ABB ACS800 RSYC-01 Synchronizing Unit User`s Manual
Contents
1. a 27 DO 28 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Introduction to the manual What this chapter contains This chapter includes a description of the contents of the manual In addition it contains information about the compatibility safety and intended audience Compatibility The manual is compatible with RSYC 01 Synchronizing Unit The drive parameter data refers to ACS800 Standard Control Program Safety instructions Follow all safety instructions delivered with the drive e Read the complete safety instructions before you install commission or use the drive The complete safety instructions are given at the beginning of the drive Hardware Manual Read the software function specific warnings and notes before changing the default settings of the function For each function the warnings and notes given in this manual in the section describing the related user adjustable parameters Intended audience This manual is intended for the people who are responsible for installing commissioning using and trouble shooting the synchronization system with the RSYC unit The reader is expected to have knowledge of electrical fundamentals electrical wiring practices electronic components and electrical schematic symbols The person in charge of testing and commissioning a system this c2. 5800 User s Manual RSYC 01 Synchronizing Unit ED ED PREDED Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com RSYC 01 Synchronizing Unit User s Manual Code 3AFE68827370 REV A EN EFFECTIVE 29 06 2007 200 2007 All Rights Reserved Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Table of contents Table OF COMLCIUS ii AA AAA 5 Introduction to the manual _______ __________ 7 VV al ENS Chale iii 7 Compatibles 7 IASTUCUONS spa Su 7 Hr EE 7 Gia _ _ 7 Description of operation and hardware nun ann ann ann ann nun nnn nun ann ann anne 9 Whats Chapter CONAM SAO 9 Intended use OF the RSY C Nasa aa 9 CS ATION ES RM COS 9 Overall VIEN ON ENS __ ___ _______ __________ 10 RSTE IT UNIE WIEN COVER TRITICI 10 iso UNIEWILNOUECOVER ee ea ee ae ee 10 TU mE PPP ET 11 Terminals connections of the unit iii 12 Connections of RSYC unit to the drive n eene 12 Mech
3. 1 x 0 5 mm Signal cable use Connection of the RSYC unit to the drive transformers and control relays Synchronization accuracy 21 21 Transformer cable size Max cross section 4 mm Transformer cable use Connection between the measuring transformers and main circuit at drive output and input Mounting rail 7 5 x 35 mm EN50022 CV 2 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 26 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 27 Dimension drawing Cover of the RSYC enclosure The dimensions are given in millimetres Dimension in mm 1 mm 0 039 1 25 4 mm HM x 166 4 x D 4 Dimension drawing Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 28 RSYC enclosure body 4 3 30 4 0 7 6H tos ae screw MOS 6H y 1 feed hole 3 30 M4x0 7 6H feed hole 2x 05 Dimension drawing Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com
4. PID controller output is relative to maximum speed limit Par 20 02 Trim reference is equal to actual signal when the synchronization conditions are valid i e when Al1 5 V See parameter 40 07 above Other macros except PID CNTRL are also possible PID cannot be used as the PID controller is reserved for Trim function Define the motor parameters 99 05 99 10 See ACS800 Standard Control Program 7 x Firmware Manual 3AFE64527592 English WARNING Read and follow the instructions in the drive Hardware Manual Ignoring the instructions can cause physical injury or death or damage to the equipment Ensure that the drive is disconnected from the supply line and all other precautions described in the safety instructions have been taken into consideration Before starting ensure that the contactor control circuit connection at terminal J2 of the RSYC unit is disconnected For the use of control panel see ACS800 Standard Control Program 7 x Firmware Manual 3AFE64527592 Enolish Start up Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 19 Set drive parameters according to instructions However See Parameter settings on page 17 switch Trim function off parameter 40 14 OFF for the time being Shift control panel to local control mode Use LOC REM key Letter L on first row of display indicates local control Select following actual values to panel display 01 02 A
5. RSYC kit contains e RSYC unit two synchronizing transformers 8 meters of cable for RSYC connections this manual Note Following items are not included but must be acquired separately switch over contactors the relays of the contactor control circuit cable between transformer 1 and main circuit and fuses for the cable and cable between transformer 2 and main circuit and fuses for the cable Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 14 Mechanical installation Mounting the RSYC unit Mount the unit by snapping the feet onto a 7 5 x 35 mm mounting rail 1 2 Mounting Mechanical instalation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 15 Electrical installation What this chapter contains This chapter contains a reference to the connection diagram and a list of items to consider in the electrical installation Connection diagram See Connection diagram on page 11 Considerations Follow the cabling recommendations of the drive Hardware Manual Leave at least 0 5 m space between the unit and the power cables and drive module If 0 5 m is impossible install as far as possible Use shielded twisted pair cables between the transformers and the RSYC unit Ground the shields with as short pigtails as possible Cut and insulate any unused conductors at both ends of the cables
