

The Logic Mask parameter can be used to mask (disable) orunmask (enable) either an HIM or communication module.When an adapter is masked, its control functionality over theSMP-3 is disabled. Conversely, when an adapter is not masked,its control functionality over the SMP-3 is completely enabled.

Each bit in the Logic Mask parameter represents a portaddress. Since the SMP-3 overload relay only supports Port # 1and #2, only bits 1 and 2 of the Logic Mask are used, as shownin Figure 8.1:

Figure 8.1 Logic Mask Parameter

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

MASK

Not Used

Port #1

Port #2

Not UsedNot Used

Not Used

Not Used

Not Used


Note: The adapter connected to Port #1 is considered adapter1, while the adapter connected to port #2 is considered adapter2.

When a Logic Mask bit is set to “1,” the adapter connected tothe respective port is enabled.

00000X10 – Port ID #1 is enabled000001X0 – Port ID #2 is enabled00000110 – Port ID #1 and #2 are enabled

Chapter 8 – Programming

8-2

Conversely, when a Logic Mask bit is set to “0,” the adapterconnected to the respective part is disabled.

00000X00 – Port ID #1 is disabled.000000X0 – Port ID #2 is disabled.00000000 – Port ID #1 and #2 are disabled

Note: If the SMP-3 HIM is disabled/masked out, the ON andRESET buttons will be disabled and the Start/Reset DisabledLED will be energized. The OFF/STOP buttons, however, willstill be functional

Note: To remove an adapter from an energized SMP-3overload relay without causing a communications fault, thecorresponding bit for that adapter must be set to “0.”

ILLEGAL LOGIC MASK SETTINGS

For safety reasons, certain configurations of the logic maskparameter will not be allowed. These conditions are:

� If either OUT A or OUT B is energized and two adaptersare connected to the SMP-3, only one adapter can be

masked out/disabled. At least one adapter must remainenabled to ensure the outputs can be de-energized.

� If either OUT A or OUT B is energized and only oneadapter is connected to the SMP-3, that adapter can not bemasked out/disabled

Any HIM will allow the user to toggle to an illegal Logic Maskparameter setting. However, the SMP-3 overload relay will notallow the user to actually program the mask parameter to anillegal setting. Rather, it will default back to the prior setting ifan illegal mask is attempted. The user should observe the“Start/Reset Disabled” LED on the SMP-3 HIM to confirmmasking. This will help avoid an inadvertent communicationloss fault when the HIM is disconnected.

“Start/Reset Disabled” LED ON = Masked = OK todisconnect

“Start/Reset Disabled” LED OFF = Unmasked = DO NOTdisconnect


8-3

Mask Programming (Using the HIM in Program Mode)The following procedure describes the programming steps required to mask out any communication adapter using the HIM inprogram mode.


or

ESC SEL

To Select Mode

or

Select Device Port #

SEL

or

ESC ESC

1. Press any key to go from the Status Display to the Choose Mode menu.

2. Press the up/down keys to toggle to “Program” in the display.

3. Press Enter to go to the Program menu.

4. Press the up/down keys until Device Port # appears.

5. Note the characters on the lower line. There will be a 1 at either the second orthird position from the right. This indicates which port address the HIM is at.

6. Press the up key to move to the Mask parameter display. (the “M” will be flashing,indicating that this parameter can be programmed)

7. Press select to move to the lower line.

8. Press up/down keys until a zero appears at the position of the 1 noted in step 5.DO NOT alter the other bit.

9. Press Enter. The HIM communicating with the selected port is now masked outand can be disconnected. The start/reset disabled LED (on the SMP-3 HIM)should be illuminated.

10. Press Escape twice to return to the Status Display.

A=OXX B=OXXX.X AMPS

Choose ModeProgram

Average Current0.0 AMPS 1

DEVICE PORT #00000XX0 6


Note: The mask will remain in effect until either the 1 is returned to the position it was removed from in Step 8, or the SMP-3 overload relay is de-energized.Note: If a second adapter is connected to port #2 of the SMP-3 overload relay via a port expander, it can be masked out using the procedure described above (i.e., ifthe HIM is connected to port 1 and a communication module to port 2, set the third position from the right in the mask parameter to 0 to mask out the communicationmodule).


