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SyncPro Installation Manual

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1. Run Control Circuit u 1 4 00 NOT STOP NN 1 4 01 START Emergency Shutdown Circuit 0 3 06 RUN O L External 0 3 01 TRIP 1 4 07 EQUIP SHUTDOWN Figure 3 4 Two Wire Control Installation 3 5 In both cases the RUN output will follow the state of the START input provided that all starting conditions are met Note that in all cases stopping the motor is done via the hardwired control circuit logic and notification only is given to the SyncPro Figure 3 4 shows a typical two wire control circuit The selector switch is used to control the NOT STOP and the START as a pair It is also used to ensure the motor is stopped via the hardwired control circuit logic even though in this case the RUN output will be removed when the selector switch is turned off The ESR circuit ensures the motor is stopped for any fault condition occurring either externally or when detected by the SyncPro Once the ESR has dropped out detected by the loss of 1 4 07 the selector switch must be switched off and on to initiate a start This prevents a premature start if the fault condition is cleared and the selector switch is still in the run position Figure 3 5 shows a typical three wire control circuit The STOP PB must be maintained high in order to initiate a start and to run the system The button also ensures that the motor is stopped via the hardware circuit The momentary START PB is used to create a RUN START output signal o
2. Allen Bradley SyncPro Bulletin 1901 Installation Manual FIDE mum 4 mm a i at rh ii Automation Important User Information Read this document and the documents listed in the Additional Resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipme
3. ENTER Allowable Range 50 or 60 Hz Factory Default Setting 60 Hz Power Factor Faults Chapter 6 Monitoring Power in DC circuits is the product of voltage and amperes thus W watts E x I However in AC power circuits some period of time in each cycle may have voltage and current of opposing sign positive or negative and their product will be negative denoting negative power This must be subtracted from the positive power for each cycle to yield the net power The correction factor applied to make this is then a factor by which we multiply apparent power to obtain actual power This is known as Power Factor In a single phase AC circuit we find that W E x I x PF POWER and that VA volt amperes E x I APPARENT POWER For each cycle the power is positive when E and I are both either positive or negative The power is negative when one value is positive with the other negative The result is a power flow of twice the line frequency in and out of the load with the actual power transmitted being the difference of the two Mathematically it can be demonstrated that the Power Factor of a circuit is equal to the cosine of the angle Q of lag or lead of the current with respect to the voltage Fault Detection and Diagnostics The product incorporates numerous fault detections in addition to the starting squirrel cage protection and running pullout protection previously mentioned Prior to starting the motor
4. The field winding has more turns than the stator winding and when power is applied to the stator the field acts like the secondary windings of a current transformer A field winding without a discharge path will produce a voltage greater than its insulation rating and as such requires a means to discharge or limit the voltage If the discharge resistor is not connected during a start the induced voltage can build to a point where the field winding insulation can be damaged The resistor is also used to provide reference points to the SyncPro synchronous motor protector refer to Chapter 4 Field Contactor FC The field contactor provides two normally open and one normally closed power poles The normally open contacts apply DC power to the motor field windings when the contactor is energized Prior to energization and after de energization the normally closed pole makes the path to the discharge resistor to allow the dissipation of energy induced in the field during starting It also provides a path to discharge the stored energy in the large inductive motor field winding on stopping of the motor Resistors Rr1 and Rr2 These resistors are used to attenuate the voltage which reaches the analog digital pulse board Set up of these resistors is important because if the signal voltage to the board 1 too low too much resistance then pulses will not be produced If too little resistance 15 used the voltage may be too high which could dam
5. 3 Set Point 4 Squirrel Cage Protection Time at 95 speed This time setting determines the maximum length of time the synchronous motor may run at 95 speed before it is shut down The squirrel cage winding of the synchronous motor is not rated to run the motor continuously even at no load and therefore must be shut down if synchronism does not occur Time should be set to motor manufacturer s specifications Allowable Range 5 to 80 seconds Factory Default Setting 5 5 5 seconds Set Point 5 Squirrel Cage Protection Trip Time at 50 speed It is possible that a synchronous motor can accelerate only to an intermediate speed and either not accelerate further or take too long to accelerate further due to overloading This would cause the squirrel cage windings to overheat if allowed to continue unchecked This setting limits the time that the motor can operate at 50 speed to the safe maximum recommended by the manufacturer Allowable Range 2 s to Value in Set Point 4 Factory Default Setting 25 2 seconds Set Point 6 Squirrel Cage Protection Trip Time at stall In the event that a synchronous motor fails to accelerate at start up it will go into a stall condition at zero speed This can occur if the motor is overloaded at start The time entered at this set point should be the maximum allowable stall time on the Squirrel Cage Winding as defined by the motor manufacturer NOTE The squirrel cage winding of a synch
6. NIVIN esI 199 S3end wd DN E La La LN3HHTIO 201831NI 4004 AO w Halls ONTOS _ y a ADEL 4 T gl P 51 1NI0d Adda NS 1531 sng due IT Ge posh DET eL De PON E que a sna 1591 zl 430 Figure 3 7 Typical Wiring Diagram 3 wire Control 1901 UM020C EN P June 2013 Setup Chapter 4 Set up and Commissioning Check the following components of the SyncPro once it has been installed Lithium Battery Ensure the supplied lithium battery is connected This battery maintains power to the processor preserving programmed set points loaded into RAM memory through the DTAM verify the connection remove the processor in slot 0 of the I O rack The battery is on the printed circuit board with wires extending from it to a keyed connector The connector must be plugged into the matching keyed receptacle Analog Card DIP switches Remove the analog card from slot 1 of the I O rack and verify that the DIP switches on the side of the printed circuit board have both been set to the position For further details refer to the analog card publication number 1746 NIO4I These are normally set at the factory Programmer Display DTAM Prior to usage the DTAM must be configured as follows while connected to a functional SyncPro 5 03 with the Synchronous Protector program Refer to the DTAM manual 1747 ND013 for more de
7. as given by the motor manufacturer i e induced current 9 0 speed 20 Amps induced current 95 speed 12 Amps discharge resistance 50 ohms therefore induced voltage 0 speed 20A x 50 ohms 1000V induced voltage 95 speed 12A x 50 ohms 600V b A measurement can be taken using a storage oscilloscope or a strip chart recorder refer to Rockwell Automation publication 1900 2 10 for correct set point values The waveform obtained will have a peak value which must be converted to an rms value This is done by dividing the peak to peak value by 2N 2 or 2 828 NOTE When doing this a portion of the discharge resistor only should be used 1 ohm can then be used to determine the value which will be on the entire resistor For example a strip chart recording is taken across a 1 ohm portion of a 50 ohm discharge resistor The following peak to peak values are obtained 0 speed 56 V P P 95 speed 34 V P P 0 speed rms voltage across 1 ohm 56 2 828 20V 95 speed rms voltage across 1 ohm 34 2 828 12 0 speed rms current across 1 ohm 20V lohm 20A 95 speed rms current across 1 ohm 12V lohm 12A Once the induced voltage has been determined make the appropriate selection from Table 4 A Wires from each end of the discharge resistor should then be determined to the appropriate taps on the and RE2 resistors Both the 0 and 95 speed induced voltages must fall between the upper and lower lim