6. See Connection diagram Use shielded twisted pair cables between the RSYC unit and the drive Ground the shields at the drive module end according to the instructions given in the drive Hardware Manual Use shielded twisted pair cables between the unit and the contactor control circuitry Ground the shields with as short pigtails as possible Dimension selects the cable in between the main circuit and the synchronizing transformers according to the main circuit voltage Protect the cable with fuses if necessary Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 16 Cable clamping grounding example To network supply measurement transformer To inverter output supply measurement transformer 4 z mI gt i uc vig E 4 4 nn de 2 4 3 43 BUF OUT Spe supply signal signal Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 17 Start up What this chapter contains This chapter instructs in setting the drive parameters and in checking the system Parameter settings The table below instructs in parameter settings for a drive with ACS800 Standard Control Program starting a four pole motor 50 Hz With these settings the trim control can affect 20 rpm to final speed reference 1 of the defined ma
7. dal i T M a 1 1 00 _ Mi0 0ms Chi 1 60 2Jan 2006 0 000005 09 17 00 When there is a phase difference waveforms are as shown in the graphic below T2 2ms jw 6 13ms 1 Ch2 Freq 50 48 H2 TUNIS NE ch2RMS R av E MA O E N 1 1 Chi Freq Ez 4 4 49 92 AR A IR Mi0 0ms A Chi f 1 42 22 Nov 2005 ii 2 7 30005 09 04 44 When the frequencies are different the signals move respective to each other the speed is low enough the board may generate a SYNC pulse Fault tracing Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 24 Miscellaneous measurement graphs The graph below shows the measurements of the voltages U and U 4 and phase currents and when synchronizing to the network 1200 1000 800 The graph below shows the drive output voltage network voltage and one phase current KUN 5 UUK5 S sample 50 0115 27 8195 200mv 15 15 25 Fault tracing Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 25 Technical data RSYC power supply voltage 24 V DC 5 5 RSYC power consumption 25 35 mA Signal cable type JAMAK by NK Cables Signal cable size 2 x 2
8. 4 OFF for the time being Use LOC REM key to select remote control The drive is now ready to be Letter R on first row of display controlled externally with the control panel indicates remote control mode of Start drive Check output frequency from display If it is not 50 Hz adjust the reference in small steps so that output frequency from display shows 50 Hz Write down this value again Stop drive Set trim function on parameter 40 14 TRIM MODE DIRECT The speed reference and output frequency will now be affected by Trim function slightly Set speed reference to value that was equivalent to 50 Hz output frequency Start up Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 20 Start drive and monitor panel RSYC status LED The following indicates successful Trim control loop Drive accelerates to speed reference which was defined above Output frequency starts oscillating around 50 Hz is 2 5 V 7 V RSYC LED blinks the first time after 5 20 seconds LED starts blinking in shorter time intervals and finally LED illuminates steady for several seconds Increase 40 17 TRIM RANGE ADJUST slightly e g 1 596 if faster Excessive value may lead to synchronization is required unstable control Stop drive Final check Connect the contactor control circuit cable J2 SYNC to RSYC unit 553 ME Test the system and verify the oper
9. 50 Hz motor Define the stop mode for the run 20 07 COAST The drive will cut off output voltage immediately enable function after run enable is switched off Settings of PID controller used by Trim function Parameter group 40 0 Activate error value inversion 40 05 YES RSYC unit feature Activate 1 for PID controller 40 06 1 EX Start up Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 18 Parameter value 40 07 AN Select analogue input Al1 for actual signal for PID controller 40 09 0 00 40 10 100 00 40 13 OFF Set minimum value for ACT1 Set maximum value for ACT1 Deactivate integration term of PID controller Activate Trim function and define trimming relative to maximum speed Select parameter 40 16 for the source of the trim reference Set trim reference to 50 40 14 DIRECT 40 15 PAR 40 16 40 16 50 00 Define the maximum effect of trim that is added to the drive reference Macro selection and motor control mode 99 02 FACTORY Select factory macro Select motor control mode Checking the operation of the RSYC unit AN Additional information BUF OUT signal from RSYC unit 0 10 V Below 5 V supply line frequency exceeds drive output frequency 5 V Supply line frequency and drive output frequency are equal and phases match Above 5 V supply line frequency is lower than drive output frequency
