1902 In001 - en e

Installation Instructions
SYNCPRO II
Publication 1902-IN001B-EN-E
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.
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).
IMPORTANT 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.
Table of Contents
Chapter 1
Product Description 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
Chapter 2
Receiving and Storage Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 3
Installation 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 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
Programming SyncPro II 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 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 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 Phase Angle/Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fault Detection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Power Factor Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Rockwell Automation Publication 1902-IN001B-EN-E - April 2013

Table of Contents
Chapter 7
Troubleshooting Last Trip Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 8
Spare Parts SyncPro II Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Table of Contents
Notes:

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 protection relay, the SyncPro II
provides the necessary overload protection to the brush-type synchronous
motor.
IMPORTANT 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.
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

Chapter 1 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 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 ,
based on Ohms Law.

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 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 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.
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).

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 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 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.
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 % 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.

Typical Synchronous Starter Motor Contactor (M)

Components
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 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.

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).

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 Listing

Control
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.
IMPORTANT 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 and Figure 5).
RUN OUTPUT (O: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.

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. 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 (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.

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.

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.

Specifications General
Operating Power
Input Line Voltage 120V AC, 50/60 Hz
Input Current 0...5 A
Temperature and Humidity
Temperature Operating: 0...40C (32...104F)
(Maximum Ambient)
Storage: -20...65C (-4...149F)
Humidity 5...95% (non-condensing)
Maximum temperature: 40 C (104 F)
For Phase Angle Transducer

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
PVc C400 Specifications See Publication 2711C-IN001_-EN-P, pages 30...31.
MicroLogix 1500 See Publication 1764-UM001_-EN-P, Appendix A.

Specifications

Notes:

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 If the SyncPro II is an 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.
Store the controller in a clean, dry, dust-free environment.
Storage temperature must be maintained between -20...65 C (-4...149 F).
Relative humidity must not exceed 95%, non-condensing.

Chapter 2 Receiving and Storage
Notes:

Chapter 3
Installation
Arrangements The SyncPro II is 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 II Component Configuration

Chapter 3 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 II processor. Mount the PanelView in a suitable location to make this
connection.
Figure 2 - Mounting Dimensions
18.02 [458]
0.38[10] 16.75 [425]
20.00 18.95
[508] [481]
13.29
[338]
5.1
0.63 [16] 13.75[349] 0.36 [9] dia.
[113]
(4) Mounting Holes
Front View
Side View

Installation Chapter 3
Figure 3 - Component Layout

Conditioning Resistors,
RF1 and RF2
Bul. 1606 DC Power Supply
Analog/Digital Pulse
Converter Board
Terminal Blocks
FSR, ESR Relays
Phase Angle Transducer
SyncPro II
Integral to a completed low voltage or medium voltage controller
The SyncPro II 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.
Grounding 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.

Wiring Guidelines 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
O:0/1 RUN output
If using two-wire control, the two inputs (I: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 command (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
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 ).

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 and
on to initiate a start. This prevents a premature start if the fault condition is
cleared and the selector switch is still in the run position.
Figure 5 shows a typical three-wire control circuit. The STOP PB must be

maintained high in order to initiate a start and to run the system. The button also
ensures that the motor is stopped via the hardware circuit. The momentary
START PB is used to create a RUN (START) output signal 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

28
ISOLATING SWITCH
____V AC, 3, __Hz 113
Chapter 3
L1 L2 L3 GRD 304
IS 100:1
DOOR INTERLOCK
GFCT CT1
T1 F1 105
F1 SYNCHRONOUS FROM RECTIFIER ASSEMBLY
MOTOR (+) (+) SHT.2, LINE K-238
CT2 RF
T2
F1
101 ANALOG/DIGITAL
R1 A/DPC PULSE CONVERTER
Installation
CT3 F1 G
T3 F2 RD BLK
F1 N
(-) R
CURRENT LIMITING M R2 P FROM SHT.4
BLK
W
POWER FUSES W LINE H-415
C
42
44
46
47
CURRENT LIMITING F2 V
PRIMARY FUSES F2 __E F2 __E F __E F __E F __E 91
102 FROM SHT.3
90
LINE E-337
____ V ____ V ____ V
H2 RF
PT H1 H3
CPT 3 PHASE
1L1A
1L2A
500 VA
PAT
103
X1 X3 FROM RECTIFIER ASSEMBLY
X2 SHT.2, H-238
120 V 120 V 120 V 104
TO SHT.2
5 (-)
PHASE ANGLE TRANSDUCER