8-4

Mask Programming (Using the HIM in Control Status Mode)The following procedure describes the programming steps required to mask out the HIM using the control status mode.Note: Earlier versions of the HIM may not support this mode.


or

ESC SEL

To Select Mode

SEL

or

ESC ESC

1. Press any key to go from the Status Display to the Choose Mode menu.

2. Press the up/down keys to toggle to “Control Status” in the display.

3. Press Enter to go to the Control Status menu.

4. Press select to move to the lower line.

5. Press up/down keys to toggle to either disabled or enabled.

6. Press Enter. When Disabled is selected the HIM is masked out and can bedisconnected without faulting the SMP-3 overload relay.

7. Press Escape twice to return to the Status Display.

A=OXX B=OXXX.X AMPS

Choose ModeControl Status

Control LogicEnabled

Control LogicDisabled

Note: This procedure can only be used to mask out the HIM. The procedure in the previous example must be used to mask out a second adapter.

ATTENTION: The Mask parameter is a volatile parameter. If power is cycled to the SMP-3 overload relay, theSMP-3 will power-up with the Mask parameter in its default state ports 1 and 2 (enabled (00000110). The mask must bere-programmed after a power-up or power loss.

9ChapterTroubleshooting and Fault Information

9-1

CHAPTER OBJECTIVES

This chapter provides information about:

� LED diagnostics

� General troubleshooting procedures

� SMP-3 fault information

LED DIAGNOSTICS

The SMP-3 overload relay contains four status LEDs that areintended to aid in troubleshooting and performing faultdiagnostics on the SMP-3 overload relay.

Power This green LED, when illuminated, indicatesthat power is applied to terminals 50 and 60.

AC Out A This yellow LED, when illuminated, indicatesthat output terminal 10 is energized.

AC Out B This yellow LED, when illuminated, indicatesthat output terminal 20 is energized.

Trip This red trip LED, when illuminated, indicatesthat the SMP-3 overload relay is faulted. Whena fault occurs this LED will flash a specificcode that corresponds to a specific fault condi-tion. The code consists of a specific number offlashes and then a pause. This code will contin-ue to be displayed on the trip LED until thefault is cleared. (See Table 9.A for flash codeinformation.)

ATTENTION: The yellow OUT A and OUT BLEDs only indicate that the micro-controllerattempted to turn the output On/Off and is not anindication that the output did in fact turn On/Off.

ATTENTION: To avoid electric shock hazard ordamage to the equipment only qualified personnelshould perform the following procedures

Chapter 9 – Troubleshooting and Fault Information

9-2

GENERAL TROUBLESHOOTING PROCEDURES

The following steps are a few techniques that can be used to troubleshoot the SMP-3.

Failure Type General Problem Action to Take

OUT Aor

OUT B

OUT A or B do not appear to turn on whencommanded to do so.

1. Check the supply voltage.2. Remove power from the SMP-3 overload relay, then check the wiring to control terminals 10

and 20.3. Check for a fault condition. If a fault exists, refer to the Fault Information section in this

chapter for instructions on how to clear the fault.4. Check the appropriate OUT A or B status LED. If the appropriate status LED does not turn

on, check the communication connection. Refer to Communication Loss Fault in Table 9.B.5. Remove power from the SMP-3, then check the user replaceable fuse on the side of the

SMP-3 overload relay. If the fuse is open, replace the fuse with the correct fuse size and typeas specified in Appendix A. Check the control circuits for shorts and verify that the circuitdoes not exceed the maximum voltage or current rating of the outputs.

6. Check the Logic Mask parameter. Refer to Chapter 8 for programming instructions.

OUT Aor

OUT B

The contactor connected to OUT A or Bappears to “chatter” when the OUTPUT isturned on.

1. Verify that the appropriate OUT A or B LED remains On.2. Check the control voltage. Verify that the voltage is within the SMP-3 output and contactor

coil ratings.3. Remove power from the SMP-3 overload relay. Verify that all control terminal wiring is

properly fastened.

OUT Aor

OUT B

The contactor connected to OUT A or Bappears to “chatter” when the OUTPUT isturned off.