10. IT is the 0 10 V DC status signal from the SPEED 01 03 FREQUENCY 01 18 V unit Start drive and increase speed reference until output The difference between the speed reference and frequency is as close to 50 Hz as possible Write down actual the actual speed depends on the slip which in speed and speed reference at 50 Hz output frequency turn depends on the motor load Drop speed so that output frequency is 45 47 Hz Ensure Increase speed reference so that output frequency is 52 55 Hz Ensure that Al1 is O 1 V DC Checking of the trim function and synchronization This check makes sure that the trim function affects the speed control of the drive in the correct manner Finding a right value for trim range adjustment parameter 40 17 is essential for stable control and fast synchronization Then the system reaches the synchronization with decreasing oscillations around 50 Hz and actual signal for Trim function settles to approximately 5 V DC For the use of control panel see ACS800 Standard Control Program 7 x Firmware Manual 3AFE64527592 English Reserve at hand the value of the speed reference and actual speed that were equivalent to 50 Hz output frequency defined in the previous section Checking the operation of the RSYC unit on page 168 Adios Set drive parameters according to instructions However switch Trim function off See Parameter settings on page 17 parameter 40 1
11. anical ipsala UON iS NEUEM vate aa 13 Wnhnatthis ChaptercoONtalAS ana TTE 13 Delivery check contents of the RSYC kit 13 Mechanical installation cursi sia 14 Mounto NS RS peace iia dera 14 TINS TAN AU ON Mp 15 Vint IRIS chapler AE ins lios 15 COMME CON a 15 des canada co nee 15 Cable clamping and grounding example 16 Stal 17 VV Nal EMS COMTI iret as 17 RaramelerSclnds 17 Checking the operation of the RSYC unit 18 Checking of the trim function and synchronization 19 ett se TE 20 Disabling the synchronization I A 20 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Mes ee edo cab la 20 Fault mr a D M 21 THIS CHaplerconlains a ine 21 PROUD IC SMO OU OMA a 21 Measuring with an OSCIIOSCODG un 22 Miscellaneous measurement graphs sisi 24 O 25 DIMENSION GTAWIN Dti AAA A AAA A 27 Cover ofthe RSYC
12. ation The system will synchronize in less than 15 seconds and will remain in the synchronization status for tens of seconds when it is properly installed and commissioned Disabling the synchronization To disable synchronization function e Change the external control location in the drive application program from EXT2 to EXT1 parameter 11 02 or switch the drive to local control mode by the LOC REM key of the control panel e Turn operating switch S1 in the contactor control circuit to the OFF position Resetting the system The relay logic can be reset to initiate another synchronizing cycle by turning the operating switch S1 of the contactor control circuit to the OFF position and then to again 1 0 1 Start up Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Fault tracing What this chapter contains 21 This chapter gives the troubleshooting information Troubleshooting hints Unit operates illogically despite all connections and parameters are correct BUF OUT signal from RSYC board is constantly low i e 0 1 VDC Drive output frequency remains too close to 50 Hz and occasional short synchronization pulses take place The speed control is unstable Excessive motor current peak at synchronization The board is affected by radiated interference BUF OUT signal is not stable and as a consequence synchronization is not possible Signals from synch
13. former signals 4 Cable screen clamps Description of operation and hardware Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 11 Connection diagram 4 uonses 998 sexouo ajdwex3 m Description of operation and hardware Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 12 11 Supply line voltage measurement as 10 120 V AC signal 3 phase potential measuring transformer with static shield T2 Motor voltage measurement as 10 120 V AC signal 3 phase potential measuring transformer with static shield Terminals connections of the RSYC unit Synchronizing unit power supply from the Motor Control and I O board RMIO via terminal X23 Output 0 24 V control pulse for external contactor control circuitry Output 0 10 V signals indicating the synchronization status for the drive Motor voltage measurement MAINS Supply line voltage measurement RMIO board terminal Synchronization status indication Power supply for RSYC Description of operation and hardware Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 13 Mechanical installation What this chapter contains This chapter contains mounting rail instructions and contents of the RSYC kit Delivery check contents of the RSYC kit
14. not need to be dimensioned according to continuous current only the contactor The choke must not saturate through See Connection diagram on page 11 Check and correct the transformer connection Check and correct the transformer connection Check and change the connections Fault tracing Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 22 Measuring with an oscilloscope Checking the supply line MAINS and inverter output INVRTR signals from the board may be the only way to see what is actually happening if there is no SYNC signal There is a potential interference risk as it is possible that the probes pick up the interference and conduct it to the board circuits All loops should be kept as small as possible and measuring circuits should be routed as far away from the drive and other cables as possible The following figure shows the measuring points TPVREF and TP4 TPVREF Y AW SBA Fault tracing Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 23 When the signals are in synchronization the oscilloscope shows the following waveforms TekRun gt Chi Freq 30 08 H2 Ch2 Freq 39 90 Hz A Las H D op oc E died opi oe e d A on dial RI ee Rr A mi
