SYNCPRO II - Rockwell Automation
Contents
1. 15 SUI i tos ae POSE ee E E ee eee 16 CIO ben utr cep EM aaa 16 Spec Neato ne 17 E 17 For Phase Angle Transducer 17 PVC CA00 Specificatii nS v bete secede sabes 17 1500 Specifications aei d do ys 18 Chapter 2 RECEIVING saliente 21 OCRA TA 21 Chapter 3 Aa SINGH o bere 23 Component Level 23 Open Frame Configuration svo res ii 24 tru ees 25 Wiring Guidelines hd in iaia 26 tech bahar tanec 32 Rockwell Automation Publication 1902 IN001B EN E April 2013 3 Table of Contents Setup and Commissioning Programming SyncPro Il Monitoring Chapter 4 33 RE LGC REZ Resistor Setup 33 Procedure for Selection of Resistors 0c cece cece sence eese 35 ISI Go INE serus eR ide ads 35 RT SCCUINGS ras ea resi 35 COMMISSIONING 60 edn sav peas 36 Chapter 5 er et eee ee 39 Mai Ment Vie cus 40 SyHc Pro IL SUU2. 50 E ae nse roe gaat ti ecole op Paare EA aru 51 o Ice 51 Chapter 6 Phasc Anel Power Factor Lc diano dmi 53 bien S INSULE 54 Fault Detection and 54 Power Factor Circuit ducks ou Gare V ERIS te ERAS 54 Rockwell Automation Publication 1902 IN001B EN E April 2013 Table of Contents Chapter 7 Troubleshooting Ease hol able T 55 Chapter 8 Spare Parts SynePro TIS pate rota 57 Rockwell Automation Publication 1902 IN001B EN E April 2013 5 Table of Contents Notes 6 Rockwell Automation Publication 1902 IN001B EN E April 2013 Chapter 1 Product Description Introduction The SyncPro II consists of a programmable small logic controller MicroLogix 1500 with the following additional peripheral items PanelView Component Terminal C400 Power Factor Transducer Analog Digital Pulse Board Conditioning Resistors Interposing Relays FSR and ESR The SyncPro II system is designed to provide supervisory protection and field control to a brush type synchronous motor controller proper field application timing squirrel cage 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 protectio
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4. ec 22 lt HOLIMS C 1915 S YIGINNS ATENASSY YII110IY S3SNI ONILINIT eH V1HS 11084 iH VIAL YAWYOASNVUL 331 1934 29 Rockwell Automation Publication 1902 IN001B EN E April 2013 Figure 8 Typical Wiring Installation Chapter 3 SIHL NMOHS LON ONIZIS 303 9NIMVSO NOISNANIO OL 43333 S320 18 IVNINHIL AHL Ad CIYNDIANO CINNVYOOYd 38 OL OVAITTALNI lt 0 co TIN FLO LO lt e N 79078 HINOLSNO SALON YOLSIYVA 3GIXO WLAN HINOLSNI 391430 GALNNOW 3009 SOVLIOA LNAWdINDA 31038 9NILO3NNOO HIdNNr INONIY LNAWdINODA FLONIU NOILVHIdO TVINHON OLNI MOVE YILYYLS ONILLAd 330338 CINONIY 33V SYIAINN AUNSNA N338 3AVH SLOWLNOS OUdONAS ASIHL dl ATNO IAOW LS3L NI 93194340 38 9 TOULNOO 5 JHL LAdLNO 1109 FINGOW IVAITTILN FINGOW OVAITISLNI YOLOVINOO NIVIN LAdNI HOLIOVdVS TVNYILXI FINCON OVAITTALN LAdLNO 109 9 8019 FINCON OVAITIALN 301994405 31000 9VAITT3IN dA LYVLS 380338 HINOLSNI 445 SALVLS INGON 33VS
5. Allowable Range 1 80 seconds Factory Default Setting 3 seconds Set Point 8 Power Factor Trip Allowable Range 60 100 of unity Factory Default Setting 80 0 8 lagging power factor Rockwell Automation Publication 1902 IN001B EN E April 2013 47 Chapter 5 48 Programming SyncPro Il Set Point 9 Power Factor Trip Time Delay Allowable Range 0 100 s 0 01 second units Factory Default Setting 50 s 0 5 second delay Set Point 10 Diagnostic Fault Mask The Fault Mask value can be calculated by selecting either a Fault Mask groups or individual faults When switching between mask groups it is recommended that the fault code be cleared reset by selecting Enable All Faults Figure 22 Diagnostic Fault Mask Enable All Faults Mask Commissioning Faults Mask All PF Faults Mask PFT Circuit Faults Either group or individual mask can be used at one time The resultant fault mask code will be function of the 16 bit fault mask word use 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 at Syncpro II and No Signal at Syncpro II the mask value would be 528 16 512 Refer to Table 4 on page 49 for additional information Figure 23 Mask Individual Faults Mask Individual Faults PET Normu J NO PET CT OpeniShort EB PFT CT Reversed Rockwell Automation Publication 1902 IN001B
6. April 2013 23 Chapter3 Installation Open Frame Configuration The SyncPro II components are mounted on a panel except the PanelView display module and the illuminated push button for trip indication and reset function See Figure 2 for mounting dimensions of the main unit panel Quick installation within the main controller is possible with this arrangement IMPORTANT The PanelView is supplied with a two meter cord for connection with the SyncPro Il processor Mount the PanelView in a suitable location to make this connection Figure 2 Mounting Dimensions E 18 02 458 lt 16 75 425 gt A A eee AES FS HF Ft HHOH HHY 20 00 18 95 508 1481 13 29 338 Y Y Y 0 63 a9 13 75 349 gt ee 9 dia i 4 Mounting Holes Front View idee 24 Rockwell Automation Publication 1902 IN001B EN E April 2013 Conditioning Resistors RF1 and RF2 Analog Digital Pulse Converter Board Terminal Blocks Phase Angle Transducer Grounding Figure 3 Component Layout i nn EHI A 2 Integral to a completed low voltage or medium voltage controller Installation Chapter 3 Bul 1606 DC Powe
7. Chapter3 Installation Summary 32 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 II Once the ESR has dropped out a start will not be permitted until the fault 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 II such as a power factor trip 1 The RUN output will follow the state of the START input given there are no faults detected by the SyncPro II 2 Once a fault is 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 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 Rockwell Automation Publication 1902 IN001B EN E April
8. The phase angle transducer board provides a 4 20mA output proportional to 90 90 The SyncPro II utilizes this input to calculated Power Factor PF Cos 0 To provide an accurate measurement the voltage and current inputs must be in the proper relationship V and Figure 30 Voltage and Current Inputs Relationship Va lt 0000000000000 Q cecccccccccco Vb Rockwell Automation Publication 1902 IN001B EN E April 2013 53 Chapter 6 Faults 54 Monitoring 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 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 tansducer Lack of the EQUIPMENT SHUTDOWN external fault signal d Loss of Setpoint Data 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 shorted CT input loss of control power to transducer or a faulted transducer A
