Rockwell Automation 1902 User Manual

Installation Instructions

SYNCPRO II™

Publication 1902-IN001B-EN-E

Important User Information

IMPORTANT

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 your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/ 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.

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.

available from

) describes some

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).

Identifies information that is critical for successful application and understanding of the product.

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.

Product Description

Chapter 1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Synchronous Motor Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Protection Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Display/Metering Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Synchronous Starter Components . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor Contactor (M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor Contactor Pilot Relay (CR1 or MR) . . . . . . . . . . . . . . . . . . . . 11

Field Voltage Relay (FVR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Equipment Shutdown Relay (ESR) (Included with SyncPro II) . . 11

Phase Angle Transducer (Included with SyncPro II). . . . . . . . . . . . . 11

Discharge Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Field Contactor (FC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Resistors Rf1 and Rf2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Analog/Digital Pulse Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Input/Output Descriptive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Field Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Custom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

For Phase Angle Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PVc C400 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

MicroLogix 1500 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Receiving and Storage

Installation

Chapter 2

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 3

Arrangements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Component Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Open Frame Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 3

Table of Contents

Chapter 4

Setup and Commissioning

Programming SyncPro II

Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

RF1 & RF2 Resistor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Procedure for Selection of Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

RF1 & RF2 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

“RF” Resistor tap settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SyncPro II Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

View Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Set Point 1: Minimum Percent Synchronous Slip Frequency . . . . . 41

Set Point 2: Operating Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Set Point 3: Function Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Set Point 4: Squirrel-Cage Protection Trip Time (at 95% speed). . 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 8: Power Factor Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Set Point 9: Power Factor Trip Time Delay . . . . . . . . . . . . . . . . . . . . . 44

Set Point 10: Diagnostic Fault Mask. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Edit Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Set Point 1: Minimum % Synchronous Slip Frequency. . . . . . . . . . . 45

Set Point 2: Operating Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Set Point 3: Function Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Set Point 4: Squirrel-Cage Protection Trip Time (at 95% speed). . 47

Set Point 5: Squirrel-Cage Protection Trip Time (at 50% speed). . 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 Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Set Point 9: Power Factor Trip Time Delay . . . . . . . . . . . . . . . . . . . . . 48

Set Point 10: Diagnostic Fault Mask. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Chapter 6

Monitoring

4 Rockwell Automation Publication 1902-IN001B-EN-E - April 2013

Phase Angle/Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fault Detection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Power Factor Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Chapter 7

Table of Contents

Troubleshooting

Spare Parts

Last Trip Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Chapter 8

SyncPro II Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Product Description

IMPORTANT

Chapter 1

Introduction

The SyncPro II consists of a programmable small logic controller (MicroLogix™ 1500) with the following additional peripheral items:

• PanelV iew™ 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 protection relay, the SyncPro II provides the necessary overload protection to the brush-type synchronous motor.

Although the SyncPro II 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.

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 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 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 Ω, based on Ohms Law.

8 Rockwell Automation Publication 1902-IN001B-EN-E - April 2013

Product Description Chapter 1

Protection Theory

Theory of Operation

When the NOT STOP and START signals go high, an internal timer is started (see Figure 4 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 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.

and Figure 5). The START signal must be dropped before another

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:

• Set Point 4: at synchronizing = 95%

• Set Point 5: at 50% speed

• Set Point 6: at stalled

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).

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 9

Chapter 1 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.

Display/Metering Features

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 lagging power factor during running to detect a loss of

synchronism

Fiel d Voltage Failure Rel ay Input Monitors the condition of the static exciter output. This relay must be

supplied by the customer if the SyncPro II is not supplied as a configured unit within an Allen-Bradley motor controller.

Optional Equipment

• Field Current Failure Relay

• Load and Unload Auxiliary Contacts – The outputs are energized 2 sec.

after the field is applied and is maintained until the field is removed.

The product in conjunction with the 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 % 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

10 Rockwell Automation Publication 1902-IN001B-EN-E - April 2013

for complete details.

Product Description Chapter 1

Typical Synchronous Starter Components

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 holdin 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 cannot occur.

Equipment Shutdown Relay (ESR) (Included with SyncPro II)

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 II)

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 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 II 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. 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 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 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 (see Figure 10 on page 33

12 Rockwell Automation Publication 1902-IN001B-EN-E - April 2013

Product Description Chapter 1

IMPORTANT

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.

Input/Output Descriptive Control

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 software identifies this as a normal stop for the motor.

The SyncPro II 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

RUN OUTPUT (O:0/1)

and Figure 5).

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.

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Chapter 1 Product Description

EQUIPMENT SHUTDOWN RELAY (ESR) INPUT (I:2/7)

This fault input is used to group all external faults. It notifies the SyncPro II that the system has stopped for 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 (O: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 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.

. The trip output is

Field Application

TRANSITION COMPLETE CONTACT INPUT (I: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 (O:0/2)

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.

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Product Description Chapter 1

Feedback

MOTOR CONTACTOR FEEDBACK CONTACT INPUT (I: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 II 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, 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: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.

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Chapter 1 Product Description

SLIP GENERATOR POWER INPUT (I: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 (+) (I:0/2)

Connect to the positive terminal (P) of the Slip Pulse Generator.

Status

AUTO LOAD OUTPUT (O: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 (O: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 (O: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 (O: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.

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Product Description Chapter 1

Specifications

General

Operating Power

Input Line Voltage 120V AC, 50/60 Hz

Input Current 0...5 A

Temperature and Humidity

Temperature (Maximum Ambient)

Humidity 5...95% (non-condensing)

Operating: 0...40ºC (32...104ºF)

Storage: -20...65ºC (-4...149ºF)

Maximum temperature: 40 ºC (104 ºF)

For Phase Angle Transducer

General

Accuracy 3% span

Housing Flame retardant plastic case

Weight 2.4 kg maximum

Climate

Storage -20...70 ºC (-4...158 ºF)

Temperature range Operational at 0...60 ºC (32...140 ºF)

Calibrated at 23 ºC (73 ºF)

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)

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

Burden 1 VA maximum

PVc C400 Specifications

MicroLogix 1500 Specifications

See Publication 2711C-IN001_-EN-P, pages 30...31.

See Publication 1764-UM001_-EN-P, Appendix A.

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Chapter 1 Product Description

Notes:

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