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, equipment, 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.
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.
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
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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.
and Operation Manual
1746-NM003Analog Card publication
1900-2.10Measuring for Synchronous Motor Data
900-1.0Synchronous Motor Control
SGI-1.1Safety Guidelines for the Application,
Installation and Maintenance
1746-2.35Discrete Input and Output Modules
1746-2.36SLC500 Modular Chassis and Power Supplies.
1901-UM020C-EN-P – June 2013
1-2Product Description
Synchronous Motor TheoryThe 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 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 squirrelcage 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 95%).
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 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.
1901-UM020C-EN-P – June 2013
Protection FeaturesTheory 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 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 the DTAM. 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.
Product Description1-3
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 are:
• maximum allowable starting times at the stalled condition
• 50% speed
• maximum 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 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).
1901-UM020C-EN-P – June 2013
1-4Product Description
Protection Features (cont.)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 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.
Display/Metering FeaturesThe 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 of the slope of the
acceleration/stall time trip curve).
– incomplete sequence timer trip delay
– fault mask for PF transducer diagnostics
1901-UM020C-EN-P – June 2013
(Refer to Chapter 5 for complete details.)
Product Description1-5
HardwareThe system consists of the following hardware:
Typical Synchronous Starter
Components
•SyncPro5/03 Processor
:
•1747-L532EEPROM
•1746-ITB16High Speed DC Input Module
•1746-NIO4IAnalog Input/Output Module
•1746-0X8Isolated Relay Output (or any 8-point output)
•1746-IA16120VAC Input Module (or any 16-point input)
: 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
connectedto, 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 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
1-6Product Description
Typical Synchronous StarterField Voltage Relay (FVR)
Components (cont.)
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 (Component included with SyncPro)
The phase angle transducer provides a conditioned 4- to 20milliamp 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.
1901-UM020C-EN-P – June 2013
Product Description1-7
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. 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 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. 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
1-8Product Description
Input/Output DescriptiveControl
Listing
NOT STOP (I: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 output. After a fault has
occurred, this input must be taken low before another start
command will be recognized.
RUN OUTPUT(O: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 (I: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 faults and the FAULT RESET
PB is momentarily raised high.
1901-UM020C-EN-P – June 2013
Product Description1-9
Field Application
TRANSITION COMPLETE CONTACT (I: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 (O: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 (I: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 CONTACTOR FEEDBACK CONTACT (I: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 (I: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.
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 (I: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 FACTOR (I: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 (I: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 (-) (I:1/00)
Connect to the negative terminal (N) of the Slip Pulse Generator.
SLIP GENERATOR POSITIVE (+) (I:1/02)
Connect to the positive terminal (P) of the Slip Pulse Generator.
1901-UM020C-EN-P – June 2013
Product Description1-11
Status
AUTO LOAD (O: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 (O: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 (O: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 optional trip output.
INCOMPLETE SEQUENCE TRIP (O: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.
SpecificationsGeneral Specifications
Operating Power
Input Line Voltage – 120 Volts AC 50/60 Hz
Input Current – 0-5 Amps.
Accuracy:3% span
Housing:Flame retardant plastic case
Weight:2.4 kg maximum
Climate
Storage:-20 to 70
Temp. range:-20 to 70
Operational @ 0 to 60
Calibrated @ 23
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:2kV RMS to BS 5458
Impulse Test:5kV transient as BEAMA 219 & BS923
Surge Withstand:ANSI C37-90A
Certification:CSA Approved
°C (-4 to 158°F)
°C (-4 to 158°F) storage
°C (32 to 140°F)
°C (73°F)
1901-UM020C-EN-P – June 2013
DTAM Specifications
Refer to Publication 1747-NC013, Appendix A-1, A-2.
SLC500 Specifications
Refer to Publication 1747-NI002, SHT 1-4
Power Supply Specifications
Refer to Publication 1747-NI002, SHT 1-7
Chapter 2
Receiving and Storage
ReceivingUpon 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.
StorageIt 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°C (-4°F and 158°F).
• Relative humidity must not exceed 95%, non-condensing.
1901-UM020C-EN-P – June 2013
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