9. fault protection etc which are still necessary for the bump See Figure 8 for the jumper placement and the points at which to disconnect the wires Pb volts are present at the and Rf2 resistors To avoid shock hazard do ATTENTION During synchronization voltages that may exceed 1000 not touch the resistors 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 Ifthe RF1 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 e The time to accelerate to rated subsynchronous speed e The point at which the I O point 0 0 2 picks up which normally would energize the field contactor occurs to see if it appears to be occurring at 95 speed e Monitor Power Factor during acceleration It should be lagging e 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 swi
10. 203 D e Za Ic riu _ E ci ex st z 1015 ILVI 69LL LANI 0051 xiBo1o oIN CISN LON LAdNI 116 9 LHS WO 901 LON oavuoe v YAONASNVEL Vd 31 ONIMVG SIHL NO NMOHS LON ONIZIS ININOdINO9 303 ONIMYYO NOISN3MIG OL 333 SALON 391440 GALNNOW 3009 39YL10A QN3911 LAAN 2 109 9 INV 2 o 0 o di SONANDAS 3131dWOONI di l vl INOTINA YOLON E NOLLO3IONd UI IA YOLON 399 TIYUINOS 0 ES 9110 v1no ueosw NO AVOTOLNY E JOMINOO AVOTOLNY En LULA 2 2100 9 4 OL 91 3 3N 1 LHS OL En 100 v1 3 3NI1 1HS OL 75 3 INIT LHS OL gt QUI IA 0100 818 4 3NI1 LHS OL 816 4 OL E ES m OM vH SISSVHO OL 9 os a 29 40 41 69 ES 31010001 LNdNI DOWNY eee 0091 XiBo 10J91IN LHS A Rockwell Automation Publication 1902 IN001B EN E April 2013 OLNI 6NI 8NI c WOO od LNI NI HI d WOO od 901 0 EN L IHSOL N ZNI c 166 INIT 0 NOI LHS WOU od WOO AvC M3INT3NVd 3sVa 1015 30 3903 HdT 94 In 0091 x 6010J01
11. EN E April 2013 Programming SyncProll Chapter 5 Figure 24 Individual Faults Mask Individual Faults PFT No Signal PLC NO PFT Abnormal Operation NO F3 PLC Reversed PF Figure 25 Individual Faults cont d Mask Individual Faults 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 i e The value of 272 16 256 corresponds to 1 Table 4 Fault Mask Word Mask Fault Mask Word 16bit Mask Description Code 151413 mm 11019 18 17 16 15 43 21110 jo fe fo fo te fo felt te fo fo Enable ll Faults 2000 00900 3 D 0000 Mask All PF Faults 1984 o Jo fo fo Mask PFT Circuit Faults s o o fo o o o rein 128 o fo fo o o jo fo PFT CT Open Short 256 o o o t o o jo o jo fo PFT CT Reversed 512 o Jo o o 0 No Signal 1024 o o o Jo o o fo PFT Abnormal Operation 2 8 ntm Rockwell Automation Publication 1902 IN001B EN E April 2013 49 Chapter5 Programming SyncPro Alarm Histo ry The Alarm Banner screen will appear if any alarm condition exists in the system The screen provides three user options e Clear Alarm e Acknowledge Alarm e Acknowledge All Alarms The clea
12. PLC Reversed Mask Fauls PF Trip NO 100 Rockwell Automation Publication 1902 IN001B EN E April 2013 39 Chapter5 Programming SyncPro Main Menu SyncPro Il Status 40 The main menu provides access to the following screens SyncPro Il Status Provides idle starting running status information View Set Points Allows viewing of SyncPro Il operation and protection set points Edit Set Points Allows viewing of SyncPro Il operation and protection set points Alarm History Lists alarm fault history recorded with relative time stamping Access Code Allows users to log in or log out to provide access control to operation and protection set points Settings Allow editing of general HMI configuration such as language relative time date stamp These screens are displayed when the motor is idle starting or running The PVc C400 automatically switches to one of the following screens after a period of inactivity Figure 13 Ready Mode Mode Ready 02 11 13 14 10 43 Ready mode Figure 13 indicates the SyncPro II has not detected any software or hardware faults and is ready to start Figure 14 Starting Mode Mode Starting Slip Frequency o0Hz Power Factor lt 0 Time Remaining Exit 02 11 13 14 12 28 02 11 13 14 12 28 14 12 28 During the Starting mode Figure 14 the motor slip frequency in Hz power factor in 96 and time to a squirrel cage protection in seconds are
13. SALVLS YOLOVINOO 193333 NI 38V SILVIS dN HYIMOd NOILYHNOIANOO CITIVISNI SHL 31 YIMOd LAOHLIM NMOHS SLOVLNOS AVTIY SILON OVATTTSINI aN3941 4628 GLYSdW AOW 021 099 XNV 9 LHS I OHdONAS OL ere ore zre one dr XW AUVITIXNV 60 ere aF USI Av 134 NMOGLNHS LNAWdINOA ezr 612 353 AV 138 HOLIMS 01315 ce ere zoe ze ne ab IN HO LOV LNOO NIV Il OHdONAS OL na woa NOH sere L 1HS OL gt 3 ATANISSV 431511934 65 asg 20121 IlOHdONAS o o 13S3W dlWl 83 L3S3Y dIUL I OMdONAS d O D 330 lt pe O Di 1 Le A 0 i OUdONAS INANIYOLIVINO 2 86 00 0 0 4 5 Le 1ndlno diL IVISONZIHL grey 3391 11934 8548 QuvO8 HOLIMS 01414 S388nNS 4828 Sd Il OHdONAS 104110 884 OHdONAS 84 HeH ASI INIOd AlddNS 1531 F1HS 7 1HS Rockwell Automation Publication 1902 IN001B EN E April 2013 30 Chapter 3 Installation Figure 9 Typical Wiring D Lc 9 LHS X9vaq33a3 YOLOVLNOO NIV 3137dIN09 NOLLISNVHL ION Sz 9 LAdNI 14 e IHS WON 13939 WOO
14. an external reason The SyncPro II 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 II for logging and control and also tied into the hardware to stop the motor TRIP OUTPUT 0 0 0 This output is high during normal conditions When the SyncPro II detects a fault the output goes low and the SyncPro II stops the motor The trip output is typically wired into the ESR circuit It will be set high when there are no faults and the FAULT RESET PB is momentarily raised high Field Application TRANSITION COMPLETE CONTACT INPUT 1 2 6 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 II 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 OUTPUT 0 0 2 This out
15. displayed The power factor value is accompanied by either a or gt symbol to indicate lagging or leading power factor Typical power factor readings during staring are lagging If leading power factor is displayed please confirm voltage and current input connections for proper sequencing e g Vap I Rockwell Automation Publication 1902 IN001B EN E April 2013 View Set Points Programming SyncPro Il Chapter 5 Figure 15 Running Mode Mode Running Slip Frequency 2 lt 0 02 11 13 14 13 30 In the Running mode the slip frequency and power factory is displayed During Power Factor normal operation the slip frequency is 0 Hz and power factor is approximately 100 for unity Figure 16 Minimum Slip Frequency Min Slip Frequency 8 Operating Frequency 60Hz Set Point 1 Minimum Percent Synchronous Slip Frequency This set point determines the percentage of synchronous speed at which the DC voltage is to be applied by the field switch contactor The SyncPro II monitors the frequency of the induced voltage across the discharge resistor during starting When this frequency indicates that the motor has achieved the desired sub synchronous speed at which it is allowable to synchronize the SyncPro energizes the coil of the field switch contactor The SyncPro ensures that the application of the field contactor coincides with the rising edge of the induced voltage wavefor