LINE B-202
46A
ISa
VA VB VC
STB CAUTION:
SHORTING USE OF SHORTING TERMINAL BLOCK
TERMINAL WILL OVERRIDE METERING DEVICES
BLOCK AND/OR PROTECTION RELAYS.
BLK
42A
44A
46B
47A
7 6
TO SHT.3
LINE C-301
CM 1 3 5
CONVERTER MODULE
2 4 6
Figure 6 - Typical Wiring A
1.0A
VAA
F5 TO SHT.3 TO SHT.3
VB
LINE C-318 LINE D-330
VCA
F5
BLK
W
1
52
51
12
1.0A
! N
L1
L2
L3
13
23
24
96
95
98
14
T1
S1
S2
A2-
A1+
DANGER TO SHT.3
MORE THAN ONE LINE D-331 PHASE FAILSAFE
LIVE CIRCUIT VOLTAGE
INPUT NON
PTC
Rockwell Automation Publication 1902-IN001B-EN-E - April 2013

INPUT
TO MCM
FAILSAFE
1
POWER
12
CBCT
AUX 1
AUX 2
ALARM
D MIO OPTION CARD TRIP

(THERMISTOR) T2
23
24
25
26
19
20
21
22
MPS BUL. 825P MODULAR PROTECTIVE SYSTEM FRONT PANEL
! DANGER ! DANGER LOCAL PROGRAMMING
+ N 120VAC NOT USED PORT
CONTROLLER 120 V PIO OPTION CARD
MAY AUTOMATICALLY + N 240VAC RS232
3
4
5
6
START/RE-START AFTER
AUX
AUX
AUX
AUX
HIGH VOLTAGE A PROTECTIVE DEVICE IS

DEVICENET
ANALOG
OUTPUT
INPUT 4
INPUT 3
INPUT 5
COM
RESET OR RESETS
RX
MPSRTD BUL.825P RTD MODULE OPTION CARD

INDUCED FIELD VOLTAGES AUTOMATICALLY.
FIBRE OPTIC
I-
B
R
I+
W
ARE PRESENT DURING

33
34
43
44
53
54
63
64
Y2-
Y1- COM
Y22
Y24
Y26
Y12 INPUT 1
Y14 INPUT 2
BLK
REMOVE MAIN CONTACTOR RTD 1 - RTD 12 CONNECTOR

STARTING AND MAY CONTROL SIGNAL BEFORE 500M MAX.
EXCEED 1000 VOLTS. RESETTING ANY DEVICE.
CONTACT WITH
SYNCHRONOUS MOTOR UNEXPECTED ENERGIZATION SHOWN ON SHT.3 TO DEVICENET NETWORK
FIELD CONNECTED OF LOAD CAN RESULT IN LINE N-302 BUL.825P NOTES:
(OPTIONAL)
COMPONENTS CAN RESULT SEVERE INJURY OR DEATH. OUTPUT RELAY CONTACTS SHOWN WITHOUT CONTROL
IN SEVERE INJURY. POWER APPLIED. THE FOLLOWING FACTORY INSTALLED
OR DEATH CONTACT POWER-UP STATES ARE IN EFFECT:
TRIP - FAIL SAFE
AUX.1/ALARM - NON FAIL SAFE
AUX.2 - NON FAIL SAFE
LEGEND BUL.825P TO BE PROGRAMMED BY THE CUSTOMER
BEFORE START-UP.
REMOTE EQUIPMENT
"IEEE" NUMBER FOR PROTECTIVE DEVICE
D LOW VOLTAGE DOOR MOUNTED DEVICE
CUSTOMER WIRING
NOTES
REFER TO DIMENSION DRAWING FOR COMPONENT SIZING NOT SHOWN ON THIS DRAWING.
RECTIFIER TRANSFORMER
RTR
____kVA
106
H1 X1
X3 3
FROM SHT.1 160V/320V
LINE G-111 X2
H2 X4 107
PRIMARY CURRENT SECONDARY FUSES

LIMITING FUSES
FROM SHT.3
RECTIFIER ASSEMBLY LINE D-333
BLK
R
1
12
R
5 4 3 2 1
J3
1 2 3 4 5 6 7 8 SCR-X1 SCR+X1 5 4 3 2 1
P8 X1
L1
L2
(3) (1) (2)
J8
SFSB 1 2 3 4 5 6 7 8 RST J6
J1 J1
SNUBBER RECTIFIER G (6) G (4) W 3
L1
L2
L3
FIELD STACK 1 1 G
(7) (5) R +X1 4
+ BUS
SWITCH K K 2 2 K
BOARD W
5 5 G
(NOT USED)
(NOT USED)
(NOT USED)
R -X1
THERMOSTAT
6 6 K J4
P9 J9 113
113 1 1
1 1 114
114 24 VAC MOV 2 2
2 2 SCRFB
SCR+X2 SCR-X2 3 3
3 3 X2 FCRO4100 112
(NOT USED) MOV MOV (3) (1) (2) SINGLE PHASE I1 4 4
4 4 SCR FIRING 5 5 FSR
5 5 BOARD 111
G (6) G (4) W +12 6 6
6 6
52 K (7) K (5) R +5 7 7
FROM SHT.3 7 7 THERMOSTAT
53 J2 J2 COM 8 8
Figure 7 - Typical Wiring B
LINE D-319 8 8 THERMOSTAT

