ABB RSYC-01 User manual

—
OPTIONS FOR ABB DRIVES
RSYC-01 synchronizing unit for ACS580 and
ACS880 drives
User's manual

RSYC-01 synchronizing 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

Table of contents
1 Safety instructions
7Contents of this chapter ...........................................................................
7Use of warnings and notes .......................................................................
8Safety in installation, start-up and maintenance ...............................................
8Electrical safety precautions .....................................................................
2 Introduction to the manual
11Contents of this chapter ...........................................................................
11Applicability .........................................................................................
11Target audience ....................................................................................
11Terms and abbreviations ..........................................................................
12Related documents ................................................................................
3 Operation principle and hardware description
13Contents of this chapter ...........................................................................
13Overview ............................................................................................
13Operation principle .................................................................................
14Layout ...............................................................................................
4 Mechanical installation
15Contents of this chapter ...........................................................................
15Examining the delivery ............................................................................
16Installing the unit ...................................................................................
5 Electrical installation
17Contents of this chapter ...........................................................................
17Warnings ............................................................................................
17Required components .............................................................................
17Switch-over contactors [K1] and [K2] ........................................................
18Control relay [K4] ..............................................................................
18Contactor [K7] ...................................................................................
18Other components ..............................................................................
18Wiring requirements ...............................................................................
19Connection diagrams ..............................................................................
19ACS580 drives with CCU control unit .......................................................
20ACS880 drives with BCU control unit .......................................................
21ACS880 drives with ZCU control unit ........................................................
22Control unit terminal connections ............................................................
22RSYC-01 terminals .............................................................................
6 Start-up
23Contents of this chapter ...........................................................................
23Commissioning the synchronizing unit ..........................................................
23Start up the system ............................................................................
Table of contents 5

24Check the synchronizing unit operation .....................................................
24Check the trim function and synchronization ...............................................
25Complete the installation ......................................................................
25Disabling or resetting the synchronization circuit .............................................
25Parameter settings .................................................................................
7 Fault tracing
29Contents of this chapter ...........................................................................
29Fault tracing .........................................................................................
30Measuring with an oscilloscope ..................................................................
8 Technical data
33Contents of this chapter ...........................................................................
33Technical data ......................................................................................
9 Dimension drawings
35Contents of this chapter ...........................................................................
36Cover ................................................................................................
37Enclosure body .....................................................................................
Further information
6 Table of contents

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install, start
up, operate and do maintenance work on the synchronizing unit and synchronization circuit.
If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to 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,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 7

Safety in installation, start-up and maintenance
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation or maintenance work.
This manual does not contain the complete safety instructions of the drive. It only includes
the instructions related to the scope of this manual. For the complete safety instructions,
refer to the drive hardware manual.
Only a qualified electrical professional is permitted to install, start up and do maintenance
on the drive, the synchronizing unit and synchronization circuit.
Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive, motor
cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance 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 device in
the drive cabinet does not disconnect the voltage from the AC input power busbars
of the drive cabinet.)
•Open the auxiliary voltage switch-disconnector (if present), and all other possible
disconnecting devices that isolate the drive from dangerous voltage sources.
•If you have a permanent magnet motor connected to the drive, disconnect the motor
from the drive with a safety switch or by other means.
•Disconnect all dangerous external voltages from the control circuits.
•After you disconnect power from the drive, always wait 5 minutes to let the intermediate
circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
8 Safety instructions
3

5. Measure that the installation is de-energized. If the measurement requires removal or
disassembly of shrouding or other cabinet structures, obey the local laws and regulations
applicable to live working (including – but not limited to – electric shock and arc
protection).
•Before and after measuring the installation, verify the operation of the voltage tester
on a known voltage source.
•Make sure that 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 grounding (PE) busbar.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation work.
Safety instructions 9

10

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
This manual is applicable to the RSYC-01 synchronizing unit, which is compatible with
ACS580 and ACS880 drives.
The drive parameter data refers to ACS580 standard control program and ACS880 primary
control program.
Target audience
This manual is intended for the people who are responsible for installing, commissioning,
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
DescriptionTerm
Industrial assistant non-Bluetooth control panelACS-AP-I
Standard assistant control panelACS-AP-S
Industrial assistant control panel with Bluetooth interfaceACS-AP-W
Type of control unitBCU
Type of control unitCCU
Frequency converter for controlling AC motorsDrive
Converts direct current and voltage to alternating current and voltage.Inverter
2
Introduction to the manual 11