16. 00 15 490 950 17 5 560 1100 20 640 1300 1 Resistance value is per resistor two required 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 and the induced currents are 30 A at 0 speed and 18 A at 95 speed then the induced voltage seen by the feedback resistors will range from 600V 0 speed to 360V 95 speed The selection would then be 10 on each of the two 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 Contact Rockwell Automation for assistance at 1 519 740 4790 1 Complete and verify that the setup procedures see page 33 have been completed This should include verifying that the parameters programmed into the SyncPro are appropriate for the motor See Chapter 5 for further details on programming 2 Verify that the SyncPro II has been wired into the motor starter circuit as indicated by the wiring diagram 3 Remove the wire from the Field Contactor Relay FCR coil either at the I O point 0 0 2 or at the FCR coil itself Tie back and insulate the wire so that it cannot accidentally short o
17. 2 IN001B EN E April 2013 Typical Synchronous Starter Components Product Description Chapter 1 Motor Contactor M The following details outline some of the common components that which the SyncPro II can be connected to or are part of the SyncPro II protection package The motor contactor is used to provide and switch the power supplied to the motor stator It is controlled by the SyncPro II 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 the SyncPro II 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 II 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 1764 24BWA output contact 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 II does not have the ability to determine the level of the exciter output voltage It is needed to prevent unnecessary starts when synchronization canno
18. 2013 Setup Chapter 4 Setup and Commissioning Check the following components of the SyncPro once it has been installed Rr1 amp Rr2 Resistor Setup The synchronous motor field discharge resistor feedback resistors RF1 RF2 are necessary to attenuate the induced voltage waveform which appears across the field discharge resistor during starting Figure 11 The resistors RF1 RF2 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 Table 1 on page 36 The resistance value shown is the amount of resistance which is required on each lead which is connected to the A D pulse board F1 F2 For example if the induced voltage on the discharge resistor is 1000V at zero speed and 600V at 9596 speed across the entire discharge resistor then it is necessary to select taps on the RF1 and RF2 to provide 20 kQ at RF1 and 20 kQ at RF2 Figure 10 Discharge Resistor Installation These settings must be made prior to any start attempt Rockwell Automation Publication 1902 IN001B EN E April 2013 33 Chapter4 Setup and Commissioning Determining the induced voltage which will appear across the discharge resistor during starting can be done two ways 1 If motor data is available the voltage can be determined by multiplying the discharge resistance by the induced currents at z
19. D card failed the RF RF2 selection is incorrect or ifthe connection is not made from the A D board to the SyncPro Review the RF1 RF2 setup parameter and verify the procedure performed see Commissioning item 4 on page 4 7 The main contactor coil has failed Replace the coil The connection of the M auxiliary contact has not been made Check the wiring The contact has failed Replace Ensure the connector is matched properly Replace the 1 0 board Check the fuse Turn the key switch to the RUN mode position The phase angle transducer as wired from the factory is set up for the customer to run his wiring with and 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 56 Rockwell Automation Publication 1902 IN001B EN E April 2013 SyncPro Il Spare Parts List Chapter 8 Spare Parts Table 6 Spare Parts List Part Number 800H PRTH1GR 800T N65 800T N318R 700 CF220D X 251089 80165 778 51 R 80025 817 01 R 700DC P20071 7000 20072 80190 020 01 80190 020 02 2711 1761 CBL PM02 1606 XLP50E 1769 IF4X0F2 1764 24BWA 1764 LRP 17694116 1 Analog Digital Board 20 tapped Power Resistor 20 tapped Field Voltage
20. Installation Instructions Allen Bradley SYNCPRO II Publication 1902 INO01B EN E Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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 equipment or software described in this manual
21. Operation Fault 16 Mask PLC Reversed Power Factor Fault Figure 18 Minimum Slip Frequency Set Point 1 Minimum Synchronous Slip Frequency Allowable Range 2 10 slip at which synchronization will occur as a percentage of synchronous speed Factory Default setting 5 95 speed Typically set at 5 Rockwell Automation Publication 1902 IN001B EN E April 2013 45 Chapter5 Programming SyncPro Set Point 2 Operating Frequency Allowable Range 50 or 60 Hz Factor Default 60 Hz Figure 19 Function Number Set Point 3 Function Number Allowable Range 1 5 Factory Default Setting 3 Function curve 3 In the example below the 50 speed has been set to 5 seconds and the 95 speed is set to 20 seconds for a 60 Hz system Figure 20 Trip Time DAH mz Rockwell Automation Publication 1902 IN001B EN E April 2013 Programming SyncPro Il Chapter 5 Set Point 4 Squirrel Cage Protection Trip Time at 95 speed Allowable Range 5 80 seconds Factory Default Setting 5 s 5 seconds Set Point 5 Squirrel Cage Protection Trip Time at 50 speed Allowable Range 2 s to Value in Set Point 4 Factory Default Setting 2 s 2 seconds Set Point 6 Squirrel Cage Protection Trip Time at stall Allowable Range 1 s to Value in Set Point 5 Factory Default Setting 1 s 1 second Figure 21 Incomplete Sequence Trip Time Set Point 7 Incomplete Sequence Trip Time Delay
22. Relay 125 V DC exciter 1 Field Voltage Relay 250 V DC exciter 1 FVR Phase Angle Transducer Board 120V 240 V PanelView Component C400 Terminal 1 RS 232 DF1 cable 1 DC Power Supply Analog 1 0 Module MicroLogix 1500 Base Unit MicroLogix 1500 Processor unprogrammed Digital Input Module Rockwell Automation Publication 1902 IN001B EN E April 2013 57 Chapter8 Spare Parts Notes 58 Rockwell Automation Publication 1902 IN001B EN E April 2013 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you e
23. 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 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 ARC FLASH 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 Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockw
24. S usa baeo rens aiia tete paw tenes 40 View siii sato fac eu lve be oL eI de E RE ES 4 Set Point 1 Minimum Percent Synchronous Slip Frequency 41 Set Point 2 Operating 42 Set Point 3 Function Number usse eee 42 Set Point 4 Squirrel Cage Protection Trip Time at 95 43 Set Point 5 Squirrel Cage Protection Trip Time at 50 speed 43 Set Point 6 Squirrel Cage Protection Trip Time at stall 43 Set Point 7 Incomplete Sequence Trip Time Delay 44 Set Point 9 Power Factor 44 Set Point 9 Power Factor Trip Time Delay 44 Set Point 10 Diagnostic Fault eee ee eee ee 45 Edit Se CPO natalie iii 45 Set Point 1 Minimum 96 Synchronous Slip Frequency 45 Set Point 2 Operating oiov ets e 46 Set Point 3 Function Number suse 46 Set Point 4 Squirrel Cage Protection Trip Time at 95 47 Set Point 5 Squirrel Cage Protection Trip Time at 50 47 Set Point 6 Squirrel Cage Protection Trip Time at stall 47 Set Point 7 Incomplete Sequence Trip Time Delay 47 Set Point 8 Power Factor 47 Set Point 9 Power Factor Trip Time Delay 48 Set Point 10 Diagnostic Fault Mask iier Ets 48 VULT Entro M PP
25. Timing Relay Trips the system if the overall starting time is exceeded Pull Out Protection Monitors the lagging 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 Il is not supplied as a configured unit within an Allen Bradley motor controller Optional Equipment e Field Current Failure Relay e Load and Unload Auxiliary Contacts The outputs are energized 2 sec after the field is applied and is maintained until the field is removed Display Metering Features The product in conjunction with the PanelView 300e Micro Terminal PV 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 for the following maximum 96 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 at 95 speed function order allows adjustment 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 10 Rockwell Automation Publication 190
26. XI AYN ANY ONILUVIS ONIN LN3S33d SAOVLIOA 01315 J9YL10A V YSONVG V 3513 AYYNIYd SISNA YIMOd ONILINIT INIHUNO quo en At zH GEOVA HOLIMS 9NILV T1OSI VOOTHILNI HOOG Rockwell Automation Publication 1902 IN001B EN E April 2013 28 01 0 VLHS OL Chapter 3 cal XV INFYYNI 01915 954 Installation Y3LINNY 2 CAI 062 Si CE Ls HOLIMS 30193135 15 INIYYNI 91514 ayog YOLVINDIY ese ONIUIT YIS 3SVHd 1915 00170393 Figure 7 Typical Wiring 55 1HS IVLSOWYSHL XNIS LV3H 0 HOLIMS YOLSISSY JDYVHOSIG V1HS OL Sud 901 VOL 9 MOWLS 9331 14934 SISNA AHV INOO3S ANTIVA WAWIXVW IHL OL dA LNAYYND YOLOW SHL 18 OL GASN SI CAILNNON Y000 SONILLIS INIHYNO 91314 SALON 301430 CILNNON YOOd 9 MOT JAIM FUNLIVHAdNIL 5 OV NOCE EX CX 104100 YALIOXA ANS 303 OW A091 1 HAdINNF LNdLNO HALIOXA 2 9 E GNSOS1 15 1 1 INIT HV LSOWYSHL E LHS gt des aasn LON e lt
27. all 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 SF 1 Rockwell Automation Publication 1902 IN001B EN E April 2013 43 Chapter 5 44 Programming SyncPro Il IMPORTANT _ Thesquirrel cage winding of a synchronous 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 Set Point 7 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 Incomplete Sequence Timing Relay 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 min
28. all encompassing fault and could include anything from the CT the transducer board or the PLC analog card 55 Chapter7 Troubleshooting Table 5 Troubleshooting Guide Continued Problem or Trip Indicated Pulse Board 24 V Failure PULSE BOARD 24 VDC FAILURE Field Voltage Loss FIELD VOLTAGE LOSS Field Current Loss FIELD CURRENT LOSS No Field Coil Feedback NO FIELD COIL FEEDBACK Reversed PF SyncPro II REVERSED PF AT PLC External Hardware Fault EXTERNAL HARDWARE FAULT Pulse Board Positive and Negative Pulse Missing PULSE BOARD POSITIVE MISSING PULSE BOARD NEGATIVE MISSING Contactor Feedback Lost NO MOTOR CONTACTOR FEEDBACK Halt Synch Relay Indication of the following conditions Connection has not been made between the analog digital pulse board and the SyncPro Il DC input card or from the discharge resistor to the same A D pulse board 24VDC power supply has had a failure The static exciter is not actively producing DC or the FVR relay coil has failed Wrong polarity on FVR coil Incorrect voltage rating of FVR coil Exciter Enable EE relay did not pick up The current relay which monitors the motor field current is not providing an energized contact to verify that the Static is functional The SyncPro II has requested the field contactor to energize but the feedback contact from this contactor is not showing as closed The connections from the PF transdu
29. 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 it 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 9596 These field windings are connected through slip rings to a discharge resistor during start up The resistor is 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 with 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 s
30. cer to the analog card have been accidentally reversed An external device to the SyncPro Il is not functioning as expected The SyncPro Il 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 The SyncPro Il monitors the status of the synchronous motor stator contactor while running The male female connector of the vacuum contactor is not matched properly The PLC 1 0 card slot 2 input 8 is faulty The program remote run switch on the PLC processor may be in program mode Possible Solutions Check the connections at the A D pulse board Check fuse in power supply Check for 24 V at power supply Replace power supply if necessary Replace A D pulse board Service the static exciter or repair the FVR relay AC Voltage to the bridge absent 10 VDC on Op Amp Board Absent Check polarity on FVR coil Check voltage rating of FVR coil Verify the control circuit Check both the field current relay and the static exciter for possible failures 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 Switch the positive and negative transducer output leads at the analog card Check external devices Pulse train would be lost if either the A
31. d 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 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 RUN START output signal of the same duration as the input signal as long as there are no faults detected by the SyncPro II Figure 5 Three wire Control START PB CE STOP PB 2 0 NOT STOP ESR or CR E STOP 27 EQUIP SHUTDOWN Rockwell Automation Publication 1902 IN001B EN E April 2013 27 Installation Chapter 3 Figure 6 Typical Wiring A 1VNOLLdO _ CON XHOML3N 13N39IA30 OL LHS NO NMOHS XVIN 11009 OF JINON GLY 92871089 M CBS 0951 LON iIIa BEN DIN 3 359513 n 23 aa 9 ey 4 34vsiiv4 EEN RE 1HS OL FINS OL TINS OL Ni 01 11 1HS OL 1HS OL 1541 YVA VOL aum ii SAYTAY NOIL93LOHd HO ONV 32018 S391430 ONIMALSW TIM TVNINYIL 39018 IVNINYIL ONILHOHS 40 SN He Uol lo ONILYOHS ww ld YYY Y 2 202 4 0 2 Z LHS OL 862 C1HS m N ATAWASSY 431 1153 WOU