4 4 G 9 9
-X2 116
5 5 K SIG HI 10 10
W 115
1 1 G COM 11 11
R +X2
2 2 K 12 12
- BUS
NEG-K
NEG-G
THERMOSTAT
R2-G
R2-K
1 2 3 4 5 6
J7
P7
1 2 3 4 5 6
BLK
W
DISCHARGE RESISTOR
1
12
(6) SWITCH
(3) R2 DRS
HST HEATSINK
R THERMOSTAT

(5)
(1)
PSRB
(2) 5 4 3 2 1 TB1
LEM
W (4) POWER
5
R (7) SUPPLY/
REGULATOR
ENABLE
REMOTE
BR BOARD
D
BR
FIELD CURRENT ADJUST
- + CONTROL
VOLTAGE TB3
SELECTOR 115
SWITCH FU FIRING 10
SW1 COMMAND 116 (2)
(0.5V) 9 (3) (1)
115 230 108
COM 8
DOOR 110
SIG 7
POT 109
+10V@10mA 6
R56
COM 5 D
REMOTE
FIELD CURRENT COMMAND SIG 4 DC AMMETER
MAX. LIMIT POT. (0-10V)
LEGEND +10V@10mA 3
- 117 A +
DCCT TB2 DC 2
3 FOR 125VDC EXCITER OUTPUT JUMPER X1-X3, X2-X4 FOR 160V AC. AMMETER 118
(0-10mA) + 1
FOR 250V DC EXCITER OUTPUT JUMPER X2-X3 FOR 320V AC
Installation
5 HIGH TEMPERATURE WIRE
D LOW VOLTAGE DOOR MOUNTED DEVICE 104 103 105

(-) (+)
NOTES
TO SHT.1
FIELD CURRENT SETTINGS: TO SHT.1 LINE Q-103
LINE Q-111
DOOR MOUNTED POTENTIOMETER IS USED TO ADJUST THE MOTOR FIELD
CURRENT UP TO THE MAXIMUM VALUE.
29
Chapter 3
30
CUSTOMER TERMINAL BLOCKS
FROM SHT.1, LINE C-117 CTB
OFF
MPSRTD (825P) 14A F7 14 EXCITER
Chapter 3
NORMAL TEST + TERMINAL BLOCKS

8 7 6 01 VAA F5 VA
X X -
(6) (5) (1) (2) 02 VCA F5 VC ETB
RTD 1
RTN 03 VB 1
TEST SUPPLY POINT + 04 1 3
ISb -
9 10 TS 11 05 1 4
RTD 2
X X
(7) (8) 120 V 60 Hz (3) (4) RTN 06 1 4A
+ 07 1 12
V M-IV
Installation
- 08 1A 31
RTD 3
1 - 4 M
EC TCO RTN 09 2 51
F3 4.0A 2 + 3
MOV + 10 3 52
A M B N C MAIN CONTACTOR (M) - 11 2
15 13 17 4 53
RTD 4
11 6 M 311 321
AUX CCO RTN 12 4A 54
12 5 20 307 313 322 +
2.0A 13 12
14 14A
1 F7 L1 G - 14 12
RTD 5
RTN 15 12
+ 16 14
START
STOP D 1A 2 D 3 NOT STOP/START INPUT 12 -17 14
RTD 6
SYNCPRO II
V M-IV I:2/00 AC COMMON RTN 18 30
I:2/01 31 G M H
15 16 + 27
32
CONTACTOR 2 - 28
RTD 7
STATUS RTN 29 33
V M-IV 34
RUN OUTPUT ESR + 30
4A 35 K M L
SYNCPRO II 9 + - 10 - 31
RTD 8
O:0/01 4 36
CLOSE RTN 32
+ 33 37
SS FIELD SWITCH - 34 51
FSR OUTPUT RELAY (FSR)
RTD 9
50 RTN 52
SYNCPRO II FSR 219 428 35
O:0/02 + 53
36 2
SNUBBER FIELD SWITCH BOARD - 54 MX
SFSB EQUIPMENT SHUTDOWN 37
D MPS (825P) 60
RTD 10
RECTIFIER SS RELAY (ESR) RTN