1. Verify that the appropriate OUT A or B LED remains Off.2. Check the control voltage. Verify that the current and voltage are within the SMP-3 OUT A or

B ratings. Then consult the factory.


9-3

Failure Type Action to TakeGeneral Problem

TripRelay

The trip relay does not appear to befunctioning correctly.

1. Remove power from the SMP-3 overload relay, then check the wiring to control terminals 30and 40.

2. Induce a Test fault on the SMP-3 by turning the Test DIP switch On. The SMP-3 overloadrelay should fault and the Trip LED should flash one time. There should also be an audibleclick corresponding to the trip relay opening. Turn the Test DIP switch Off and reset the fault.There should be another audible click corresponding to the trip relay closing.

3. Remove power from the SMP-3 overload relay, then remove the trip relay wiring. Reapplypower to terminals 50 and 60. Check the impedance across the trip relay terminals 30 and40. When the SMP-3 overload relay is energized and no fault exists, the trip relay should beclosed �� 0�). When the SMP-3 overload relay is de-energized or faulted, the trip relayshould be open �� High impedance).

PowerUp

The green Power LED on the SMP-3overload relay does not turn on whenpower is applied to the SMP-3.

1. Remove power from the SMP-3 overload relay, then check the wiring to control terminals 50and 60 on the SMP-3 overload relay.

2. Apply power to the SMP-3 overload relay, then check terminals 50 and 60 to ensure thecontrol voltage is present and is within the rating of the SMP-3 input.


9-4

Failure Type Action to TakeGeneral Problem

Communication The communication link between theSMP-3 and an adapter does not appear tobe functioning.

1. Check the HIM display (if applicable). If the display appears to be cycling between menus:a. Check the communication connection per the procedure described in Table 9.B for a

Comm Fault.b. Induce a Test fault on the SMP-3 overload relay. If the SMP-3 overload relay does not

trip, consult the factory.If the display is de-energized:a. Check the communication connection per the procedure described in Table 9.B for a

Comm Fault.b. Follow the Power-up Failure troubleshooting procedure previously described.

2. Check the SCANport status LED (if applicable) on the Communication Module. If the LED is“On”:a. Check the non-SCANport communication connections (i.e., RIO, DeviceNet).If the LED is “Off”:a. Check the communication connection per the procedure described in Table 9.B for a

Comm Fault.b. Induce a Test fault on the SMP-3 overload relay. If the SMP-3 overload relay does not

trip, consult the factory.3. Check the Logic Mask Parameter. Refer to Chapter 8 for programming instructions.

Communication Comm Fault exists. Refer to Table 9.B for instructions regarding how to correct Comm faults.


9-5

FAULT INFORMATION

HIM Display. When an HIM is connected to a faulted SMP-3overload relay, a brief fault description will be displayed on thetext line of the HIM display. and a fault code will be displayedon the value line of the HIM display, as shown below.

Figure 9.1 Fault DisplayIllegal FLC SetF 5

Note: Refer to Table 9.A for a listing of all SMP-3 faultdescriptions and fault codes.

HIM Fault LED. When an SMP-3 HIM is connected to a faultedSMP-3, the Fault LED on the HIM will be energized.

SMP-3 Trip LED. The SMP-3 overload relay is equipped with ared trip LED that flashes a fault code when a fault occurs. Thenumber of flashes indicates the type of fault (refer to Table 9.Afor the Fault/Number of Flashes correlation). The LED flashesthe code, pauses, then flashes the code again. This is repeateduntil the fault is reset.

Remote Reset LED. The remote reset LED is located on theremote reset push button (Allen-Bradley Cat. No. 800T-NX1311) which can be purchased as an accessary to the SMP-3overload relay. When connected to the SMP-3 overload relayvia the remote reset port, the remote reset LED will functionand flash the same as the SMP-3 Trip LED (see SMP-3 TripLED for operational description).

ATTENTION: Resetting a fault will not correctthe cause of the fault condition. Corrective actionmust be taken to fix the fault cause beforeresetting the fault.

How to Clear a Fault

A fault on an SMP-3 overload relay can be cleared byperforming one of the following:

� Press the blue RESET button on the SMP-3.