32. d see Figure 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 II to stop see Summary on page 32 Momentarily closing the START input will start the SyncPro II given that all permissives are satisfied In this configuration the RUN output acts as a start command see Figure 5 Figure 4 Two wire Control RUN CFF 3 1 2 1 START 4 5 O 0 0 1 RUN O ESR CR CR E STOP 8 9 10 Cl L 0 0 0 TRIP O 1 2 7 9 SHUTDOWN 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 II Figure 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 Rockwell Automation Publication 1902 IN001B EN E April 2013 Installation Chapter 3 The ESR circuit ensures the motor is stopped for any fault condition occurring either externally or when detected by the SyncPro II Once the ESR has dropped out detected by the loss of I 2 7 the selector switch must be switched off an
33. diagram Rockwell Automation Publication 1902 IN001B EN E April 2013 Chapter 5 Programming SyncPro II Overview The SyncPro II programming is performed via the PV300 display unit provided The SyncPro II menu structure has been designed to optimize workflow Please refer to Menu Map below Figure 12 Programming Menu Map SyncPro I Alarm History gt Access Code CLEAR ALARM r rocx PLANAS Settings Copyright 19962013 Rockwell Automation Mode Ready 4 Configuration 3190 Operating Frequency Exit 02113 141043 Next Next Mode Starting d 2 e Time Remaning 0 2 HI amp xt amna tarza Eaj Back Nex ex sv Mode Running Ine Sequence Trip Time 4 inc sequence Trip Tima A Cm Slip Frequency SOHz Trip Level 50 PF Trip Level 83 Power Factor lt 0 5 PE Trip Delay 014 Fa PE Trin Delay 016 Mask Code 200 Bra ta corro SEE back DONE Enatie Fautts Mask Commissioning Faults DE Mook PF Faula PFT Circuit Faults Exit Next Mask Individual Faults ZI PPT input IC CT OpenShat NO PFT Revorned Bac Next 1 Mask individual Fauits PFT No Signal NO E
34. ell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Product Description Receiving and Storage Installation Table of Contents Chapter 1 bd Sata tita mie y Related Documentation LL 7 Synchronous Motor Ehcor EE SERES 8 0 9 Theor ides ad 9 Opona l tee pU PUT EPOR UE Edad 10 Display Metering coreani dose dicen 10 Typical Synchronous Starter Components 11 Motor Contactor MD suere redo e ah dee boa 11 Motor Contactor Pilot Relay CRI or MR 11 Field Voltage Relay SP eai E 11 Equipment Shutdown Relay ESR Included with SyncPro II 11 Phase Angle Transducer Included with SyncPro 11 ischarse esl at Nero a 12 Field Contactor DG Ub PSP 12 Resistots REL ANG RE ouv costae duns tet E coat ata 12 Puialos Wicital Pulse Board zoe create ton 13 Input Output Descriptive 0 2 cece eee eee eens 13 ru PUT 13 Field Application ER 14 127 1010 Gina sais 15 Faule Detection
35. ero and 95 speed as given g y g by the motor manufacturer EXAMPLE Induced current 0 speed 20 A Induced current 9596 speed 12 A Discharge resistance 50 Therefore Induced voltage 0 speed 20A x 50 1000V Induced voltage 95 speed 12A x 50 Q 600V 2 A measurement can be taken using a storage oscilloscope or a strip chart recorder see 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 2V2 or 2 828 When doing this a portion of the discharge resistor only should be used 1 Q can then be used to determine the value which will be on the entire resistor EXAMPLE strip chart recording is taken across a 1 portion of a 50 O discharge resistor The following peak to peak values are obtained 0 speed 56V p p 9596 speed 34V p p Therefore 0 speed rms voltage across 1 Q 56 2 828 20V rms 95 speed rms voltage across 1 Q 34 2 828 12V rms 0 speed rms current across 1 Q 20V 1Q 20 rms 95 speed rms current across 12V 10 12 rms Once the induced voltage has been determined make the appropriate selection from Table 1 on page 36 Wires from each end of the discharge resistor should then be determined to the appropriate taps on the RF1 and RF2 resistors Both the 0 and 9596 speed induced voltages must fall between the upper and lower limits de
36. fined on the chart 34 Rockwell Automation Publication 1902 IN001B EN E April 2013 Setup and Commissioning Chapter 4 Procedure for Selection of Dischargeresistance Resisto rs RSD Sample resistance Vpp0 0 speed peak to peak voltage V Vpeak 0 Vpp95 95 speed peak to peak voltage V Vpeak 95 Vrms 0 Induced voltage 0 speed V Vrms 0 Vp0 2 828 Vrms 95 Induced voltage 95 speed V Vrms 95 Vp95 2 828 lo Induced current 0 speed A Arms 0 Vrms0 Rs 195 Induced current 95 speed A Arms 95 Vrms95 Rs V0 Induced voltage 0 speed VIO x Rd V95 Induced voltage 9596 speed V195 x Rd 0 speed induced voltage across the entire discharge resistor 50 Q 20 A 1000V 95 speed induced voltage across the entire discharge resistor 50 Q 12 A 600V RF1 RF2 Resistance Required amp RF2 Resistor RF Resistor tap settings Figure 11 Discharge Resistor Setup QU PAK SYNCHRONOUS MOTOR Pd in Em 29 fe FC R R 5 DISCHARGE RESISTOR p 100 103 ASK ANALOG DIGITAL PULSE CONVERTER CT FC FC Le 4149 To MicroLogix Slot 1 To MicroLogix 24V DC Power Supply Rockwell Automation Publication 1902 IN001B EN E April 2013 35 Chapter4 Setup and Commissioning Commissioning 36 Table 1 Feedback Resistor Values Synchronous Field Feedback Board Usable Voltage Range RF1 RF2 Resistance KO 7 5 230 480 10 320 640 12 5 400 8
37. he Slip Pulse Generator Status AUTO LOAD OUTPUT 0 0 3 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 OUTPUT 0 0 8 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 OUTPUT 0 0 9 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 optional trip output INCOMPLETE SEQUENCE TRIP OUTPUT 0 0 10 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 Custom I 2 10 to I 2 15 are custom fault inputs If any are true they trip the unit off Rockwell Automation Publication 1902 IN001B EN E April 2013 Temperature and Humidity Temperature Maximum Ambient Humidity For Phase Angle Transducer Product Description Chapter 1 Specifications General Operating Power Input Line Voltage 120V AC 50 60 Hz Input Cur
38. he 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 RF1 and RF2 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 is too low too much resistance then pulses will not be produced If too little resistance is used the voltage may be too high which could damage the analog digital pulse board see Figure 10 on page 33 Rockwell Automation Publication 1902 IN001B EN E April 2013 Input Output Descriptive Control Product Description Chapter 1 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 II 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 Listing NOT STOP INPUT I 2 0 This signal must be maintained high for the SyncPro II to operate When the signal is taken low the softwa