TRIP OUTPUT 38
14 51 52 P9 J9 THERMOSTAT J9 P9 53 54 61 MX
95 96 SYNCPRO II ESR 313 429 + 39
O:0/00 - 62
7 8 325 40
63
RTD 11
98 2 RTN 41 MX
SS 64
TRIP AUXILIARY RELAY (MX) + 42
65 MX
MX 316 317 318 319 - 43
66
RTD 12
RTN 44
MAIN CONTACTOR INPUT 12 67
SYNCPRO II
Figure 8 - Typical Wiring C
I:2/08 70
E M F
30 31 D RUN 71
1 R
72
I M J
34 35 D OFF 73
1 G
74
90
D SYNCPRO II
TRIP/RESET 91
58 TRIP/RESET
SYNCPRO II
I:2/02
ESR
59
R
RECTIFIER
ASSEMBLY FAN
PAT
INPUT POWER

LEGEND
MPS (825P) V INTELLIVAC NOTES:

D INPUT POWER OUTPUT RELAY CONTACTS SHOWN WITHOUT
CONTROL POWER APPLIED. THE FOLLOWING FACTORY
INSTALLED CONFIGURATION/POWER-UP STATES
ARE IN EFFECT:
MPSRTD CONTACTOR STATUS - FAIL SAFE
INPUT POWER MODULE STATUS - FAIL SAFE
INTELLIVAC TO BE PROGRAMMED/CONFIGURED BY THE
CUSTOMER BEFORE START-UP.
AUX - INTELLIVAC MODULE VACUUM CONTACTOR AUXILIARY INPUT
SCRFB CCO - INTELLIVAC MODULE CLOSING COIL OUTPUT
INPUT POWER EC - INTELLIVAC MODULE EXTERNAL CAPACITOR INPUT
L1 J3 L2 M-IV - MAIN CONTACTOR INTELLIVAC MODULE
TCO - INTELLIVAC MODULE TRIP COIL OUTPUT
DC POWER SUPPLY 2 THE STARTER CONTROL CAN BE OPERATED IN TEST MODE, ONLY
IF THESE SYNCPRO CONTACTS HAVE BEEN JUMPERED OUT.
ENSURE JUMPERS ARE REMOVED BEFORE PUTTING STARTER
BACK INTO NORMAL OPERATION.
REMOTE EQUIPMENT
D
90 90 REMOVE JUMPER WHEN CONNECTING REMOTE EQUIPMENT
TO SHT.1
PANELVIEW 91 91 LINE Q-108 D LOW VOLTAGE DOOR MOUNTED DEVICE
CUSTOMER WIRING
1 TO SHT.4 MOV METAL OXIDE VARISTOR
LINE H-413 12
NOTES
TO SYNCPRO II TO SYNCPRO II REFER TO DIMENSION DRAWING FOR COMPONENT SIZING NOT SHOWN ON THIS DRAWING.
SHT.4, LINE C-422 SHT.4, LINE C-422
MicroLogix 1500
1764-LPR PROCESSOR D
1764-24BWA
SLOT: BASE PANELVIEW
+24V
POWER
OUT
DC 91 FROM SHT.3
COM 0 LINE E-337
W (C)
BLK (N) TO SHT.1

LINE Q-106
DC
COM 1 R (P)
DC
COM 2
12
Figure 9 - Typical Wiring D
FROM SHT.3 MicroLogix 1500 MicroLogix 1500

LINE 339 MOV
ANALOG INPUT MODULE INPUT MODULE
1 1 120/240 1769-IF4X0F2 1769-IA16
VAC 12 SLOT: #1 SLOT: #2
VAC
G NEUT
TO CHASSIS GROUND EARTH
GND 53 3 START
VAC/ TO SHT.3, LINE F-318
#14 AWG 54 VDC 0 98 PA TRANSDUCER NOT STOP 3
TO SHT.3, LINE F-318 FROM SHT.3
VAC/ 2 99 98 LINE G-311 58 TRIP RESET
TO SHT.3, LINE F-314 + - FROM SHT.3
4 VDC 1 FVR INPUT (NOT USED) LINE G-325
TO SHT.3, LINE F-314 FLR INPUT
VAC/ 14 (4-20mADC) 1 (NOT USED)
TO SHT.3, LINE F-316 FSR
50 VDC 2 68
TO SHT.3, LINE F-316 TRANSITION COMPLETE
71 1 (NOT USED)
VAC/ AUTOLOAD CONTROL ESR
70 VDC 3 69

AUTOLOAD CONTROL
VAC/
VDC 4
MAIN CONTACTOR
31 FEEDBACK
FROM SHT.3
LINE G-321
1 VAC/ 73 SQUIRREL CAGE MOTOR

VDC 5 PROTECTION TRIP
72
MOTOR PULLOUT 74
TRIP INCOMPLETE SEQUENCE TRIP
12 AC
COM 2 12
AC
LEGEND COM 1
D LOW VOLTAGE DOOR MOUNTED DEVICE
NOTES
REFER TO DIMENSION DRAWING FOR COMPONENT
SIZING NOT SHOWN ON THIS DRAWING.
Installation
31
Chapter 3
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.
Summary 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 II 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.