8. diagnostics are performed that detect the a Lack of 24V supply to the slip frequency generator b Reversed Power Factor Leads between the SyncPro and isolator c Lack of the EQUIPMENT SHUTDOWN external fault signal d Loss of Setpoint Data 1901 UM020C EN P June 2013 6 2 Monitoring Faults cont 1901 UM020C EN P June 2013 Fault Detection and Diagnostics cont Upon starting the motor additional diagnostics are performed Any of these conditions will abort the start Diagnostics performed are a Lack of either pulse signal from the slip frequency generator b Lack of field voltage or field current if applicable c Power Factor Transducer Circuit Fault Power Factor Circuit Fault This fault covers a number of possibilities such as reversed leads at the CT shorted CT input loss of control power to transducer or a faulted transducer An incomplete start sequence timer setpoint parameter is utilized to abort the starting if abnormal periods are encountered This time is set independent of the squirrel cage protection times While the motor is running the motor is protected by monitoring fault conditions for a Loss of synchronization Minimum power factor lag is selectable as is the duration of running b Loss of feedback from the field contactor c Loss of the EQUIPMENT SHUTDOWN caused by an external fault In all cases faults are displayed on the DTAM and can be reset via the RESET push
9. motor If the timer expires prior to achieving the maximum asynchronous speed the starting sequence will halt the TRIP output will be dropped and the DTAM will display a message indicating the faulted condition The TRIP signal is restored when there are no faults and the Fault Reset PB input is received NOTE The NOT STOP and START can be tied together to indicate a RUN condition to control the device without separate signals The RUN output follows the start input if the motor is permitted to start i e no faults and the EQUIPMENT SHUTDOWN is high If the programmed percentage of synchronous speed is obtained within set time limits refer to programming of set point Chapter 5 the FIELD RELAY is energized The power factor is now monitored and displayed on If the power factor drops below the programmed values the TRIP and FIELD RELAY outputs will be dropped and the DTAM will display a message indicating the faulted condition Under normal conditions the FIELD RELAY is maintained until the NOT STOP signal is removed The slip frequency is calculated from a square wave input represent ing the slip frequency Based on this frequency the allowable starting time is calculated This calculation is based on three set points which are entered by the user as well as a function order used to shape the curve The three required set points are maximum allowable starting times at the stalled condition 50 speed ma
10. of the slope of the acceleration stall time trip curve incomplete sequence timer trip delay fault mask for PF transducer diagnostics Refer to Chapter 5 for complete details Product Description 1 5 Hardware Typical Synchronous Starter Components The system consists of the following hardware SyncPro 5 03 Processor 9 1747 L532 EEPROM 1746 ITB16 High Speed DC Input Module 1746 NIOAI Analog Input Output Module 1746 0X8 Isolated Relay Output or any 8 point output 1746 IA16 120V AC Input Module or any 16 point input 1746 A7 7 Slot Rack 1746 P1 Power Supply 1747 DTAM Data Table Access Module 700 F220A1 Interposing Relay FCR ESR e 80165 998 51 Phase Angle Transducer e 80025 817 01 20 kilohm Tapped Conditioning Resistors e 80165 778 51 Analog Digital Pulse Board e 800T PB16R Red Illuminated Push Button Contains specialized patented hardware for synchronous application on EEPROM that cannot be viewed accessed The following list of components are devices which the SyncPro is connected to or are part of the SyncPro protection package Motor Contactor M The motor contactor is used to provide and switch the power supplied to the motor stator It is controlled by the SyncPro package and is necessary to remove stator power in the event of a stop command or a trip condition Two normally open contactor auxiliaries may be required one mandatory N O contact to give contactor status information to
11. optional trip output INCOMPLETE SEQUENCE TRIP 0 3 04 Output is set high when an Incomplete Start Sequence Fault occurs It is reset when the TRIP output goes high This signal can be used for indication via a pilot light or it can be used as an optional trip output General Specifications Operating Power Input Line Voltage 120 Volts AC 50 60 Hz Input Current 0 5 Amps Temperature and Humidity Temperature Operating 0 C to 40 C 32 F to 104 F Storage 20 C to 65 C 4 F to 149 F 5 to 95 non condensing Maximum Temp 35 C 95 F Humidity 1901 UM020C EN P June 2013 1 12 Product Description Specifications cont 1901 UMO20C EN P June 2013 Specific Specifications for Phase Angle Transducer General Accuracy Housing Weight Climate Storage Temp range 396 span Flame retardant plastic case 2 4 kg maximum 20 to 70 C 4 to 158 F 20 to 70 C 4 to 158 F storage Operational 0 to 60 C 32 to 140 F Calibrated 9 23 C 73 F Humidity Up to 95 RH Non condensing Input Frequency 50 or 60 Hz Current Any value between 0 2 and 10 A Range A 20 120 Burden 5 VA Maximum Voltage Between 115V 230V 10 Range V 20 20 120 with sep aux Burden 1 VA maximum Overload Capacity Six times rated current for 30 seconds 1 25 rated voltage for 10 seconds Electrical Tests Dielectric Test Impu
12. the DC excitation Verify that when the DC current to the field is reduced the motor power factor becomes more lagging and if increased the motor power factor becomes more leading Setup and Commissioning 4 9 Phase Angle SLC Analog Transducer Input Module Output Sheet 3 To Customer Autoload Circuit if required Autoload output 367 0 307 37 To24 VDC gt Power Supply Sheet 2 e ese Main Contactor Pilot Relay MR Field Contactor Pilot Relay FCR Field Contactor FC Customer 8 Interlocks 9 1 1 0301 1 1 Equipment Shutdown Relay ESR Phase Angle Transducer FR O z EVR INPUT Field Voltage Relay Input FLR INPUT Field Loss Relay Current FC 2 FC INPUT 14 Field Contactor Feedback Contact TC Q 30 SYNCHRONIZATION ENABLE INPUT Transition Complete EQUIPMENT SHUTDOWN INPUT E 1 407 Reset Permitted MO x MAIN CONTACTOR INPUT gt CIs Main Contactor Feedback Contact SCP Trip Squirrel Cage Protection Trip Pullout Synchronous Pullout Trip Incomplete Sequence Incomplete Sequence Trip n Customer supplied equipment Install any protective device external to the SyncPro in series in this circuit as shown Logic must be that contact is closed if running is permitted FLC and TC are optional customer supplied inputs
13. the SLC analog card Ensure that there is power to the transducer board Replace the SLC analog card or transducer board as required Transducer Problem PF XDCR PROBLEM The transducer is behaving unpredictably This is an all encompassing fault and could include anything from the CT the transducer board or the SLC analog card Pulse Board 24 V Failure Connection has not been made between the Check the connections at the A D pulse board PULSE BOARD 24 V analog digital pulse board and the SyncPro DC input card or from the discharge resistor to the same A D pulse board e 1746 P2 power supply has had a failure of the 24 Check fuse in power supply Check for 24 V at V supply power supply Replace power supply if necessary Replace A D pulse board Field Voltage Loss The static exciter is not actively producing DC or Service the static exciter or repair the FVR relay FIELD VOLT LOSS the FVR relay coil has failed Wrong polarity on FVR coil Check polarity on FVR coil Incorrect voltage rating of FVR coil Check voltage rating of FVR coil Exciter Enable EE relay did not pick up Verify the control circuit Field Current Loss FIELD AMPS LOSS The current relay which monitors the motor field current is not providing an energized contact to verify that the static is functional Check both the field current relay and the static exciter for possible failures Field