39. ignal 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 based on Ohms Law Rockwell Automation Publication 1902 IN001B EN E April 2013 Protection Theory Product Description Chapter 1 Theory of Operation When the NOT STOP and START signals go high an internal timer is started see Figure 4 and Figure 5 The START signal must be dropped before another start can be initiated The timer is preset based on the slip frequency of the motor If the timer expires prior to achieving the maximum asynchronous speed the starting sequence will halt the TRIP output w
40. ill be dropped and the PanelView 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 the FIELD RELAY is energized The power factor is now monitored and displayed on the PanelView If the power factor drops below the programmed values the TRIP and FIELD RELAY outputs will be dropped and the PanelView 300 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 representing 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 for squirrel cage protection trip time are e Set Point 4 at synchronizing 95 e Set Point 5 at 50 speed e Set Point 6 at stalled The time curve between stalled frequency and 50 speed is assumed to be linear The time between 50 speed a
41. imizes motor heating during an equipment failure SP fier Set Point 8 Power Factor Trip As discussed earlier power factor can be sued 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 SP PF trip Set Point 9 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 5 pr _ Delay Rockwell Automation Publication 1902 IN001B EN E April 2013 Edit Set Points Programming SyncPro Il Chapter 5 Set Point 10 Diagnostic Fault Mask This parameter screens are used to define a fault mask code that will disable individual diagnostic faults The value is based on the 16 bit Fault Mask Word Please refer to Edit Set Points section for additional information Table 3 Mask Description Code Mask Description 0 Enable All Faults 272 Mask Commissioning Faults 2000 Mask All Power Factor Faults 1984 Mask Power Factor Transducer Circuit Faults 64 Mask Power Factor Transducer No Input Fault 128 Mask Power Factor Transducer CT Open Shorted Fault 256 Mask Power Factor Transducer CT Input Reversed Fault 512 Mask Power Factor Transducer No Signal at PLC Fault 1024 Mask Power Factor Transducer Abnormal
42. ipping 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 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 he 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 II synchronous motor protector see 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 t
43. 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 2 4 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 FACTOR INPUT I 1 0 The signal supplied to the SyncPro II is from the Phase Angle Transducer representing a power factor of zero 0 lagging to zero 0 leading respectively Note that the SyncPro II firmware has been tailored to this specific transducer No substitution is allowed Rockwell Automation Publication 1902 IN001B EN E April 2013 15 Chapter 1 16 Product Description SLIP GENERATOR POWER INPUT 1 0 1 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 INPUT I 0 0 Connect to the negative terminal N of the Slip Pulse Generator SLIP GENERATOR POSITIVE INPUT 1 0 2 Connect to the positive terminal P of t
44. m which makes for a smooth transition If the motor pulls into synchronism due to reluctance torque the SyncPro II will detect no pulses and then will apply DC voltage to the field after a one second delay SP Gem _ slip Rockwell Automation Publication 1902 IN001B EN E April 2013 41 Chapter 5 42 Programming SyncPro Il Set Point 2 Operating Frequency This set point determines the operating system frequency This allows the SyncPro II to properly determine the appropriate minimum percent slip frequency SP Jose g Figure 17 Function Number Function Number SCP Trip Time ASYNC 6s SCP Trip Time 50 4s SCP Trip Time Stall Set Point 3 Function Number The function number entry determines the slope of the curve between the 50 speed trip time and the 95 speed trip time set point 4 and 5 Although the trip time is set as 50 and 95 speed the intermediate points between these values can be shaped to cause the trips for 51 and 94 to occur more or less quickly depending on which function number is selected According to Figure 17 more time is allowed when function 1 is selected and less time is allowed when function 5 is selected SP F f t t SP f EN EE ET SP tlf fiy lt f lt f Mf sp6 sp2 Json i 2 Low k 2 5277 fY _ bo Mf B k t t k Rockwell Automation Publication 1902 IN001B EN E A
45. n incomplete start sequence timer setpoint 7 is utilized to abort the starting if abnormal long 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 PanelView 300 and can be reset via the RESET push button Rockwell Automation Publication 1902 IN001B EN E April 2013 Last Trip Table Troubleshooting Chapter To aid in troubleshooting the unit stores the last 50 recorded faults These can be accessed by viewing the contents of the alarm history Table 5 Troubleshooting Guide Problem or Trip Indicated Pullout trip power factor PULL OUT TRIP POWER FACTOR Squirrel cage Protection Trip SQUIRREL CAGE PROTECTION TRIP Incomplete Start Sequence Time Exceeded INCOMPLETE START SEQUENCE TRIP No Transducer Input POWER FACTOR XDCR NO INPUTS CT Open Shorted POWER FACTOR XDCR CT OPEN SHORT CT Reversed POWER FACTOR XDCR CT REVERSED No Signal SLC POWER FACTOR XDCR NO SIGNAL AT PLC Transducer Problem POWER FACTOR XDCR CIRCUIT FAULT Indication of the following conditions Motor
46. n integral component of a brush type synchronous starter special receiving and handling instructions will apply For details refer to the service manual provided with the equipment Storage It is important to consider the following storage requirements if you are not installing your controller immediately after receiving it e Store the controller in a clean dry dust free environment e Storage temperature must be maintained between 20 65 C 4 149 F e Relative humidity must not exceed 95 non condensing Rockwell Automation Publication 1902 IN001B EN E April 2013 21 Chapter2 Receiving and Storage Notes 22 Rockwell Automation Publication 1902 IN001B EN E April 2013 Arrangements Analog Digital Pulse Converter Resistor RF 1 Resistor RF2 Chapter 3 Installation The SyncPro IIis offered in three arrangements Component Level The SyncPro II may be ordered as individual components for maximum flexibility when installing the 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 II processor has adequate ventilation provided around it Refer to Figure 6 for typical wiring of the components Figure 1 SyncPro Il Component Configuration Controls amp Indicators OO OO Phase Angle Transducer PanelView C400 Rockwell Automation Publication 1902 IN001B EN E