Chapter 4
Setup and Commissioning
Setup Check the following components of the SyncPro II once it has been installed.
RF1 & RF2 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 95%
speed (across the entire discharge resistor), then it is necessary to select taps on
the RF1 and RF2 to provide 20 k at RF1 and 20 k at RF2.
Figure 10 - Discharge Resistor Installation
These settings must be made prior to any start attempt.

Chapter 4 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 zero and 95% speed as given
by the motor manufacturer.
EXAMPLE Induced current @ 0% speed: 20 A

Induced current @ 95% speed:12 A
Discharge resistance: 50
Therefore:
Induced voltage @ 0% speed: 20A x 50 = 1000V
Induced voltage @ 95% speed: 12A x 50 = 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 22 or 2.828.
When doing this, a portion of the discharge resistor only should be used, 1 can
then be used to determine the value which will be on the entire resistor.
EXAMPLE A strip chart recording is taken across a 1 portion of a 50 discharge

resistor. The following peak to peak values are obtained:
0 speed: 56V p-p
95% speed: 34V p-p
Therefore:
0 speed rms voltage across 1 56 / 2.828 = 20V rms
95% speed rms voltage across 1 34 / 2.828 = 12V rms
0 speed rms current across 1 20V / 1 = 20A rms
95% speed rms current across 1 12V / 1 = 12A 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 95% speed induced voltages must fall between the upper and lower
limits defined on the chart.

Setup and Commissioning Chapter 4
Procedure for Selection of RD = Discharge resistance __________

Resistors 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
Io = Induced current (0% speed) __________ A (Arms@0)Vrms0/Rs
I95 = Induced current (95% speed) __________ A (Arms@95)Vrms95/Rs
V0 = Induced voltage (0% speed) __________ V I0 x Rd
V95 = Induced voltage (95% speed) __________ V I95 x Rd
0 speed induced voltage across the entire discharge resistor 50 * 20 A= 1000V
95% speed induced voltage across the entire discharge resistor 50 * 12 A = 600V
RF1/RF2 Resistance Required __________
RF1 & RF2 Resistor RF Resistor tap settings

Figure 11 - Discharge Resistor Setup

Table 1 - Feedback Resistor Values Synchronous Field Feedback Board

Usable Voltage Range
RF1/RF2 Resistance (K)(1)
Lower Limit Upper Limit
2.5 80 160
5 160 320
7.5 230 480
10 320 640
12.5 400 800
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 k 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.
Commissioning 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 II 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 out to ground or another electrical
point. This will disable the field contactor so that the starter will not
attempt to synchronize.
IMPORTANT The contactor must be disabled in this manner rather than removing
the field cables from the contactor. The discharge path through the
discharge resistor must be maintained; otherwise, a voltage high
enough to damage the field insulation will occur at the open field
windings. This is similar to the effect which occurs if a current
transformer secondary winding is left open circuited.

Setup and Commissioning Chapter 4
4. If during the previous setup procedure for the discharge resistors RF1 and
RF2, the induced currents were not known, then the next step would be to
bump the motor with the RF1 and RF2 resistors disconnected. The
method detailed in publication 1900-2.10 for determining the motor data
by measurement using a strip chart recorder should be done at this time.
The RF1 and RF2 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 II 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, 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.
ATTENTION: During synchronization, voltages that may exceed 1000

volts are present at the Rf1 and Rf2 resistors. To avoid shock hazard, do
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. If the 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.
The time to accelerate to rated subsynchronous speed
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
Monitor Power Factor during acceleration. It should be lagging.
This will also prove that the power factor transducer connection is in
the correct orientation with the incoming current and voltages. If the
polarity is incorrect, switching the C3A and C3B connections should
correct the situation.
The phase angle transducer connections are correct provided that the transducer
power and voltage reference inputs are connected to Line 1 and 2 and the current
reference is Line 3. If the incoming connections into the starter have been made
B-A-C, rather than A-B-C, the polarity will also be incorrect even though the
correct starter lines have been brought to the transducer. In either event, the
correction is the same, reverse the C3A and the C3B current transformer
connections.