14. with the phase angle transducer The following values for the fault masks are used 0 faults are enabled default 1 Commissioning faults are disabled This consists of Reversed PF SyncPro and CT Reversed 2 Diagnostics associated with the Power Factor are disabled 16 Reversed PF SyncPro 32 of the following individual faults are disabled 64 No Transducer Input 128 CT Open Shorted 256 Reversed 512 NoSignal SyncPro 1024 Transducer Problem It is possible to selectively mask individual faults by adding up the fault values and entering the result For example to disable the Reversed PF SyncPro and No Signal SyncPro the mask value would be 528 16 512 NOTE The value entered during prompting may not be the same value displayed if the value can be represented more clearly by some other combination of faults ie the value of 272 16 256 corresponds to 1 1901 UM020C EN P June 2013 5 6 Programming Additional Parameters 1901 UMO20C EN P June 2013 System Frequency The SyncPro can function on either 50 or 60 Hz power systems The unit as standard is shipped to operate at 60 Hz The unit may be changed to operate at 50 Hz by entering a value of 50 in integer word N23 1 To change back to 60 Hz a value of 60 can be re entered To access word N23 1 press ESC then the FO key followed by the 2 key The register will be displayed Enter the desired value and press
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16. 2 458 38 10 Y 16 75 425 Uus WE h d EHHHHHHHES rh H lo HHH I 5 sl F H 0 2 A gt 20 00 18 95 4 508 481 lannnilannn E 1329 338 o B L 4 6 12 6316 39 lt 137549 36 9 dia 155 4 Mounting Holes Front View Side View Note Dimensions are in inches millimeters Figure 3 2 Mounting Dimensions 1901 UM020C EN P June 2013 Installation 3 3 Open Frame cont Analog Digital Pulse Converter Board Fusible Terminal Blocks dec Conditioning Resistors RF Terminal Blocks FCR Relay DIN Rail Mounted ESR Relay Phase Angle Transducer DIN Rail Mounted DIN Rail Mounted Bulletin 1746 7 slot Card Rack with P1 Power Supply Ground Bar Figure 3 3 Component Layout Integral The SyncPro is also available as a component of a Rockwell Automation Allen Bradley synchronous motor starter Bulletin 1912B incorporating the components shown in Figure 3 3 Although the layout in the starter is different control and functionality remain the same Grounding The grounding required by the SyncPro panel has been brought to a common grounding bar mounted on the panel It is important that once the unit is installed that this grounding bar is wired to the
17. B Troubleshooting Guide Problem or Trip mor OE lution indicated Indication of the following conditions Possible Solutions Pullout trip power factor Motor overloaded Lessen the motor loading and or overload POWER FACTOR TRIP Loss of DC excitation Repair static exciter Static exciter DC current level set too low Increase current setting on static exciter Squirrel cage Protection Trip SQ CAGE PROT N Motor overloaded at start Remove or lessen load for start Incomplete Start Sequence Time Exceeded INCOMPLETE START Motor overloaded at start Field contactor or FC pilot relay coil failure Remove or lessen load for start Replace coil s No Transducer Input PF NO XDCR INPUT The transducer is putting out less than 12 mA when the motor is off should be 12 mA Check the wiring for the voltage sensing on the transducer board Replace phase angle transducer board if necessary Replace analog card in SyncPro rack CT Open Shorted PF CT OPEN SHORT The CT is either open or shorted Check the wiring between the CT and the transducer board Replace the CT if necessary CT Reversed PF CT REVERSED The CT is incorrectly wired to the transducer board Reverse the leads of the CT at the transducer board No Signal SLC PF NO SIGNAL O SyncPro There is no signal at the SLC analog card from the PF transducer board Check the wiring between the transducer board and
18. CTOR 1 2 0 The signal supplied to the SyncPro is from the Phase Angle Transducer representing a power factor of zero 0 lagging to zero 0 leading respectively Note that the SyncPro firmware has been tailored to this specific transducer No substitution is allowed SLIP GENERATOR POWER 1 1 01 This fault input is monitored during idle and starting periods It is normally held high by the power supply to the Slip Pulse Generator SLIP GENERATOR NEGATIVE 1 1 00 Connect to the negative terminal N of the Slip Pulse Generator SLIP GENERATOR POSITIVE 1 1 02 Connect to the positive terminal P of the Slip Pulse Generator Product Description 1 11 Specifications Status AUTO LOAD 0 3 07 Output is energized two seconds after the field is applied and remains closed until the field is removed from the motor by a stop or a fault SCP TRIP 0 3 02 Output is set high when a Squirrel Cage Protection Fault occurs It is reset when the TRIP output goes high after pushing the reset button This signal can be used for indication via a pilot light or it can be used as an optional trip output MOTOR PULLOUT TRIP 0 3 03 Output is set high when the power factor lags for longer than the programmed trip time delay indicating that the motor has pulled out It is reset when the TRIP output goes high after pushing the reset button This signal can be used for indication via a pilot light or it can be used as an
19. Coil Feedback FIELD CONTACTOR The SyncPro has requested the field contactor to energize but the feedback contact from this contactor is not showing as closed The field contactor coil has failed Replace the coil The connection to the FC auxiliary has not been made Check the wiring The FC auxiliary contact has failed Replace the contact Reversed PF SyncPro The connections from the PF transducer to the Switch the positive and negative transducer REVERSED PFOSLC analog card have been accidentally reversed output leads at the analog card External Hardware Fault An external device to the SyncPro is not Check external devices EXTERNAL TRIP functioning as expected 1901 UM020C EN P June 2013 Troubleshooting T 3 Table 7 B Troubleshooting Guide cont Problem or Trip indicated Indication of the following conditions Possible Solutions Pulse Board Positive and Negative Pulse Missing PULSE BOARD VE PULSE BOARD VE The SyncPro is not seeing a pulse train being supplied from the A D board at the time of starting The RF1 RF2 resistor selection is not correct The signal is too weak to provide the necessary pulse train Pulse train would be lost if either the A D card failed the RF RF2 selection is incorrect or if the connection is not made from the A D board to the SyncPro Review the RF1 RF2 setup parameter and verify the procedure performed see Commissi
20. L SCP TRIP PILOT LIGHT OPTIONAL MOTOR PULLOUT TRIP PILOT LIGHT OPTIONAL INCOMPLETE SEQUENCE TRIP PILOT LIGHT AUTOLOAD nue sl CONNECTED INTERNALLY Figure 4 3 Typical Schematic Sheet 3 of 3 FIELD LOSS RELAY CURRENT DO FIELD CONTACTOR O FEEDBACK CONTACTOR SYNCHRONIZATION ENABLE INPUT OQ TRANSITION COMPLETE EQUIPMENT SHUTDOWN RELAY INPUT RESET PERMITTED MAIN CONTACTOR FEEDBACK CONTACTOR 1901 UM020C EN P June 2013 4 12 Setup and Commissioning 1901 UM020C EN P June 2013 Set Points Chapter 5 Programming the SyncPro Prior to use the Synchronous Protector must be programmed with nine common set points and possibly one additonal parameter To start the programming procedure a macro has been defined in the DTAM as F 1 Press ESC then the F key followed by the 1 key The register N23 0 will be displayed Enter a value of 1 and press ENTER to start the sequence During the sequence the following set points are entered Minimum Synchronous Slip Frequency of synchronous Power Factor Trip 9 of unity Power Factor Delay Trip x 0 01 Seconds Squirrel Cage Protection Trip time at 95 speed Squirrel Cage Protection Trip time at 5096 speed Squirrel Cage Protection Trip time at stall Function Order 1 5 Incomplete Sequence Trip Time Delay Seconds Diagnostic Fault Mask A 9 T The programmin
21. Point 4 Squirrel Cage Protection Trip Time at 95 speed 5 3 Set Point 5 Squirrel Cage Protection Trip Time at 50 speed 5 3 Set Point 6 Squirrel Cage Protection Trip Time at stall 5 3 Set Point 7 Function Number eese 5 4 Set Point 8 Incomplete Sequence Trip Time Delay 5 5 Set Point 9 Diagnostic Fault Mask eee 5 5 Additional Parameters eese eren nennen 5 6 Chapter 6 Power Pacos reses LR UP IE T oes es tects 6 1 Iti 6 1 Fault Detection and Diagnostics 6 1 Power Factor Circuit Fault 6 2 Chapter 7 Last Trip Codes Table 7 A 7 1 Troubleshooting Guide Table 7 B see 7 2 Chapter 8 Spare Parts List for SyncPro 8 1 Description Documentation Chapter 1 Product Description The SyncPro consists of a programmable small logic controller SLC 500 with the following additional peripheral items Data Table Access Module DTAM Power Factor Transducer Analog Digital Pulse Board Conditioning Resistors nterposing Relays FCR and ESR The SyncPro system is designed to provide supervisory protection and field control to a brush type synchronous motor controller proper field application timing squirrel ca