� Set the AUTO/MANUAL DIP switch to AUTO allowing anoverload fault to automatically reset (Overload fault only).

� Press the remote reset push button (A-B Cat. No.800T-NX1311), when used.

� Press the RESET key on the SMP-3 HIM, if applicable.➀

� Press the STOP key on the Drive HIM, if applicable.➀

� Cycle the Clear Fault bit of the SMP-3 logic command froma communication adapter, if applicable.➀

� Cycle power to the SMP-3 overload relay (applies only tonon-protection faults).

Note: The Reset, Stop, or Clear Fault command will not cleara fault if the SMP-3 Logic Mask parameter is configured suchthat the adapter is masked out/disabled.


9-6

Table 9.A Fault Codes

Fault Description Number of Flashes HIM Fault Text HIM Fault Code Protection Fault ➀ Reset

Test 1 Trip/Test F1 Manual

Overload 2 Overload F2 ✓ Auto/ Manual

Phase Loss 3 Phase Loss F3 ✓ Manual

Ground Fault 4 Ground Fault F4 ✓ Manual

Jam/Stall 5 Jam/Stall F5 ✓ Manual

<Min. Allowable FLC Setting 6 Illegal FLC Set F6 Manual

Non-volatile Memory Fault 7 Non Vol Memory F7 ✓ Manual

Communications Loss 8 Comm Fault F8 Manual

➀ The ✓ indicates the protection faults.

Note: When the SMP-3 Auto/Manual DIP switch is in theAUTO position, an overload fault (F2) will automatically resetafter a defined reset time (see Chapter 4 for Reset times). Allother faults must be manually reset, but they can be resetimmediately after the fault occurs.

Note: All protection faults are non-volatile. If power isremoved from the SMP-3 overload relay after a protection faultoccurs but before the fault is cleared, the SMP-3 overload relaywill power up in a faulted state once power is re-applied.


9-7

Table 9.B Fault Descriptions

Fault Name and Number Fault Description Action to Take

Test F1

The TEST DIP switch on the SMP-3 overload relay is ON. Turn off the TEST DIP switch and reset the SMP-3 overloadrelay.

OverloadF2

The SMP-3 overload relay detected current greater than the triprating of the SMP-3 overload relay for a period of time such thatthe percent TCU reached 100%.

1. Check the motor for excessive load.2. Check the motor for damage to the insulation.3. Check motor conductors for shorts.

Phase LossF3

The SMP-3 overload relay has detected the current imbalancebetween phases to be >50% for ≥1 second while operating at≥30% FLC current.

1. Check the power supply to ensure that all phases arepresent.

2. If protected by fuses, check for a blown fuse.3. Ensure that the SMP-3 connection to the contactor is

secure.4. Check conductors to motor.5. Check the motor for an open phase.6. Single phase applications must be wired so that the current

passes through all three phases of the SMP-3 overloadrelay. (See the single phase wiring diagram on page 3-16.)

Ground Fault F4

The Ground Fault (GF) DIP switch on the SMP-3 overload relayis ON, and ≥50% phase current is not returning to the SMP-3overload relay for ≥0.5 second after the SMP-3 overload relayhas operated at ≥30% FLC for more than one trip class timeperiod.

1. The GF DIP switch must be OFF when used with singlephase motors.

2. Check conductors to the motor for shorts to ground.3. Check the motor for low resistance to ground. Moisture or

conductive dust may cause this fault.


9-8

Table 9.B Fault Descriptions (cont.)

Fault Name and Number Fault Description Action to Take

Jam/StallF5

The Jam DIP switch on the SMP-3 overload relay is ON, andgreater than 400% of the FLC current for ≥0.5 second has beendetected after the SMP-3 overload relay has operated at ≥30%FLC for more than one trip class time period.

1. Ensure that the motor is free to rotate.2. Check the load and drive system for high friction or jam.

Illegal FLC SettingF6

The DIP switches on the SMP-3 overload relay are set below theminimum allowable FLC setting for that device.

Ensure that FLC DIP switches on the SMP-3 overload relay areset higher than the minimum FLA. (See Table 3.I on page 3-36.)