ATTENTION: To avoid damage to the motor, do not allow the motor to run
without synchronizing (at 95% speed) for longer than required to perform this
test. Most motors are only capable of running for about 60 seconds at 95%
speed without synchronizing.
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 diagram.

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

Chapter 5 Programming SyncPro II
Main Menu The main menu provides access to the following screens.
SyncPro II Status Provides idle, starting, running status information
View Set Points Allows viewing of SyncPro II operation and protection set points.
Edit Set Points Allows viewing of SyncPro II 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
SyncPro II Status 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
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
During the Starting mode (Figure 14), the motor slip frequency in Hz power factor in %,
and time to a squirrel cage protection in seconds are displayed. The power factor value is
accompanied by either a < or > 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. Vab, Ic).

Programming SyncPro II Chapter 5
Figure 15 - Running Mode
In the Running mode, the slip frequency and power factory is displayed. During
normal operation, the slip frequency is 0 Hz, and power factor is approximately
100% for unity.
View Set Points Figure 16 - Minimum Slip Frequency
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 II
energizes the coil of the field switch/contactor. The SyncPro II ensures that the
application of the field contactor coincides with the rising edge of the induced
voltage waveform which makes for a smooth transition. If the motor pulls into
synchronism due to reluctance torque, the SyncPro II will detect no pulses and
then will apply DC voltage to the field after a one second delay.
f Minimum _ slip
SP1 =
f operating

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.
SP2 = f operating
Figure 17 - Function Number
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.
SP3 = F ( f , ta , tb )
SP3 = tb , if f < f 50%
SP3 = ta , if f 50% f < f sp 2
t sp 5 t sp 6
M = , B = t sp 6 Mf sp 2
f 50% f sp 6
( f 50% f sp1 ) x ( f 50% f ) x

ka = , kb =
t sp 4 Mf sp1 B ka
ta = Mf + B, tb = ta + kb

Table 2 - Function Numbers

Variable Function Number
tsp4 Squirrel-Cage Protection Trip Time (at 95% speed)
tsp5 Squirrel-Cage Protection Trip Time (at 50% speed)
tsp6 Squirrel-Cage Protection Trip Time (at stall)
f Detected slip frequency
fsp1 Minimum Percent Synchronous Slip Frequency
f50% Squirrel-Cage Protection Trip Frequency
fsp2 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 manufacturers specifications.
SP4 = t sp 4

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.
SP5 = t sp 5
Set Point 6: Squirrel-Cage Protection Trip Time (at stall)
In the event that a synchronous motor fails to accelerate at start up it will go into
a stall condition at zero speed. This can occur if the motor is overloaded at start.
The time entered at this set point should be the maximum allowable stall time on
the Squirrel-Cage Winding as defined by the motor manufacturer.
SP6 = t sp 6

IMPORTANT The squirrel-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 minimizes motor heating during an equipment failure.
SP7 = t IST
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.
SP8 = PFtrip
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.
SP9 = t PF _ Delay

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 Operation Fault
16 Mask PLC Reversed Power Factor Fault
Edit Set Points 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%

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

Allowable Range: 5...80 seconds
Factory Default Setting: 5 s (5 seconds)
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
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)

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
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

Figure 24 - Individual Faults
Figure 25 - Individual Faults (contd)
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
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Enable All Faults
272 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 Mask Comm. Faults
2000 0 0 0 0 0 1 1 1 1 1 0 1 0 0 0 0 Mask All PF Faults
1984 0 0 0 0 0 1 1 1 1 1 0 0 0 0 0 0 Mask PFT Circuit Faults

64 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 PFT: No Input
128 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 PFT: CT Open/Short
256 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 PFT: CT Reversed
512 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 PFT: No Signal @ PLC
1024 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 PFT: Abnormal Operation
16 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 PLC: Reversed PF

Alarm History The Alarm Banner screen will appear if any alarm condition exists in the system.
The screen provides three user options:
Clear Alarm
Acknowledge Alarm
Acknowledge All Alarms
The clear 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
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

Access Code 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 is 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
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.
Settings 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

Notes:

Chapter 6
Monitoring
Phase Angle/Power Factor A key protection component of the SyncPro II 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).
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 ( )
To provide an accurate measurement the voltage and current inputs must be in

the proper relationship, Vab and Ic.
Figure 30 - Voltage and Current Inputs Relationship
Va
Ic
Vab
Vb

Chapter 6 Monitoring
Faults 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 II and tansducer.
c. 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 CT,
shorted CT input, loss of control power to transducer or a faulted transducer.
An 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.