22. R FEEDBACK CONTACT 1 4 05 This input indicates to the SyncPro that the field contactor has picked up confirming that the field has been applied The signal must come from the auxiliary of the coil which ultimately applies the field i e contactor If missing the SyncPro detects a fault in the field circuit TRIP RESET PB INPUT 1 4 02 This input from the push button on the panel will reset any fault condition in the SyncPro Once no fault exists the fault condition will be removed from the DTAM and the TRIP output will be set 1901 UM020C EN P June 2013 1 10 Product Description Input Output Descriptive Listing cont 1901 UM020C EN P June 2013 Fault Detection FIELD VOLTAGE RELAY INPUT 1 4 03 When the signal is low it indicates a lack of field voltage This input is monitored for a fault condition only while starting prior to applying the field Tie this input high if it is not used When this contact is high it verifies that the static exciter is providing an appropriate DC voltage FIELD CURRENT RELAY INPUT 1 4 04 OPTIONAL When the signal is low it indicates a lack of field current This input is monitored for a fault condition after the field has been applied Tie this input high if it is not used This optional input verifies there is DC current flowing from the static exciter to the motor field It is redundant since the power factor trip feature will trip if the field current is lost POWER FA
23. ab com mvb Publication 1901 UM020 CE N P J une 2013 Supersedes Publication 1901 UMO20B EN P April 2004 Copyright 2013 Rockwell Automation All rights reserved Printed in Canada
24. age the analog digital pulse board Refer to Chapter 4 page 4 2 Analog Digital Pulse Board This board converts the voltage sinusoidal waveform across the discharge resistor and by examining the zero crossings creates a digital pulse train of an equal frequency to the induced slip frequency occurring in the discharge resistor At start zero speed the frequency will be 60 Hz at 95 speed the frequency will be 3 Hz for a 60 Hz system This feedback is used by the SyncPro to determine the speed of the motor at any time during acceleration and when the motor has reached the desired speed set point to synchronize 1901 UM020C EN P June 2013 1 8 Product Description Input Output Descriptive Listing 1901 UM020C EN P June 2013 Control NOT STOP 1 4 00 This signal must be maintained high for the SyncPro to operate When the signal is taken low the software identifies this as a normal stop for the motor Important The SyncPro does NOT have control over stopping the motor The main portion of the motor controller performs this control function The NOT STOP signal must be given in parallel to that of the hardware i e from the same PLC output or push button START INPUT I 4 01 The rising edge of this signal starts the operation of the SyncPro This signal is maintained high for two wire control or may be dropped after initial starting if three wire control is used In both cases this signal controls the START ou
25. ammed into the SyncPro are appropriate for the motor See Chapter 5 for further details on programming Verify that the SyncPro has been wired into the motor starter circuit as indicated by the wiring diagram Remove the wire from the Field Contactor Relay FCR coil either at the I O point 0 3 0 or at the FCR coil itself Tie back and insulate the wire so that it cannot accidentally short out to ground or another electrical point This will disable the field contactor so that the starter will not attempt to synchronize Important The contactor must be disabled in this manner rather than removing the field cables from the contactor The discharge path through the discharge resistor must be maintained otherwise a voltage high enough to damage the field insulation will occur at the open field windings This is similar to the effect which occurs if a current transformer secondary winding is left open circuited If during the previous setup procedure for the discharge resistors and RF2 the induced currents were not known then the next step would be to bump the motor with the RF1 and RF2 resistors disconnected The method detailed in Allen Bradley publication 1900 2 10 for determining the motor data by measurement using a strip chart recorder should be done at this time The 1 and RF resistors should then be set up as indicated on page 4 3 with the data obtained It is necessary to use jumpers at the SyncPro trip output O 3 1 a
26. aults and the FAULT RESET PB is momentarily raised high Product Description 1 9 Field Application TRANSITION COMPLETE CONTACT 1 4 06 OPTIONAL The field relay output will not be energized until this input permissive is given Once the field relay is picked up this permissive is no longer required If the permissive is not given prior to the squirrel cage protection timing out or the incomplete sequence timing out the SyncPro will fault and stop the motor If unused it must be tied high This input is intended for an external input such as the RUN contact of an autotransformer starter It prevents synchronization until the autotransformer starter has first transitioned to full voltage RUN mode FIELD RELAY 0 3 00 This output controls the field contactor relay which applies the field to the motor This output is energized when the transition complete permissive is given and the synchronous setpoint has been reached The field is then applied either on the rising waveform or after a fixed time period of one second if the motor synchronizes on reluctance torque The output is dropped whenever the NOT STOP is removed the EQUIPMENT SHUTDOWN RELAY is removed or a fault is detected Feedback MOTOR CONTACTOR FEEDBACK CONTACT 1 4 08 This input indicates to the SyncPro that the motor contactor is closed confirming that the motor is running It also allows the SyncPro to detect a fault in the contactor circuit FIELD CONTACTO
27. button Chapter Last Trip Table Troubleshooting To aid in troubleshooting the unit stores the last 10 recorded faults These can be accessed by viewing the contents of the data file N22 0 refer to the DTAM manual 1747 ND013 for information on data table access This file forms a circular queue from N22 1 to N22 10 such that when full the oldest fault 15 discarded making room for the newest The value in N22 0 gives the most recent fault For example N22 0 has the value of 6 The most recent fault is found in N22 6 the one preceding it at N22 5 The fault at N22 10 precedes the fault at N22 1 in a circular fashion The faults are denoted by the following fault codes Table 7 Last Trip Codes Fault Code Description 1 Phase Lag Pull Out 2 Squirrel Cage Protection Trip 4 Incomplete Start Sequence Time Exceeded 8 Power Factor Transducer Ckt 16 Pulse Board 24 V Failure 32 Field Voltage Loss 64 Field Current Loss 128 No Field Coil Feedback 256 Reversed PF SyncPro 512 External Hardware Fault 1024 Pulse Board Positive pulse missing 2048 Pulse Board Negative pulse missing 4096 Contactor Feedback 8192 Set Point Data Lost If more than one fault occurs simultaneously the value shown will be the total of the last trip codes ie if Field Current Loss coincided with a Pull Out the value would be 64 1265 1901 UM020C EN P June 2013 7 2 Troubleshooting Table 7
28. e controller The user may then mount the components in a configuration most suitable to his main motor controller equipment layout Care must be exercised to ensure the SyncPro processor has adequate ventilation provided around it Refer to Figure 3 6 for wiring of the components LIA INPUT OUTPUT OUTPUT INPUT SyncPro FAST DC SINK ANALOG DTAM EJ Pulse Converter mm Controls amp Analog Digital Indicators OO To Control Power Analog Digital Pulse Converter E To Discharge Resistor y To CT Phase A To Discharge Resistor Figure 3 1 SyncPro Component Configuration 2 LL gt E e Resistor RF 1901 UM020C EN P June 2013 3 2 Installation Arrangements cont Open Frame The SyncPro components are mounted on a panel except the DTAM display module and the illuminated push button for trip indication and reset function See Figures 3 2 and 3 3 for mounting dimensions of the main unit panel DTAM and 800T push button Quick installation within the main controller is possible with this arrangement NOTE The Data Table Access Module DTAM is supplied with a two meter cord for connection with the SyncPro processor Be sure to mount the DTAM in a suitable location for this connection to be made If a longer cord is required refer to Publication 1747 ND013 to find the appropriate catalog number 18 0