Non Vol MemoryF7

A protection fault has occurred, but the non-volatile memoryused to store a protection fault has malfunctioned.

1. Perform the action specified for an overload, phase loss,Ground Fault, and Jam/Stall fault.

2. Reset the SMP-3 overload relay.3. If fault continues to occur, check with the factory.

Communication FaultF8

The SMP-3 overload relay has lost communication with anadapter, such as a HIM or a communication module.

1. Check that DIN connectors are still plugged in to the SMP-3overload relay and the slave device.

2. Check that the total communication cable lengths do notexceed 10 meters.

3. Check cable for damage.4. Try another cable.5. Try another adapter.

Appendix A – Specifications

A-1

Table A.1 SpecificationsELECTRICAL – CONTROL CIRCUIT

Power Supply Input

Voltage Rating 110/240 VAC, 50/60 Hz

Operating Range 85 to 264 VAC, 47–63 Hz

Maximum Power Consumption 6 watts

Maximum Power Interruption Time 20 ms.

Trip Relay OutputFor all except

193- or 592-CIL_or CIM_

For 193- or592-CIL_ or CIM_

Type Hard Contact

Rated Operational Voltage 240 VAC

Contact Rating Designation B300 A300

Maximum Operating Current 5 mA 10 mA

Minimum Operating Current 10 mA 100 mA

Minimum Leakage Current ➀ 10 mA 10 mA

Resistive Load Rating (pF = 1.0)5A, 250 VAC5A, 30 VDC

10A, 250 VAC10A, 30 VDC

Inductive Load Rating (pF = 0.4)(L/R = 7ms)

2A, 250 VAC2A, 30 VDC

3A, 250 VAC3A, 30 VDC

Recommended Control Circuit Fuse

6A Form 101Semi-conductor

Fuse(Gould P/N A60 Q6-2)

12A Form 101Semi-conductor

Fuse(Gould P/N A60 Q12-2)

Rated Number of Operations 10,000

OUT A and OUT B OutputsFor all except

193- or 592-CIL_or CIM_

For 193- or592-CIL_ or CIM_

Type Triac

Rated Insulation Voltage 250 VAC

Operating Range 85 to 264 VAC, 47–63 Hz

Switching Element RatingDesignation SE SD

Utilization Category AC15 AC15

Rated Operational Current 0.5A 1.0A

Minimum Operational Current 20 mA 50 mA

Maximum Off-state Current 10 mA 10 mA

Maximum Voltage Drop 3.5V 3.5V

Replaceable Fuse (Ceramic 5 � 20mm, 250 VAC 2.0A 5.0A

Recommended Control Circuit Fuse1A Class CC

(ATQR-1)

5A Form 101 Semi-conductor Fuse

(Gould P/N A60 Q5-2)

Maximum Bul. 500 Contactor CoilSize 2

110–240 VACSize 4

110–240 VAC

Maximum Bul. 100 Contactor CoilA75

110–240 VACB180

110–240 VAC

Rated Number of Operations 10,000,000

➀ Leakage current is due to noise suppression circuitry.


A-2

ELECTRICAL – CONTROL CIRCUIT (cont.)

Motor Current

Phases Three-phase or SIngle Phase

Rated Insulation Voltage 660 VAC

Maximum Operational Current (See Cat. No. Code Explanation)

Operational Frequency 50–60 Hz

Current Wave Shape Undistorted Sinusodial

ENVIRONMENTAL

Ambient Temperature

Storage –40 °C to 85 °C (–40 °F to 185 °F)

Operation (Enclosed)(Open Enclosure)

–20 °C to 40 °C (–4 °F to 104 °F)–20 °C to 55 °C (–4 °F to 131 °F)

Maximum Altitude 2,000 M (6,562 ft.)

Relative Humidity 5% to 95% (non-condensing)

Cooling Method Natural Convection

Vibration 1G Operational, 2.5G Non-operational

Shock 15 Operational, 30G Non-operational

Pollution Environment Degree 2

ENVIRONMENTAL (Cont.)