Chapter 7
Troubleshooting
Last Trip Table 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 Indication of the following conditions Possible Solutions
Indicated
Pullout trip (power factor) Motor overloaded Lessen the motor loading and/or
[PULL OUT TRIP Loss of DC excitation overload
(POWER FACTOR)] Static exciter DC current level set Repair static exciter
too low Increase current setting on static
exciter if lagging
Decrease current setting on static
exciter if leading
Mask leading power factor trip if
application/ motor is designed for it
Squirrel-cage Motor overloaded at start Remove or lessen load for start
Protection Trip
[SQUIRREL-CAGE
PROTECTION TRIP]
Incomplete Start Sequence Motor overloaded at start Remove or lessen load for start
Time Exceeded Field contactor or FC pilot relay coil Replace coil(s)
[INCOMPLETE START failure
SEQUENCE TRIP]
No Transducer Input The transducer is putting out less than Check the wiring for the voltage
[POWER FACTOR XDCR 12 mA when the motor is off (should sensing on the transducer board.
NO INPUTS] be 12 mA) Replace phase angle transducer board
if necessary.
Replace analog card in SyncPro II
chassis
CT Open/Shorted The CT is either open or shorted. Check the wiring between the CT and
[POWER FACTOR XDCR the transducer board.
CT OPEN/SHORT] Replace the CT if necessary.
CT Reversed The CT is incorrectly wired to the Reverse the leads of the CT at the
[POWER FACTOR XDCR transducer board. transducer board.
CT REVERSED]
No Signal @ SLC There is no signal at the PLC analog Check the wiring between the
[POWER FACTOR XDCR card from the PF transducer board. transducer board and the PLC
NO SIGNAL AT PLC] analog card.
Ensure that there is power to the
transducer board.
Replace the PLC analog card or
transducer board as required.
Transducer Problem The transducer is behaving This is an all-encompassing fault and
[POWER FACTOR XDCR unpredictably. could include anything from the CT, the
CIRCUIT FAULT] transducer board, or the PLC analog card

Chapter 7 Troubleshooting
Table 5 - Troubleshooting Guide (Continued)

Problem or Trip Indication of the following conditions Possible Solutions
Indicated
Pulse Board 24 V Failure Connection has not been made Check the connections at the A/D
[PULSE BOARD 24 VDC between the analog/digital pulse pulse board.
FAILURE] board and the SyncPro II DC input card Check fuse in power supply. Check for
or from the discharge resistor to the 24 V at power supply. Replace power
same A/D pulse board. supply if necessary.
24VDC power supply has had a failure Replace A/D pulse board.
Field Voltage Loss The static exciter is not actively Service the static exciter or repair the
[FIELD VOLTAGE LOSS] producing DC or the FVR relay coil has FVR relay.
failed. AC Voltage to the bridge absent
Wrong polarity on FVR coil. 10 VDC on Op Amp Board Absent
Incorrect voltage rating of FVR coil. Check polarity on FVR coil.
Exciter Enable (EE) relay did not pick up. Check voltage rating of FVR coil.
Verify the control circuit.
Field Current Loss The current relay which monitors the Check both the field current relay and
[FIELD CURRENT LOSS] motor field current is not providing an the static exciter for possible failures.
energized contact to verify that the
static is functional.
No Field Coil Feedback The SyncPro II has requested the field The field contactor coil has failed. Replace
[NO FIELD COIL FEEDBACK] contactor to energize but the feedback the coil. The connection to the FC
contact from this contactor is not auxiliary has not been made. Check
showing as closed. the wiring.
The FC auxiliary contact has failed.
Replace the contact.
Reversed PF @ SyncPro II The connections from the PF transducer Switch the positive and negative
[REVERSED PF AT PLC] to the analog card have been transducer output leads at the analog
accidentally reversed. card.
External Hardware Fault An external device to the SyncPro II is Check external devices.
[EXTERNAL HARDWARE not functioning as expected.
FAULT]
Pulse Board Positive and The SyncPro II is not seeing a pulse Pulse train would be lost if either the A/D
Negative Pulse Missing train being supplied from the A/D card failed, the RF/RF2 selection is
[PULSE BOARD POSITIVE board at the time of starting. incorrect, or if the connection is not made
MISSING] The RF1/RF2 resistor selection is not from the A/D board to the SyncPro II.
correct. The signal is too weak to Review the RF1/RF2 setup parameter
[PULSE BOARD NEGATIVE provide the necessary pulse train and verify the procedure performed
MISSING] (see Commissioning, item 4, on page
4-7).
Contactor Feedback Lost The SyncPro II monitors the status of The main contactor coil has failed.
[NO MOTOR CONTACTOR the synchronous motor stator contactor Replace the coil. The connection of the
FEEDBACK] while running. M auxiliary contact has not been made.
The male/female connector of the Check the wiring.
vacuum contactor is not matched The contact has failed. Replace.
properly. Ensure the connector is matched
The PLC I/O card slot 2 input 8 is faulty. properly.
Replace the I/O board.
Check the fuse.
Halt Synch Relay The program/remote/run switch on the Turn the key switch to the RUN mode
PLC processor may be in program position.
mode.
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.