29. eted place the jumper on the plug inside the casing of the DTAM between pins 1 and 3 or remove the plug altogether Rr1 amp Rr2 Resistor Setup The synchronous motor field discharge resistor feedback resistors RF2 are necessary to attenuate the induced voltage waveform which appears across the resistor during starting The resistors reduce the voltage which is seen at the terminals of the analog digital pulse converter to a level which is acceptable to the optoisolators on the board Guidelines for resistor settings are contained in the chart shown in Table 4 A page 4 6 The resistance value shown is the amount of resistance which is required on each lead which is connected to the A D pulse board F2 For example if the induced voltage on the discharge resistor is 1000 V at zero speed and 600 V at 95 speed across the entire discharge resistor then it is necessary to select taps on the RF1 and RF2 to provide 20 kilohms at RF1 and 20 kilohms at RF2 Discharge Resistor RF RF Fi F2 20 20 0 Setup and Commissioning 4 3 Rr1 amp Rr2 Resistor Setup cont These settings must be made prior to any start attempt Determining the induced voltage which will appear across the discharge resistor during starting can be done two ways a If motor data is available the voltage can be determined by multiplying the discharge resistance by the induced currents at zero and 95 speed
30. f the same duration as the input signal as long as there are no faults detected by the SyncPro START PB O 1 4 01 START 14 00 NOT STOP ESR O 3 06 RUN E STOP O L External eti C ms pas 1 0 3 01 TRIP 20 1 4 07 EQUIP SHUTDOWN 1901 UM020C EN P June 2013 Figure 3 5 Three Wire Control 3 6 Installation Wiring Guidelines cont E STOP O L External 0 3 01 TRIP Esa Equipment Shutdown Relay START 1 4 07 EQUIP SHUTDOWN O 1 4 01 START PB STOP O10 1 4 00 NOT STOP 0 3 06 RUN Main Contactor Pilot Relay 0 3 00 FIELD RLY Field Coil Relay Pilot Relay Auxiliary Contact from final 1 4 05 FLD CONT AUX coil in chain if acceptable I 4 06 TRANS CMP 1 4 08 CONT FDBK 4 04 FLD CURRENT RLY FVR 1 4 03 FVR RELAY PB RESET C 4 02 RESET Eg Not Used Figure 3 6 Typical Wiring 1901 UMO20C EN P June 2013 Installation 3 7 In this case three wire since the START signal is only momentary the hardware must perform the sealing function using the control relay CR The START output is really an extension of the START input except that the output is conditioned by any fault conditions The ESR circuit ensures the motor is stopped for any fault condition occurring either externally or when detected by the SyncPro Once the ESR has dropped out detected by the loss of I 4 07 a start will not be permitted until the fau
31. g sequence can be started in mid stream by entering the above corresponding number to that of the parameter desired into the N23 0 register For example to enter the Function Order without the need to enter the preceding set points enter the value 7 in the N23 0 register At each prompt type the new set point if required and press ENTER If the current set point is acceptable simply press ENTER ESC If an invalid value is entered a message indicating this will be displayed showing the valid limits to be entered Once the message is removed a short pause occurs and then the prompts resume After the last entry is made the data 15 saved in the SyncPro data tables The data entry sequence may only be performed when the motor is inactive If the motor is started while data is being entered into the DTAM the data entry sequence will be aborted The operating frequency of the starter is set to either 50 or 60 Hz by entering the desired value into N23 1 This word is accessed by the macro F 2 Refer to publication 1747 ND013 for information on the usage of the 1747 DTAM 1901 UM020C EN P June 2013 5 2 Programming Set Points cont 1901 UMO20C EN P June 2013 Set Point 1 Minimum Synchronous Slip Frequency This set point determines the percentage of synchronous speed at which the DC voltage is to be applied by the field contactor The SyncPro monitors the frequency of the induced voltage across the di
32. ge protection against long acceleration and stall conditions as well as running pullout protection by monitoring motor power factor When combined with a suitable induction motor protection relay the SyncPro provides the necessary overload protection to the brush type synchronous motor Important Although the SyncPro makes use of some standard SLC 500 programmable controller components it is imperative that the controller is a dedicated unit expressly for the control and protection of the field of a single synchronous motor The firmware and hardware configuration must only be used for its designed purpose Do not attempt to modify the controller in any way for another use No additional SLC control cards can be added The following publications have pertinent information for components used in or associated with the SyncPro 1747 ND013 Data Table Access Module User Manual 1747 NI002 SLC500 Modular Hardware Style Installation and Operation Manual 1746 NM003 Analog Card publication 1900 2 10 Measuring for Synchronous Motor Data 900 1 0 Synchronous Motor Control SGI 1 1 Safety Guidelines for the Application Installation and Maintenance 1746 2 35 Discrete Input and Output Modules 1746 2 36 SLC500 Modular Chassis and Power Supplies 1901 UM020C EN P June 2013 1 2 Product Description Synchronous Motor Theory 1901 UM020C EN P June 2013 The synchronous motor is a commonly used industrial motor favored for its h
33. igher efficiency superior power factor and low inrush currents Typical applications that benefit from the constant operating speed include refiners head box fan pumps chippers etc Synchronous motors are particularly well suited to low RPM applications The synchronous brush type motor is composed of a three phase stator winding a DC rotor winding and a squirrel cage winding The stator winding is identical to that of an induction motor and as such the direction of motor rotation depends on the rotation of the stator flux The direction can be changed by reversing two of the stator leads just as 1t does with induction motors The rotor contains laminated poles which carry the DC field coils that are terminated at the slip rings It also has a squirrel cage winding composed of bars embedded in the pole faces and shorted by end rings The squirrel cage winding is also known as damper or amortisseur winding This winding enables the motor to accelerate to near synchronous speed so that the DC supply can be applied to the field windings for synchronizing the motor to the line typically 95 These field windings are connected through slip rings to a discharge resistor during start up The resistor 15 required to dissipate the high voltages that are induced into the field windings from the stator and it is removed from the circuit when the DC field voltage is applied The synchronous motor can be compared to a transformer wi
34. ime to accelerate to rated subsynchronous speed The point at which the I O point 0 3 0 picks up which normally would energize the field contactor occurs to see if it appears to be occurring at 95 speed This will also prove that the power factor transducer connection is in the correct orientation with the incoming current and voltages If the polarity is incorrect switching the C3A and C3B connections should correct the situation NOTE The phase angle transducer connections are correct provided that the transducer power and voltage reference inputs are connected to Line 1 and 2 and the current reference is Line 3 If the incoming connections into the starter have been made B A C rather than A B C the polarity will also be incorrect even though the correct starter lines have been brought to the transducer In either event the correction is the same reverse the C3A and the C3B current transformer connections ATTENTION To avoid damage to the motor do not allow the motor to run without synchronizing at 95 speed for longer than required to perform this test Most motors are only capable of running for about 60 seconds at 95 speed without synchronizing After completing the actions in Step 5 if the equipment appears to be operating in the correct manner then the leads can be reconnected to the FCR coil which was removed in Step 3 The motor can now be normally started Once the motor has synchronized a good check is to vary
35. ion ca o s onc teet e pee ede dai 1 10 LAU RT 1 11 Specifications iiti en an n SERE rU TEE n HP EAE ED Hee De 1 11 General Specifications eese 1 11 Specific Specifications tede 1 12 Specifications monere rte nter 1 12 Receiving and Storage Chapter 2 Receiving 2 1 E 2 1 Installation Chapter 3 noticias deer sete ee bebe eee or re c iei deed 3 1 Component tee ee HR Perte rie o etre 3 1 Open EraME sta ea ied PH 3 2 Ititeeral ai eea a a euet 3 3 Grounding d tente adore ta eset 3 3 Waring Guidelines ett aee ee e EE Eco 3 4 ne nee MN tint a lents etes nes 3 7 1901 UM020C EN P June 2013 ii Table of Contents SyncPro Instruction Manual Setup and Commissioning Programming the SyncPro Monitoring Troubleshooting Spare Parts 1901 UMO20C EN P June 2013 Chapter 4 PER ER eo dia 4 1 Lithium Battery 4 1 Analog Card DIP Switches ss 4 1 Programmer Display eene 4 1 and Resistor Setup 4 2 Commissioning 4 7 Chapter 5 Set Points cna ee ee e es 5 1 Set Point 1 e Minimum Synchronous Slip Frequency 5 2 Set Point 2 Power Factor Trip sese 5 2 Set Point 3 Power Factor Trip Time Delay 5 2 Set
