ABB RSYC-01, User Manual

Page 1: ... OPTIONS FOR ABB DRIVES RSYC 01 synchronizing unit for ACS580 and ACS880 drives User s manual ...

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Page 3: ...ing unit for ACS580 and ACS880 drives User s manual Table of contents 1 Safety instructions 4 Mechanical installation 5 Electrical installation 6 Start up 3AFE68827370 Rev C EN Original instructions EFFECTIVE 2021 03 17 ...

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Page 5: ...Layout 4 Mechanical installation 15 Contents of this chapter 15 Examining the delivery 16 Installing the unit 5 Electrical installation 17 Contents of this chapter 17 Warnings 17 Required components 17 Switch over contactors K1 and K2 18 Control relay K4 18 Contactor K7 18 Other components 18 Wiring requirements 19 Connection diagrams 19 ACS580 drives with CCU control unit 20 ACS880 drives with BC...

Page 6: ... resetting the synchronization circuit 25 Parameter settings 7 Fault tracing 29 Contents of this chapter 29 Fault tracing 30 Measuring with an oscilloscope 8 Technical data 33 Contents of this chapter 33 Technical data 9 Dimension drawings 35 Contents of this chapter 36 Cover 37 Enclosure body Further information 6 Table of contents ...

Page 7: ...o the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity whi...

Page 8: ...nce work Go through these steps before you begin any installation or maintenance work 1 Clearly identify the work location and equipment 2 Disconnect all possible voltage sources Make sure that re connection is not possible Lock out and tag out Open the main disconnecting device of the drive Open the charging switch if present Open the disconnector of the supply transformer The main disconnecting ...

Page 9: ...at the voltage between the drive input power terminals L1 L2 L3 and the grounding PE busbar is zero Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is zero Make sure that the voltage between the drive DC terminals UDC and UDC and the grounding PE terminal is zero In cabinet built drives measure between the drive DC busbars and and the ground...

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Page 11: ... using and troubleshooting the synchronization circuit with the RSYC 01 synchronizing unit You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Terms and abbreviations Description Term Industrial assistant non Bluetooth control panel ACS AP I Standard assistant control panel ACS AP S Industrial assistant control panel with Bluetooth...

Page 12: ...al 3AUA0000143261 ACS880 07 drives 560 to 2800 kW hardware manual Drive firmware manuals 3AXD50000016097 ACS580 standard control program firmware manual 3AXD50000048035 ACS580 drives with standard control program quick start up guide 3AUA0000085967 ACS880 primary control program firmware manual 3AUA0000098062 ACS880 drives with primary control program quick start up guide Drive option manuals and ...

Page 13: ...y the RSYC 01 unit bypasses the drive and connects the motor directly to the supply line Operation principle The RSYC 01 unit uses switch over contactors to control the connections between the motor the drive and the supply line It monitors two voltage signals one measured from the supply line and other from the drive output The signals indicate the phase shift and frequency The unit output signal...

Page 14: ...ol circuit the drive control logic stops the inverter modulation the contactor control circuit opens contactor K1 which disconnects the motor from drive the contactor control circuit closes contactor K2 which connects the motor to the supply line Layout RSYC 01 SYNCHRONIZING UNIT J3 SYNC 1 INVRTR 2 INVRTR 3 MAINS 4 MAINS COM 2 SYNC 1 BUF OUT 3 24V 1 COM 2 J2 J1 68829895 3 2 1 A 4 2 1 3 4 B RSYC 01...

Page 15: ...that the package contains these items RSYC 01 unit 2 synchronizing transformers 8 m 26 ft of cable this manual Make sure that there are no signs of damage to the items Note The package does not contain all the necessary items for installing and commissioning the unit You must get some components separately Refer to the electrical installation instructions in this manual 4 Mechanical installation 1...

Page 16: ...Installing the unit Install the unit to a 7 5 35 mm top hat type rail Push the feet onto the rail as shown in the illustration 1 2 16 Mechanical installation ...

Page 17: ...ents You must get these components separately switch over contactors K1 and K2 relays and contactors of the control circuit K1 K7 cables and fuses between transformer T1 and main circuit cables and fuses between transformer T2 and main circuit Switch over contactors K1 and K2 Select the drive switch over contactor K1 according to the drive specifications The contactor must be suitable for use with...

Page 18: ...s much distance as possible Use shielded twisted pair cables between the transformers and the synchronizing unit Ground the shields at the cable clamps with as short pigtails as possible Cut and insulate all unused conductors at both ends of the cables Use shielded twisted pair cables between the synchronizing unit and the drive Ground the shields at the drive module end according to the instructi...

Page 19: ... 1 2 SYNC COM BUF OUT 24 V COM J1 J2 RSYC 01 K1 U2 V2 W2 K6 L10 K2 K4 Run enable K3 K3 K3 K4 K2 K2 K3 K3 K2 K1 S1 K5 K6 K1 K5 230 V DC 1 0 N 3 4 3 4 K7 K7 Switch over contactors K1 K2 Control relays K3 K5 Bypass contactor K6 Contactor K7 Synchronizing transformers T1 T2 Example circuit recommended Optional connection when using line chokes Electrical installation 19 11 ...

Page 20: ... COM BUF OUT 24 V COM J1 J2 RSYC 01 K1 U2 V2 W2 K6 L10 K2 K4 Run enable K3 3 4 K3 K3 K4 K2 K2 K3 K3 K2 K1 S1 K5 K6 K1 K5 230 V DC 1 0 N 3 4 K7 K7 5 Switch over contactors K1 K2 Control relays K3 K5 Bypass contactor K6 Contactor K7 Synchronizing transformers T1 T2 Example circuit recommended Optional connection when using line chokes 20 Electrical installation ...