Chapter 8
Spare Parts
SyncPro II Spare Parts List Table 6 - Spare Parts List

Part Number Designation Description Quantity
800H-PRTH1GR Red Illuminated Push Button 1
800T-N65 Trip/Reset Lamp for Red Push Button 1
800T-N318R Lens for Red Push Button 1
700-CF220D FCR, ESR Relay 1
X-251089 F3 Fuse 4 amp. 1
80165-778-51-R Analog/Digital Board 1
80025-817-01-R 20 k tapped Power Resistor 20 k tapped 2
700DC-P200Z1 Field Voltage Relay 125 V DC exciter 1
FVR
700DC-P200Z2 Field Voltage Relay 250 V DC exciter 1
80190-020-01-R 120 V 1
Phase Angle Transducer Board
80190-020-02-R 240 V 1
2711C-T4T PanelView Component C400 Terminal 1
1761-CBL-PM02 RS-232 (DF1) cable 1
1606-XLP50E DC Power Supply 1
1769-IF4XOF2 Analog I/O Module 1
1764-24BWA MicroLogix 1500 Base Unit 1
MicroLogix 1500 Processor
1764-LRP 1
(unprogrammed)
1769-IA16 Digital Input Module 1

Chapter 8 Spare Parts
Notes:

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
TechConnectSM support programs. For more information, contact your local distributor or Rockwell Automation
representative, or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience 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 TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 1902-IN001B-EN-E - April 2013

Supercedes Publication 1902-IN001A-EN-E - March 2009 Copyright 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada.

1902 In001 - en e

Uploaded by

Copyright:

Available Formats

1902 In001 - en e

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1902 In001 - en e

Uploaded by

Copyright:

Available Formats

Installation Instructions

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

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

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 5

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

Introduction The SyncPro II consists of a programmable small logic controller

The SyncPro II system is designed to provide supervisory protection and field

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 7

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

Protection Theory Theory of Operation

If the programmed percentage of synchronous speed is obtained within set time

NOTE: If the time set point at the maximum programmed percentage of

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

When the maximum programmed percentage of synchronous speed (set point) is

Refer to Chapter 5 for complete details.

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

Typical Synchronous Starter Motor Contactor (M)

Motor Contactor Pilot Relay (CR1 or MR)

Field Voltage Relay (FVR)

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

Phase Angle Transducer (Included with SyncPro II)

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 11

The discharge resistor is specified by the motor manufacturer for a specific

Field Contactor (FC)

Resistors RF1 and RF2

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

Analog/Digital Pulse Board

Input/Output Descriptive Listing

START INPUT (I:2/1)

RUN OUTPUT (O:0/1)

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 13

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

TRIP OUTPUT (O:0/0)

TRANSITION COMPLETE CONTACT INPUT (I:2/6) (OPTIONAL)

FIELD RELAY OUTPUT (O:0/2)

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

MOTOR CONTACTOR FEEDBACK CONTACT INPUT (I:2/8)

FIELD CONTACTOR FEEDBACK CONTACT INPUT (I:2/5)

TRIP/RESET PB INPUT (I:2/2)

FIELD VOLTAGE RELAY INPUT (I:2/3)

FIELD CURRENT RELAY INPUT (I:2/4) (OPTIONAL)

POWER FACTOR INPUT (I:1/0)

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 15

SLIP GENERATOR POWER INPUT (I:0/1)

SLIP GENERATOR NEGATIVE INPUT (-) (I:0/0)

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

AUTO LOAD OUTPUT (O:0/3)

SCP TRIP OUTPUT (O:0/8)

MOTOR PULLOUT TRIP OUTPUT (O:0/9)

INCOMPLETE SEQUENCE TRIP OUTPUT (O:0/10)

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

For Phase Angle Transducer

PVc C400 Specifications See Publication 2711C-IN001_-EN-P, pages 30...31.

MicroLogix 1500 See Publication 1764-UM001_-EN-P, Appendix A.

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 17

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

Receiving and Storage

IMPORTANT If the SyncPro II is an integral component of a brush-type synchronous starter,

Rockwell Automation Publication 1902-IN001B-EN-E - April 2013 21