36. its defined on the chart 1901 UMO20CEN P June 2013 4 4 Setup and Commissioning Setup cont Rr1 amp Rr2 Resistor Setup cont Procedure for Selection of Resistors Discharge resistance ohms Sample resistance ohms 0 speed peak to peak voltage Vpeak Q0 95 speed peak to peak voltage Vpeak 95 Induced voltage 0 speed Vrms 0 Vp0 2 828 Induced voltage 95 speed Vrms 95 Vp95 2 828 Induced current 0 speed Arms 0 VrmsO Rs Induced current 95 speed Arms 95 Vrms95 Rs Induced voltage 0 speed V IOxRd Induced voltage 95 speed I95xRd 0 speed induced voltage across the entire discharge resistor 50 ohms 20 amps 1000 volts 95 speed induced voltage across the entire discharge resistor 50 ohms 12 amps 600 volts RrI RrF2 Resistance Required Ohms 1901 UM020C EN P June 2013 Setup and Commissionin 4 5 Rr1 amp Rr2 Resistor Setup cont RF Resistor tap settings QT gT3 SYNCHRONOUS MOTOR Dr Lot Sots R1 Re d DISCHARGE RESISTOR p 100 103 RF RF psa XX ANALOG DIGITAL G N PC T2 o PULSE CONVERTER TD EC L2 a EO Co SLC 5101 ToSLC 24V DC Power Supply Figure 4 1 Discharge Resistor Set up 1901 UM020CEN P June 2013 4 6 Setup and Commis
37. latory requirements for safe work practices and for Personal Protective Equipment PPE Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Table Of Contents Product Description Chapter 1 D scription pe oi pi to bb e ten SI 1 1 Documi nt tion rper tte edere pra 1 1 Synchronous Motor Theory enne 1 2 Protection Features ade ae tieniti 1 3 Theory of Operation ss ete d eere tbe ie 1 3 Optional Equipment ss 1 4 Display Metering Features esee eere 1 4 Hardware erect tte tee nr ne eei 1 5 Typical Synchronous Starter Components ees 1 5 Motor Contactors n Feier setae nie re RR eee aged 1 5 Motor Contactor Pilot Relay esee 1 5 Field Voltage Relay 5 n 1 6 Equipment Shutdown Relay eene 1 6 Phase Angle Transducer 1 6 Discharge ResIStOE a 1 7 Field Contactor arde 1 7 Resistors Rel and iei eu eee e Es 1 7 Analog Digital Pulse Board esee 1 7 Input Output Descriptive Listing eee 1 8 Control eai t Reda tr 1 8 iie iva eade 1 9 Feedback eau uetus 1 9 Fault Detect
38. ll conditions during starting Field Winding Application Control The signal that triggers application of the field excitation when the programmed asynchronous speed is obtained Incomplete Sequence Timing Relay Trips the system if the overall starting time is exceeded Pull Out Protection Monitors the power factor during running to detect a loss of synchronism Field Voltage Failure Relay Input Monitors the condition of the static exciter output This relay must be supplied by the customer if the SyncPro is not supplied as a configured unit within a Rockwell Automation Allen Bradley motor controller Optional Equipment Field Current Failure Relay Load and Unload Auxiliary Contacts The outputs are energized 2 sec after the field is applied and is maintained until the field is removed The product in conjunction with the Data Terminal Access Module DTAM will perform the following metering display functions display all detected fault conditions display the slip frequency and starting time during startup display the power factor during run mode accept set points through the DTAM for the following maximum asynchronous speed of synchronous speed power factor set point and trip delay maximum allowable time at stalled state maximum slip maximum allowable time at 50 speed maximum allowable time at synchronizing speed typically 95 speed function order allows adjustment
39. lse Test 2kV RMS to BS 5458 5kV transient as BEAMA 219 amp BS923 Surge Withstand ANSI C37 90A Certification CSA Approved DTAM Specifications Refer to Publication 1747 NC013 Appendix 1 2 SLC500 Specifications Refer to Publication 1747 NI002 SHT 1 4 Power Supply Specifications Refer to Publication 1747 NI002 SHT 1 7 Receiving Storage Chapter 2 Receiving and Storage Upon receiving the controller remove the packing and check for damage that may have occurred during shipping Report any damage immediately to the claims office of the carrier NOTE If the SyncPro is an integral component of a brush type synchronous starter Bulletin 1912B special receiving and handling instructions will apply For details refer to the service manual provided with the equipment It is important to consider the following storage requirements if you are not installing your controller immediately after receiving it Store the controller in a clean dry dust free environment Storage temperature should be maintained between 20 C and 70 4 F and 158 F Relative humidity must not exceed 95 non condensing 1901 UM020C EN P June 2013 2 2 Receiving and Storage 1901 UM020C EN P June 2013 Chapter 3 Arrangements Installation The SyncPro is offered in three arrangements Component The SyncPro may be ordered as individual components for maximum flexibility when installing th
40. lt 1747 C10 Figure 4 3 Typical Schematic Sheet 2 of 3 5 etup and Commissionin 4 11 SLOT2 INPUT OUTPUT MODULE 1746 NI041 INO INO ANLCOM IN1 ANLCOM PHASE ANGLE TRANSDUCER BLK c O Customer supplied equipment FLR and TC are optional customer supplied inputs which are jumpered to terminal blocks if not used Contact rating is 60 amp Make 10 amp Break inductive 10 amp continuous at 120 V AC A600 O _ Refer to instruction manual for tap selection guidelines on Rr1 and Rr2 resistors O Analog card switch settings SW1 ON OFF 21 Customer to take ground wire to ground bus earth ground Ground at bottom left hand mounting screw for rack or grounding bar Line to Line 2 voltage reference and Line 3 current reference must be maintained for proper operation of the phase angle transducer O Wiring supplied on enclosed assembly only 1901 AADC10 for the open frame units The customer mus amp upply these wires in addition to mounting the illuminated push button DTAM STAM cable 1747 C10 and illuminated push button are supplied loose on open frame assemblies 1901 ANDC10 SLOT3 SLOT4 120 VAC RELAY OUTPUT 120 VAC INPUT 1746 0X8 1746 1416 Kotto VACO 6 FCR RELAY START RESET TRIP NOT FAULTED FIELD VOLTAGE RELAY O OPTIONA
41. lt condition is reset It should be noted that in all cases the TRIP output is removed when a fault is detected This fault includes both external hardware faults as recognized by the EQUIPMENT SHUTDOWN signal and faults which are generated by the SyncPro such as a power factor trip SUMMARY 1 The RUN output will follow the state of the START input given that there are no faults detected by the SyncPro 2 Once a fault has been detected the START input must be taken low before the RUN output will be allowed to operate 3 All motor stopping must be controlled by hardwired control circuit logic The SyncPro is only notified of the stoppage in order to determine what is happening Any time the motor stops without first removing NOT STOP input an error condition will be detected 4 When using three wire control a contact from the CR relay must be used to seal in around the RUN output 1901 UM020C EN P June 2013 Installation 3 8 Wiring Guidelines cont eNINOISSININOS 33933034 SNINOISSIMMO 2 HO 3 OXF INAS OL 334 SNIN OISSIHINO 2 HO 3 14103 NOLL23NNO2SIQ x 1N3S34d 38 LON AMY THIN SIHL L 1
42. mponent included with SyncPro The phase angle transducer provides a conditioned 4 to 20 milliamp signal to the analog module of the SyncPro system The transducer is factory calibrated to provide a specific output at zero 0 lagging power factor at 1 0 or unity power factor and at zero 0 leading power factor These factory settings must not be altered The SyncPro processor scales and interprets this signal to compare it to the power factor trip set point and to cause a trip to occur if the power factor drops below the programmed value for more than the specified power factor trip time delay If the DC excitation is lost a low voltage condition exists or the motor is being overloaded to a point where the motor can no longer maintain synchronous speed the motor power factor will react by dropping to a very lagging value This indicates that the motor is slipping poles and the controller should be shut down to protect the motor The phase angle transducer monitors voltage across lines 1 and 2 along with the current in line 3 to obtain a power factor reading When the reading is below the set points programmed the SyncPro will shut down the starter Product Description 1 7 Discharge Resistor The discharge resistor is specified by the motor manufacturer for a specific application to obtain correct starting and pull in torques and to provide a means of discharging the motor induced field voltage when starting and stopping the motor