47. n relay the SyncPro II provides the necessary overload protection to the brush type synchronous motor IMPORTANT Although the SyncPro Il makes use of some standard MicroLogix 1500 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 PLC control cards can be added nor should the firmware program be modified Related Documentation The following publications contain information for components associated with the SyncPro II Publication 2711C IN001 EN P PanelView Component Terminal Installation Instructions Publication 1900 2 10 Measuring for Synchronous Motor Data Publication 900 1 0 Synchronous Motor Control Publication SGI 1 1 Safety Guidelines for Application Installation and Maintenance Publication 1764 UM001 EN P MicroLogix 1500 Programmable Controller Rockwell Automation Publication 1902 IN001B EN E April 2013 Chapter1 Product Description Synchronous Motor Theory The synchronous motor is a commonly used industrial motor favored for its higher 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
48. nd 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 50 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 50 speed Rockwell Automation Publication 1902 IN001B EN E April 2013 9 Chapter1 Product Description 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 A 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 stall 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
49. onnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem 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 Publication 1902 IN001B EN E April 2013 Supercedes Publication 1902 IN001A EN E March 2009 Copyright O 2013 Rockwell Automation Inc All rights reserved Printed in Canada
50. overloaded Loss of DC excitation Static exciter DC current level set too low Motor overloaded at start Motor overloaded at start Field contactor or FC pilot relay coil failure The transducer is putting out less than 12 mA when the motor is off should be 12 mA The CT is either open or shorted The CT is incorrectly wired to the transducer board There is no signal at the PLC analog card from the PF transducer board The transducer is behaving unpredictably Rockwell Automation Publication 1902 IN001B EN E April 2013 Possible Solutions e lessen the motor loading and or overload e Repair static exciter e Increase current setting on static exciter if lagging e Decrease current setting on static exciter if leading e Mask leading power factor trip if application motor is designed for it Remove or lessen load for start Remove or lessen load for start e Replace coil s e Check the wiring for the voltage sensing on the transducer board e Replace phase angle transducer board if necessary e Replace analog card in SyncPro Il chassis e Check the wiring between the CT and the transducer board e Replace the CT if necessary Reverse the leads of the CT at the transducer board e Check the wiring between the transducer board and the PLC analog card e Ensure that there is power to the transducer board e Replace the PLC analog card or transducer board as required e This is an
51. pril 2013 Programming SyncPro Il Chapter 5 Table 2 Function Numbers Variable Function Number Squirrel Cage Protection Trip Time at 95 speed tops Squirrel Cage Protection Trip Time at 50 speed Squirrel Cage Protection Trip Time at stall f Detected slip frequency fsp1 Minimum Percent Synchronous Slip Frequency 50 Squirrel Cage Protection Frequency Operating Frequency Set Point 4 Squirrel Cage Protection Trip 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 SP Cond 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 SP 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 st
52. put 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 Rockwell Automation Publication 1902 IN001B EN E April 2013 Product Description Chapter 1 Feedback MOTOR CONTACTOR FEEDBACK CONTACT INPUT 1 2 8 This input indicates to the SyncPro II 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 CONTACTOR FEEDBACK CONTACT INPUT I 2 5 This input indicates to the SyncPro II 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 II detects a fault in the field circuit TRIP RESET PB INPUT I 2 2 This input from the push button on the panel will reset any fault condition in the SyncPro II Once no fault exists the fault condition will be removed from the PanelView and the TRIP output will be set Fault Detection FIELD VOLTAGE RELAY INPUT I 2 3 When the signal is low
53. r Alarm option will remove the currently displayed fault and not record the fault in the Alarm History The Acknowledge Alarm option will remove the currently displayed fault and record the fault in the Alarm History with the relative time stamp After a single alarm has been acknowledged the next unacknowledged on if any will appear on the screen If none unacknowledged alarms are left and all faults have been cleared the Main Menu Screen will be displayed The Acknowledge All Alarm option will remove the currently displayed fault along with all additional faults in the fault stack buffer and record all the fault s in the Alarm History with the relative time stamp Figure 26 Acknowledge All Alarm Screen F1 CLEAR ALARM F2 ACKNOWLEDGE ALARM ACKNOWLEDGE ALL ALARMS The Alarm History Screen displays all the acknowledged alarms with date and time Using the arrow keys you can scroll through up to 50 previous alarm conditions The Alarm History may be cleared with the Clear key Figure 27 Alarm History Occurre Occurren ne ce Date Alarm Message 50 Rockwell Automation Publication 1902 IN001B EN E April 2013 Access Code Settings Programming SyncPro Il Chapter 5 The Access Code Screen allows authorized users to log in to secured screens and modify their own password To log in press the F1 key and enter your user ID and password using the alphanumeric keypad that opens during a login request Login i