Page 21: ...OM BUF OUT 24 V COM J1 J2 RSYC 01 K1 U2 V2 W2 K6 L10 K2 K4 Run enable K3 3 4 K3 K3 K4 K2 K2 K3 K3 K2 K1 S1 K5 K6 K1 K5 230 V DC 1 0 N 3 4 K7 K7 5 Switch over contactors K1 K2 Control relays K3 K5 Bypass contactor K6 Contactor K7 Synchronizing transformers T1 T2 Example circuit recommended Optional connection when using line chokes Electrical installation 21 11 ...

Page 22: ... X3 18 24VD 24VD 24V Power supply for RSYC 01 XD24 2 XD24 5 X2 10 DICOM DICOM DCOM XD24 3 XD24 6 X2 12 RSYC 01 terminals Description Name Terminal Power supply connection 24 V 1 J1 COM 2 Output 0 24 V control pulse for external contactor control circuitry SYNC 1 J2 COM 2 Output 0 10 V signals indicating the synchronization status for the drive COM BUF OUT 3 Motor voltage measurement INVRTR 1 J3 2 ...

Page 23: ...mission a drive with the synchronizing unit Start up the system Action Make sure that the drive is disconnected from the supply line and that all other precautions given in the safety instructions are taken into consideration Make sure that the electrical installation of the drive the synchronizing unit and the synchronization circuit is completed Disconnect the contactor control circuit cable fro...

Page 24: ... 62 65 Hz Make sure that the status signal is 0 2 V DC Stop the drive Check the trim function and synchronization This check makes sure that the trim function affects the speed control of the drive in the correct way Finding the correct value for trim range adjustment parameter 40 55 Set 1 trim adjust is necessary for stable control and fast synchronization The system then reaches synchronization ...

Page 25: ...onds and stays synchronized for dozens of seconds Disabling or resetting the synchronization circuit The information in this section is applicable when the contactor control circuit is implemented as shown in this manual To disable the synchronization circuit 1 Change the external control location in the drive application program from EXT2 to EXT1 parameter 19 11 Ex1 Ext2 selection or switch the d...

Page 26: ...nt speed selections Refer to Connection dia grams page 19 20 12 Run enable 1 source DI5 20 12 Run enable 1 source DI6 Select the source of the run enable signal Maximum speed must be higher than motor nominal speed 30 11 Minimum speed 0 rpm 30 12 Maximum speed 2000 rpm Define the minimum and maximum allowed motor speed The drive will stop modulating immediately after Run enable is switched off 21 ...

Page 27: ...fined in parameter 30 12 Maximum speed 40 51 Set 1 trim mode Direct Activate the trim function and define trimming relat ive to maximum speed Trim reference is equal to actual signal when the synchronization conditions are valid that is when AI1 ACS880 AI2 ACS580 5 V 40 21 Set 1 internal setpoint 1 50 00 Set trim reference to 50 The trim function uses Process PID as input 40 56 Set 1 trim source P...

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Page 29: ...ductors can cause electro magnetic interference EMI To re duce EMI you can install an additional metal shield between the source of the interfer ence and the unit increase the distance between the source of the interference and the unit Examine and correct the connec tions Signals from synchronizing trans formers are cross connected at the unit BUF OUT signal from the RSYC 01 unit is constantly lo...

Page 30: ... current is needed to re magnetize the motor Examine and correct the transformer connection Supply line motor and drive output are 180 out of phase due to wrong connection of the synchronization transformer Examine and correct the connec tions Supply line and drive output are 180 out of phase because the phasing between motor and supply line is different from the phasing between motor and drive ou...

Page 31: ...Refer to the illustration below for the locations 1 2 TP3 and TPVREF 1 TP4 and TPVREF 2 When the signals are synchronized the waveforms are as follows Fault tracing 31 ...

Page 32: ...When there is a phase difference the waveforms are as follows When the waveforms match the unit gives a SYNC signal 32 Fault tracing ...

Page 33: ... cable Draka JAMAK 2 2 1 0 5 mm2 or equivalent Signal cable1 21 21º Synchronization accuracy Maximum cross section 4 mm2 12 AWG Transformer cable2 7 5 35 mm EN 50022 Mounting rail 1 Connection between the RSYC 01 unit and the drive transformers and control relays 2 Connection between the synchronizing transformers and main circuit at drive output and input Synchronizing transformers ABB 690 43 3 V...

Page 34: ...Synchronizing transformers Dyn 11 Winding connection Static screen Winding separation 34 Technical data ...

Page 35: ...Dimension drawings Contents of this chapter This chapter shows dimensions of the RSYC 01 unit 9 Dimension drawings 35 ...

Page 36: ...Cover 79 166 4 2 80 4 x 238 94 31 7 50 56 112 7 9 Dimensions in mm 1 mm 0 0394 in 36 Dimension drawings ...

Page 37: ...feedhole M4x0 7 6H 4 x 92 16 11 11 4 x x 4 M4 16 for pressed screw 16 2 2 50 x 5 feedhole M3x0 5 6H 1 4 M4x0 7 6H feedhole 6 x 3 30 41 12 236 0 50 12 5 drawing pin 0 5 outwards Dimensions in mm 1 mm 0 0394 in Dimension drawings 37 ...

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Page 40: ...www abb com drives 3AFE68827370C Copyright 2021 ABB All rights reserved Specifications subject to change without notice 3AFE68827370 Rev C EN EFFECTIVE 2021 03 17 ...