43. nd the run output O 3 6 for the motor bump ATTENTION During the bumping procedure the SyncPro does not protect the motor Monitor the procedure closely to avoid damage to the motor Do not use jumpers at the ESR contact as this will also eliminate any external protective trips such as line overcurrent fault protection etc which are still necessary for the bump Refer to Figures 4 2 and 4 3 for the jumper placement and the points at which to disconnect the wires ATTENTION During synchronization voltages that may exceed 1000 volts are present at the Rr1 and Rr2 resistors To avoid shock hazard do not touch the resistors 1901 UM020C EN P June 2013 4 8 Setup and Commissioning Commissioning cont 1901 UM020C EN P June 2013 NOTE The phase angle transducer as wired from the factory is set up for the customer to run his wiring with an ABC line orientation If this was not observed the user has two options First the line cables can be moved switching any two incoming lines will do so that ABC now exists BCA or CAB are also acceptable OR the current transformer leads to the transducer can be swapped at the transducer 5 If the RFI RF2 connections were removed for step 4 they should now be reconnected at this point and set to the appropriate tap The motor may now be bumped for rotation Allow the motor to accelerate to rated subsynchronous speed and monitor the following items at this time The t
44. nt or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence P IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regu
45. oning item 4 on page 4 7 Contactor Feedback Lost MOTOR CONT FDBK The SyncPro monitors the status of the synchronous motor stator contactor while running The main contactor coil has failed Replace the coil The connection of the M auxiliary contact has not been made Check the wiring The male female connector of the vacuum The contact has failed Replace contactor is not matched properly Ensure the connector is matched properly The SLC I O card 4 input 8 is faulty Replace the I O board Set Point Data Lost The parameters entered into the SyncPro are Check the battery located in the processor SETPT DATA LOST retained in battery backed up RAM memory module The battery has either been depleted These setpoints are not being retained by the or the plug in connection has not been made SyncPro unit Note This will occur when a new unit is plugged in for the first time see Chapter 4 Halt Synch Relay The key switch on the SLC 500 processor may be Turn the key switch to the RUN mode in program mode position NOTE The phase angle transducer as wired from the factory is set up for the customer to run his wiring with an ABC line orientation If this was not observed the user has two options First the line cables can be moved switching any 2 incoming lines will do so that ABC now exists BCA or CAB are also acceptable OR the current transformer leads to the transducer can be s
46. ronous motor has a very limited capability Generally the stall time allowed by the squirrel cage winding is less than the time that the stator winding is capable of It is possible that a motor with a stator capable of a 20 second stall would have a rotor which can only endure a stall condition of 5 seconds Allowable Range 1 sto Value in Set Point 5 Factory Default Setting 1 1 second 1901 UM020C EN P June 2013 Programming 5 5 Set Point 8 Incomplete Sequence Trip Time Delay Once a synchronous starter has been commissioned the acceleration and synchronization times should remain fairly consistent provided that the starting load does not vary significantly The incomplete sequence timer can be set to a time delay that is slightly higher than the slowest acceleration time The aforementioned squirrel cage protection features protect the motor but they also let it go to its thermal limitations The ISTR set point can be adjusted to take the starter off line earlier than the squirrel cage protection trip time set point 5 in the event of a field contactor failure or some other mechanical problem that prevents synchronization This action minimizes motor heating during an equipment failure Allowable Range 1 to 80 seconds Factory Default Setting 3 seconds Set Point 9 Diagnostic Fault Mask This parameter is used to define a fault mask that will disable individual diagnostic faults associated
47. scharge resistor during starting When this frequency indicates that the motor has achieved the desired subsynchronous speed at which it is allowable to synchronize the SyncPro energizes the coil of the field contactor The SyncPro ensures that the application of the field contactor coincides with the rising edge of the induced voltage waveform which makes for a smooth transition If the motor pulls into synchronism due to reluctance torque the SyncPro will detect no pulses and then will apply DC voltage to the field after a one second delay Allowable Range 2to 10 slip at which synchronization will occur as a percentage of synchronous speed Factory Default Setting 5 95 speed Typically set at 596 Set Point 2 Power Factor Trip As discussed earlier power factor can be used to determine if a motor has pulled out of synchronism due to loss of excitation overloading or a severe undervoltage At this time the motor should be taken off line to protect the stator and field windings Allowable Range 60 to 100 of unity Factory Default Setting 80 0 8 lagging power factor Set Point Power Factor Trip Time Delay Once it is determined that the motor has a lagging power factor due to a pullout condition the trip condition can be time delayed to allow the motor a brief opportunity to pull back into synchronism Allowable Range Oto 100s 0 01 second units Factory Default Setting 50s 0 50 second delay Programming 5
48. sioning Setup cont 1901 UM020C EN P June 2013 Rr1 amp Rr2 Resistor Setup cont Table 4 A Feedback Resistor Values Synchronous Field Feedback Board RF1 RF2 Useable Voltage Range Resistance K ohm Lower Limit Upper Limit 25 60 160 5 120 320 75 170 480 10 230 640 125 290 800 15 350 950 17 5 400 1100 20 460 1300 Note Resistance value is per resistor two required NOTE Motor induced currents will cause a voltage to be produced across the synchronous motor starter field discharge resistor This voltage is connected to the feedback resistors and the tap to be selected on these resistors is dependent on this voltage level For example if the discharge resistor value is 20 ohms and the induced currents are 30 amperes at 0 speed and 18 amperes at 95 percent speed then the induced voltage seen by the feedback resistors will range from 600 volts 0 speed to 360 volts 95 speed The selection would then be 10 kilohms on each of the 2 resistors In the event that the induced voltage proves to be higher than allowed by the chart it will be necessary to tap the field discharge resistor at a point which will allow the value to fall within the chart Refer to Rockwell Automation for assistance Setup and Commissioning 4 7 Commissioning Complete and verify that the setup procedures pages 4 1 to 4 6 have been completed This should include verifying that the parameters progr
49. starter ground bus It is important that a proper ground is made as the SyncPro has a number of low voltage signals which if not properly grounded may be vulnerable to noise causing erratic operation NOTE For grounding requirements of the DTAM refer to Publication 1747 NC013 1901 UM020C EN P June 2013 3 4 Installation Wiring Guidelines 1901 UM020C EN P June 2013 The SyncPro can accept either two or three wire control The control chosen will determine the configuration of the control hardware Consider the following two inputs and single output when selecting the type of control 4 00 NOT STOP input e 4 01 START input O 3 06 RUN output If using two wire control the two inputs 1 4 00 and 1 4 01 are tied together They are both low in order to stop the SyncPro refer to the summary on page 3 6 and both high in order to run the device To start the device after a fault the START input 1 4 01 must be taken low and then closed again In this configuration the RUN output acts as a run command Refer to Figure 3 4 If using three wire control the NOT STOP input must be maintained high in order to run the device Momentarily opening this input will cause the SyncPro to stop refer to the summary on page 3 6 Momentarily closing the START input will start the SyncPro given that all permissives are satisfied In this configuration the RUN output acts as a start command Refer to Figure 3 5