15. omplicated must be an experienced professional in the field of electrotechnics Other manuals Hardware Manual of the drive ACS800 Standard Control Program 7 x Firmware Manual 3AFE64527592 English Introduction to the manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Introduction to the manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Description of operation and hardware What this chapter contains This chapter describes the operation of a synchronization application shows a connection diagram and presents the RSYC unit Intended use of the RSYC unit Operation A drive equipped with the RSYC unit is designed for applications in which a large fixed speed motor must be started to a weak supply line Drive starts the motor smoothly no high starting current as with the direct on line start simultaneously generating a high torque When the nominal speed frequency is reached RSYC unit verifies the status of the supply line and the drive output and controls the switch over contactors that shift the connection of motor from the drive to supply line The RSYC unit monitors two voltage signals one measured from the supply line and other from the drive output The signals indicate the phase shift and frequency The unit output signal BUFOUT 0 10 V indicates the synchronization status for the drive When the BUFOUT signal reaches 5
16. ronizing transformers are cross connected at the RSYC unit Too small value for parameter 40 17 TRIM RANGE ADJUST Drive cannot control the speed and output frequency loosely enough Too large value for parameter 40 17 TRIM RANGE ADJUST causes the control to overcompensate Rotor decelerates too fast and phase difference between stator and motor fluxes increase too much Motor flux decreases too much during the operation of change over contactors High current is needed to remagnetize the motor Supply line motor and drive output are 180 out of phase due to wrong connection of the synchronization transformer Supply line and drive output are 180 out of phase since the phasing between motor and supply line differs from the phasing between motor and drive output Ensure all cables that connect to the RSYC unit are shielded and shields are properly grounded Install an additional metal shield between the emission source and the unit Change location of the unit i e arrange more space between the emission source drive module or motor cables unit Check and correct connections Increase the value of parameter 40 17 Decrease the value of parameter 40 17 Make contactors operate faster if possible Contactors can operate simultaneously Connect a serial inductor 3 phase choke to the motor AC input during switching of change over contactors Equip the choke with a by pass contactor the choke does
17. volts the supply line and the drive output voltages are synchronic i e the phasing and frequency are the same The drive control program constantly corrects the drive frequency reference set to 50 Hz on basis of the BUFOUT signal by using the Trim function When the synchronizing conditions are reached i e the drive output and the supply line phasing s match and the frequencies are equal e BUFOUT signal reaches 5 volts indicating synchronic status for the drive application program e RSYC unit gives a control pulse for the contactor control circuitry e Drive control logic switches the inverter modulation IGBT control pulses off Contactor control circuit opens contactor disconnecting the motor from drive e Contactor control circuit closes contactor K2 connecting the motor to the supply line Description of operation and hardware Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 10 Overall view of the unit RSYC 01 unit with cover eri e M E gt ayi LE gu Ur AA 4 24 Um N cra e Peter PO 428514 NU 2 3 1 ha owes ula oru _ rt rn A AI Km FATA Vt Fen CM AER 2 3 4 4 1 24 DC supply for the RSYC 01 unit 2 SYNC signal K4 and BUF OUT signal 3 Inverter output T2 and network supply T1 measurement trans
18. ximum speed limit Here the panel will be used as the external control signal interface That is the recommended practise at the start up Change later to I O or fieldbus control if needed However note that analogue input and digital input 015 are reserved for the synchronization application Before starting ensure that the contactor control circuit connection at terminal J2 of the RSYC unit is disconnected For the use of control panel see ACS800 Standard Control Program 7 x Firmware Manual 3AFE64527592 English NL A Selecting control location and signal sources Select external control location EXT2 11 02 EXT2 Trim function can be used only with reference into use REF2 REF2 can be given from various interfaces Here control panel KEYPAD will be Define control panel for source of 10 02 KEYPAD used control commands for external control location EXT2 Define control panel for source of 11 06 KEYPAD speed reference for external control location EXT2 Fix rotation direction of motor to 10 03 Change of direction is disabled A er Deactivate constant speed selections 12 01 Inactive Set digital input DI5 to source for run 16 01 DI5 See section Connection diagram on page 11 enable signal Define maximum and minimum limits 20 01 0 00 rpm Maximum speed must be higher than motor for the motor speed 20 02 2000 00 nominal speed 2000 is suitable value for a 4 rpm pole
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