54. r Supply FSR ESR Relays SyncPro II The SyncPro is also available as a component of a Rockwell Automation Allen Bradley synchronous motor controller incorporating the components shown in Figure 3 Although the layout in the starter is different control and functionality remain the same The grounding required by the SyncPro II 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 starter ground bus It is important that a proper ground is made as the SyncPro II has a number of low voltage signals which if not properly grounded may be vulnerable to noise causing erratic operation Rockwell Automation Publication 1902 IN001B EN E April 2013 25 Chapter3 Installation Wiring Guidelines 26 The SyncPro II 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 I 2 0 NOT STOP input I 2 1 START input 0 0 1 RUN output If using two wire control the two inputs 1 2 0 and I 2 1 are tied together They are both low in order to stop the SyncPro II see Summary on page 32 and both high in order to run the device To start the device after a fault the START input I 2 1 must be taken low and then closed again In this configuration the RUN output acts as a run comman
55. re identifies this as a normal stop for the motor IMPORTANT The SyncPro Il 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 2 1 The rising edge of this signal starts the operation of the SyncPro II 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 output After a fault has occurred this input must be taken low before another start command will be recognized see Figure 4 and Figure 5 RUN OUTPUT 0 0 1 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 Rockwell Automation Publication 1902 IN001B EN E April 2013 13 Chapter 1 14 Product Description EQUIPMENT SHUTDOWN RELAY ESR INPUT 1 277 This fault input is used to group all external faults It notifies the SyncPro II that the system has stopped for
56. rent 0 5 A Operating 0 40 C 32 104 Storage 20 65 C 4 149 F 5 95 non condensing Maximum temperature 40 C 104 F General Accuracy 3 span Housing Flame retardant plastic case Weight 2 4 kg maximum Climate Storage 20 70 C 4 158 F Temperature range Operational at 0 60 C 32 140 F Calibrated at 23 C 73 F Humidity Up to 95 relative humidity non condensing Input Frequency 50 60 Hz Current 0 2 10 A Range A 20 120 Burden 5 VA maximum Voltage 115 230V 10 Range V 20 20 120 with separate auxiliary Burden 1 VA maximum Overload Capacity Six times rated current for 30 s 1 25 rated voltage for 10 s Electrical Tests Dielectric Test 2 kV RMS per BS 5458 Impulse Test 5 kV transient as BEAMA 219 and BS 923 Surge Withstand ANSI C37 90A Certification CSA Approved See Publication 2711C IN001_ EN P pages 30 31 PVc C400 Specifications MicroLogix 1500 See Publication 1764 UM001_ EN P Appendix A Specifications Rockwell Automation Publication 1902 IN001B EN E April 2013 17 Chapter1 Product Description Notes 18 Rockwell Automation Publication 1902 IN001B EN E April 2013 Chapter 2 Receiving and Storage Receiving 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 IMPORTANT Ifthe SyncPro Il is a
57. s successful if the Logged in as indicator displays the correct username To change your password press F3 and enter the current and new password to make the change If both passwords match then it successfully changes Press F2 key to log out in the end of the session The Logged in as indicator username will disappear Figure 28 Log In Log Out Logged in as Change Password 02 11 13 14 17 02 Prior to programming the unit a user must log in with full access writes The default administrator admin Access Code is 12345 It is recommended this be changed during product commissioning The Settings Screen provides access to PVc C400 built in HMI configuration screen and offers capability to set up SyncPro II relative time stamp Please not that the time stamp is reset when power is removed Figure 29 Settings 02 11 13 14 16 09 Rockwell Automation Publication 1902 IN001B EN E April 2013 51 Chapter5 Programming SyncPro Notes 52 Rockwell Automation Publication 1902 IN001B EN E April 2013 Phase Angle Power Factor Chapter 6 Monitoring A key protection component of the SyncPro is to monitor Power Factor Monitoring Power Factor is one of the most reliable methods to determine if a motor is running properly The SyncPro II system utilizes a Phase Angle Transducer which provided a proportional signal to the measured phase angle angle difference between motor voltage and current
58. t occur Equipment Shutdown Relay ESR Included with SyncPro 1 The ESR relay combines the status of customer supplied protective and interlock devices to a single contact input on the SyncPro II When ESR is energized it is an indication that all external trip and interlock contacts to the SyncPro II 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 II Phase Angle Transducer Included with SyncPro ll The phase angle transducer provides a conditioned 4 20 mA signal to the analog module of the SyncPro II 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 Rockwell Automation Publication 1902 IN001B EN E April 2013 11 Chapter 1 Product Description The SyncPro II 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 sl
59. tching the C3A and C3B connections should correct the situation 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 current transformer connections Rockwell Automation Publication 1902 IN001B EN E April 2013 37 Chapter 4 38 Setup and Commissioning 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 ATTENTION To avoid damage to the motor do not allow the motor to run 6 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 7 The motor can now be normally started Once the motor has synchronized a good check is to vary 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 Verify that the MicroLogix is getting all the inputs according to the circuit
60. ut 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 Rockwell Automation Publication 1902 IN001B EN E April 2013 Setup and Commissioning Chapter 4 4 If during the previous setup procedure for the discharge resistors and 2 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 publication 1900 2 10 for determining the motor data by measurement using a strip chart recorder should be done at this time The and 2 resistors should then be set up as shown in Figure 11 with the data obtained It is necessary to use jumpers at the SyncPro II trip output and the run output for the motor bump ATTENTION During the jogging procedure the SyncPro Il does not protect the motor Monitor the procedure closely to avoid damage to the motor ATTENTION Do not use jumpers at the ESR contact as this will also eliminate any external protective trips such as line overcurrent
61. xperience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation and TechC
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