50. tailed information on the procedure This setup procedure has been performed in the factory but in case of difficulty the following procedure may be used Ensure the jumper in the back of the DTAM is connected between pins 1 and 2 to enable the MODIFY mode e Apply power to the SyncPro controller e press the 7 and INC keys simultaneously until the Modify Setup Screen is obtained e Press ENTER for Confirmation e Press ENTER for English e Press the INC or DEC keys to show the number 2 press ENTER for DTAM address e Press the INC or DEC keys to show 19200 press ENTER for the Baud Rate e Press the INC key to show ON press ENTER for auto attach e Press the INC key to show ON press ENTER for Backlighting e Press the INC key to show ON press ENTER for Monitor Override Press ENTER to accept the setup 1901 UM020C EN P June 2013 4 2 Setup and Commissioning Setup cont 1901 UM020C EN P June 2013 Programmer Display DTAM cont The DTAM will now re attach to the SyncPro 5 03 The F 1 and F 2 Macros must now be programmed into the DTAM Perform the following key sequences e Shift N 2 3 Shift O ENTER Value of N23 0 is shown Shift FO FO 1 ENTER Macro 1 Defined Shift N 2 3 Shift l ENTER Value of N23 1 is shown Shift FO FO 2 JENTER Macro 2 Defined Once the above instructions are compl
51. th the three phase stator resembling the primary and the field winding acting like a secondary Through this transformer action an induced voltage is generated in the motor field during starting The induced signal can be used to protect the squirrel cage winding by monitoring the motor speed during acceleration and to determine when the DC field can be excited for synchronization At zero speed the frequency induced into the field is 60 Hz at 95 speed the frequency induced is 3 Hz for a 60 Hz system Once at 95 speed the DC field is supplied with either 125 V DC or 250 V DC and the discharge resistor is removed from the circuit The excitation in the field windings creates north and south poles in the rotor which lock into the rotating magnetic field of the stator The slip rings are used to connect the field windings to the discharge resistor and static exciter It is at these slip rings that the field resistance of the motor can be measured to confirm the required field voltage and current at rated power factor If for example the field voltage is 125 V DC and the current is 20 amps DC then the resistance measured should be about 6 ohms based on Ohms Law Product Description 1 3 Protection Features Theory of Operation When the NOT STOP and START signals go high a timer is started refer to Figure 7 1 The START signal must be dropped before another start can be initiated The timer is preset based on the slip frequency of the
52. the SyncPro and one may be needed as a hold in contact for the main control circuit Motor Contactor Pilot Relay CR1 or MR This interposing relay allows the SyncPro output to pick up the main contactor coil The power requirements of the pick up coils used in most medium voltage motor starters would exceed the switching capability of the 1746 OX8 output contact 1901 UM020C EN P June 2013 1 6 Product Description Typical Synchronous Starter Components cont 1901 UM020C EN P June 2013 Field Voltage Relay FVR When energized this DC relay indicates that the DC exciter supply is healthy and producing an adequate level of DC excitation The field voltage relay is required to prevent starting the motor unless DC excitation is available A field voltage relay is recommended as the SyncPro does not have the ability to determine the level of the exciter output voltage It is needed to prevent unnecessary starts when synchronization cannot occur Equipment Shutdown Relay ESR Component included with SyncPro The ESR relay combines the status of customer supplied protective and interlock devices to a single contact input on the SyncPro When ESR is energized it is an indication that all external trip and interlock contacts to the SyncPro are in a not tripped condition All external trips and interlocks must be wired in series with the ESR coil in order to be properly addressed by the SyncPro Phase Angle Transducer Co
53. tput After a fault has occurred this input must be taken low before another start command will be recognized RUN OUTPUT 0 3 06 This output is used to control motor starting It is the START input conditioned by all permissives That is to say that this output will follow the state of the input as long as all permissives are met Thus in two wire control this output is actually a RUN command and will stay high until either a fault occurs or a stop is issued In three wire control the output is maintained only as long as the input is maintained a fault occurs or a stop is issued EQUIPMENT SHUTDOWN RELAY ESR INPUT 1 4 07 This fault input is used to group all external faults It notifies the SyncPro that the system has stopped for an external reason The SyncPro will send a message indicating the reason for the stoppage In the normal state this signal is held high going low on a fault condition While this signal is low a start signal will not be accepted Typically all emergency stops or external faults i e overloads motor protection relays will be wired to an ESR relay This relay is then fed into the SyncPro for logging and control and also tied into the hardware to stop the motor TRIP O 3 01 This output is high during normal conditions When the SyncPro detects a fault the output goes low and the SyncPro stops the motor The trip output is typically wired into the ESR circuit It will be set high when there are no f
54. wapped at the transducer 1901 UM020C EN P June 2013 7 4 Troubleshooting 1901 UM020C EN P June 2013 Chapter 8 Spare Parts SyncPro Spare Parts Table 8A Spare Parts List 1746 1A16 1746 ITB16 1746 NIOAI 1746 OX8 1746 P1 1746 F1 Replacement Fuse for 1746 P1 1747 1532 1747 Lithium Battery Assembly 1747 DTAM E 1747 10 1747 20 800T PB16R 800T N65 Trip Reset 800T N40 700 F220A1 X 251089 80165 778 51 R Analog DigitalBoard 80025 817 01 R 7000 20071 7000 20072 80190 020 01 R 80190 020 02 R Phase Angle Transducer Board 1901 UM020C EN P June 2013 8 2 Spare Parts 1901 UM020C EN P June 2013 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www
55. which are jumpered to terminal blocks if not used Contact rating is 60 amp Make 10 amp Break inductive 10 amp continuous at 120V AC A600 Refer to instruction manual for tap selection guidelines on RF1 and RF2 resistors Analog card switch settings are swt a ON 21 Customer to take ground wire to ground bus earth ground Ground at bottom left hand mounting screw for rack or grounding bar Line 1 to Line 2 voltage reference and Line 3 current reference must be maintained for proper operation of the phase angle transducer Wiring supplied on enclosed assembly only 1901 AADC10 for the open frame units The customer must supply these wires in addition to mounting the illuminated push button DTAM STAM cable 1747 C10 and illuminated push button are supplied loose on open frame assemblies 1901 ANDC10 Output rating is 30 amp Make 3 amp Break inductive 3 amp continuous at 120V Figure 4 2 Typical Schematic Sheet 1 of 3 1901 UM020C EN P June 2013 4 10 Setup and Commissionin ANALOG DIGITAL BOARD RF1 20 kOHM TRIP RESET 12 T 20 olo 1 26 1901 UM020C EN P June 2013 DOOR EQUIPMENT REAR VIEW ON ENCLOSED UNITS DTAM 1474 DTAM E SLOT 1 24 VDC Input 17464816 SLOTO 5 03 CPU Remove Jumper If present GROUND BAR
56. ximum programmed percentage of synchronous speed The time curve between stalled frequency and 50 speed is assumed to be linear The time between 50 speed and the synchronizing speed is to the nth order such that unity makes it linear 2 5 makes it exponential in nature The higher the order the shorter the times near to 5096 speed and the higher the times near the synchronous speed set point i e bottom of curve time vs frequency is flatter and then rises more steeply NOTE If the time set point at the maximum programmed percentage of synchronous speed is set below that of the extended stall i e 50 speed curve the function between 50 speed and synchronous speed will also be treated as linear For example the slope between 50 speed and synchronizing speed is flatter than the slope between stalled and 5046 speed 1901 UM020C EN P June 2013 1 4 Product Description Protection Features cont Display Metering Features 1901 UM020C EN P June 2013 When the maximum programmed percentage of synchronous speed set point is obtained the field coil is energized on the falling pulse of the negative square wave i e a rising sinusoid from the slip frequency generator fixed time period after synchronization the autoload signal is raised The field coil is energized only if the TRANSITION COMPLETE has been received Squirrel Cage Winding Protection Protects the squirrel cage winding from long acceleration and sta

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