DescriptionTerm
In the drive control program, user-adjustable operation instruction to the drive, or
signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an object,
eg, variable, constant, or signal.
Parameter
Type of control unitZCU
Related documents
CodeManual
Drive hardware manuals and guides
3AXD50000045815ACS580-07 drives (75 to 500 kW) hardware manual
3AUA0000105718ACS880-07 drives (45 to 710 kW, 50 to 700 hp) hardware manual
3AUA0000143261ACS880-07 drives (560 to 2800 kW) hardware manual
Drive firmware manuals
3AXD50000016097ACS580 standard control program firmware manual
3AXD50000048035ACS580 drives with standard control program quick start-up guide
3AUA0000085967ACS880 primary control program firmware manual
3AUA0000098062ACS880 drives with primary control program quick start-up guide
Drive option manuals and guides
3AUA0000085685ACX-AP-x assistant control panels user’s manual
3AUA0000094606Drive composer start-up and maintenance PC tool user's manual
You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.
12 Introduction to the manual

Operation principle and hardware
description
Contents of this chapter
This chapter contains a description of the synchronizing unit.
Overview
The RSYC-01 synchronizing unit is designed for applications where a large constant-speed
motor must be started from a weak supply line. A drive with the RSYC-01 unit starts the
motor with a low current draw and a high torque. When the output frequency of the drive
reaches the supply line frequency, 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 (BUF OUT, 0 … 10 V) indicates the synchronization status for the
drive. When the BUF OUT signal is at 5 volts, the frequency and phasing of the supply line
and the drive output are synchronized.
3
Operation principle and hardware description 13

The drive control program constantly corrects the drive frequency reference (set to 50 Hz
or 60 Hz) on basis of the BUF OUT signal by using the trim function. When the supply line
and the drive output are synchronized:
•BUF OUT signal is at 5 V, indicating "synchronized" status for the drive application
program
•the RSYC-01 unit sends a signal to the contactor control 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
42
1
3
4
B
RSYC-01 with coverA
RSYC-01 without coverB
Terminal block J11
Terminal block J22
Terminal block J33
Cable clamps4
14 Operation principle and hardware description

Mechanical installation
Contents of this chapter
This chapter contains instructions for installing the unit to a mounting rail and lists the
contents of the RSYC-01 kit.
Examining the delivery
Make sure 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 15
10

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
4

Electrical installation
Contents of this chapter
This chapter contains connection diagrams and a list of items required in the electrical
installation.
Warnings
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation or maintenance work.
Required components
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 a drive. Using the incorrect type of contactor can cause damage
to the equipment.
Select the motor switch-over contactor [K2] according to the motor specifications.
5
Electrical installation 17
11

￭Control relay [K4]
Select a relay that has a maximum coil current of less than 200 mA.
￭Contactor [K7]
Select an applicable type of contactor that agrees with the network voltage and frequency.
For a supply voltage of 250 … 500 V AC and a frequency of 50 or 60 Hz, you can use, for
example, ABB AF09-30-10-14.
￭Other components
For more information about component selection, contact ABB.
Wiring requirements
•Obey the wiring instructions in the drive hardware manual.
•Keep a minimum of 0.5 m (20 in) space between the unit, the power cables, and the
drive module. If you cannot keep this much distance between them, keep as 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 instructions given in the drive
hardware manual.
•Use shielded twisted-pair cables between the synchronizing unit and the contactor control
circuitry. Ground the shields at the cable clamps, with as short pigtails as possible.
•Dimension the cable in between the main circuit and the synchronizing transformers
according to the main circuit voltage. If necessary, protect the cable with fuses.
18 Electrical installation

Connection diagrams
￭ACS580 drives with CCU control unit
ACS580 CCU
X1 X2
AI2
AGND
5
6
+24 V
DCOM
10
12
+24 V
18
DI6
X2&X3
10
M
3~
1 2 3 4
J3
INVRTR INVRTR MAINS
MAINS
1 2 3 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 K3K4 K2 K2
K3
K3 K2 K1
S1
K5 K6
K1 K5
230 V DC
10
N
34
3 4
K7
K7
Switch-over contactorsK1…K2
Control relaysK3…K5
Bypass contactorK6
ContactorK7
Synchronizing transformersT1…T2
*) Example circuit (recommended)
**) Optional connection when using line chokes
Electrical installation 19
11

￭ACS880 drives with BCU control unit
ACS880 BCU
XA I
XD24
XD24
AI1+
AI1-
4
5
+24VD
DICOM
5
6
+24VD 7
DI5
XDI
M
3~
1 2 3 4
J3
INVRTR INVRTR MAINS
MAINS
1 2 3 1 2
SYNC
COM
BUF OUT
+24 V
COM
J1 J2
RSYC-01
K1
U2 V2 W2
K6
L10
**)
K2
)**)*
K4
Run enable
K3
3 4
K3 K3K4 K2 K2
K3
K3 K2 K1
S1
K5 K6
K1 K5
230 V DC
10
N
34
K7
K7
5
Switch-over contactorsK1…K2
Control relaysK3…K5
Bypass contactorK6
ContactorK7
Synchronizing transformersT1…T2
*) Example circuit (recommended)
**) Optional connection when using line chokes
20 Electrical installation