Terminal Marking CENELEC EN 50012

Finger Protection(w/ contactor terminal cover)(w/o contactor terminal cover)(CT mounted and NEMA overload)

IP1X (Bul. 193-C1_1, 2, 3)IP1X (Bul. 193-C1_4, 5)IP0 (Bul. 193-C1_4, 5)

IP0 (Bul. 592 and Bul. 193-C1_6)

Electrostatic Discharge 8kV Air Discharge

RFI Susceptibility 10V/m

Fast Transient Susceptibility2kV (AC Lines), 1kV

(Communication Lines)

Impulse Voltage Susceptibility1kV (Line to line)

2kV (Line to ground)

Radiated Emissions CISPR11 Group 1 Class A

Conducted Emissions CISPR11 Group 1 Class A

PROTECTION FEATURES

Overload Embedded Feature

Trip Class Selectable (Class 10, 15, 20, or 30)

FLA Setting Selectable (Up to a 5:1 range)

Phase Loss Embedded Feature

Ground Fault Selectable Feature

Jam/Stall Selectable Feature


A-3

COMMUNICATIONS

AdapterMaximum current draw of all adapters

should not exceed 200 mA

Hand-held Adapter (HIM)Operational HIM (can be disconnected

from the SMP-3 overload relay)

Type of Display (HIM)16 character, 2 line LCD super twist with backlight

HIM Controls Out A (On/Off), Out B (On/Off), Reset

Communication AdapterOptional adapters provide Remote I/O or

RS232/422/485/DH485 orRS232/422/485/DF1 capability

PARAMETER MONITORING

Average CurrentDefault parameter displayed and

selectable as a displayed parameter

FLC Setting Selectable as a displayed parameter

Thermal Capacity Utilized Selectable as a displayed parameter in %

Current Imbalance Selectable as a displayed parameter in %


A-4

Appendix B – SMP-3 Accessories

B-1

ACCESSORIES

Table B.1 SMP-3 Accessories

Description Used with Cat. No. Pkg.Qty. Cat. No.

193-C1N6, 300A 199–LG1

Terminal Lugs 193-C1P6, 400A 3 199–LH1T

193-C1R6, 600A 199–LJ1

193–C1_1, 193-C1_T 193–BPM4DIN Rail/Panel Adapter

193–C1_31

193–BPM5

193–C1N6 , 300A 193–PCG1

Flexible Bus Connector 193-C1P6, 400A 3 193–PCH1B

193-C1R6, 600A 193–PCJ1

SMP-3 – Remote I/O Comm. Adapter –GM

SMP-3 – Remote I/O Comm. Adapter (120/240V Power) 1 1203–GD1

Communication ModuleDeviceNet Comm. Adpater(24V Network Powered) 1 1203–GK5

Human Interface Module 193–C1_ , 592–C1_ 1 193–HIM1

DrivAppendix B – SMP-3 Accessories

B-2

Table B.1 (cont.)

Description Used with Cat. No. Pkg.Qty. Cat. No.

Cable Length1/3 meter 1202–C03

Communication Cable 193–C1_ , 592–C1_ 1 meter 1 1202–C10Communication Cable 193–C1_ , 592–C1_3 meters

11202–C30

9 meters 1202–C90

1 meter 1202–RRC1

Remote Reset Cable 193–C1_ , 592–C1_ 3 meters 1 1202–RRC3– 5 –

6 meters 1202–RRC6

B – 5 – 8 T– XB – 5 – 8 T– XIlluminated Push Button Reset 193–C1_ , 592–C1_ 1 800T–NX1311

Splitter 193–C1_ , 592–C1_ 1 1203–SG2

Allen-Bradley, a Rockwell automation business, has been helping its customers improve pro-ductivity and quality for more than 90 years. We design, manufacture and support a broadrange of automation products worldwide. They include logic processors, power and motioncontrol devices, operator interfaces, sensors and a variety of software. Rockwell is one of theworld’s leading technology companies.

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Publication 193–5.0 – December 1996 41052–053–01(B)Copyright 1996 Rockwell International Corporation Printed in USA

PLEASE READ! IMPORTANT USER INFORMATION · 20 or 30 (2 DIPs) – Automatic or manual reset (1 DIP)...

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