RECA-01 | User manual | ABB DC drives DCS550, 20 A – 1,000 A, 230 V

ABB DC drives

DCS550, 20 A – 1,000 A, 230 V

AC

– 525 V

AC

, – 500 kW

The OEM machine manufacturing market places high demands on modern DC-drives. With its compact dimensions and robust technology, the DCS550 is an ideal drive solution for this market – both in new installations or as a replacement for older analog devices.

Integrated “winder”, high-performance field supply and various interfaces provide machine manufacturers with a maximum of flexibility in terms of machine integration.

In the DCS550, the extremely user friendly operational concept of the DCS400 has been consistently refined and optimized based on practical experience.

DCS550 – The highlights

− Compact dimensions

For installations with limited space

− Integrated high performance three phase field exciter up to 35 A

Fits all available motors without additional installations

− “Winder” with commissioning assistant

For easy and fast adaption to applications

− Different Fieldbus interfaces (incl. EtherCAT, Profinet…)

For easy integration into automation

− Additional PID-controller

For overriding control functions (e. g. pressure- or level control)

− Adaptive programming with Drive AP, ABB’s graphical PC-tool

For easy implementation of additional functions

− Various start-up assistants and auto-tune functions

For fast commissioning

− Large control panel

For straight forward and self-explanatory operation

− Rugged design

For rough environments, high reliability

− Worldwide service

Local service in more than 60 countries

DCS550 – Extensive applications

− Extruders

− Sugar centrifuges

− Wire drawing machines

− Coating lines

− Printing machines

− Presses

− Tools machines main drives

− Food processing machines

− Woodworking (wooden products and MDF industry)

− Retrofit of analog DC-technology

Modern DC-drives – More up-to-date than ever

Today, DC-drive technology is more up-to-date than ever. Their attractive cost-performance ratio and functional advantages such as high torque at low speed, light weight and low power loss turn DC-drives into the preferred solution for many applications. As far as innovation is concerned ABB’s DCdrives match the same high standards as ABB’s AC-drives.

Easy upgrade of installed older converters

The machines are frequently still in very good condition but spare parts and know-how for the installed power electronics are no longer available.

With the DCS550, existing machines can be kept in operation by replacing the old drive.

Short downtimes and low costs for the retrofit are additional advantages of an upgrade of existing machinery.

ABB DC drive DCS550

Simplicity as a principle

The DCS550 is based on the well-proven concept of ABB’s digital converters, which is highly appreciated around the world for its simplicity. Each operating step is displayed explicitly and easily comprehensible for the user.

with multilingual help function. The large graphic display allows the user to freely select actual and set values. Another additional advantage: the user can call up a list of all changed parameters. The control panel can also store parameters as a security backup or copy them for use in other converters.

The basic version of the DCS550 is already equipped with a large number of standard hardware interfaces like an encoder, an analog tachogenerator and four analog input devices.

Since the basic unit includes all important functions nearly all applications are covered – options are not necessary.

The one-volume documentation provides comprehensive information on the unit, firmware and hardware. The guided start-up and complementary support functions reduce start-up times to a minimum. The grouped structure of the parameters provides easy and clearly arranged navigation within the various features and functions. Error messages and help texts are displayed in plaintext in the user’s native language. The reduced need for training is an additional advantage created by the synergies and similarities with ABB’s DCS800 converter and ABB AC-drives.

Fieldbus: Pluggable flexibility

The pluggable fieldbus options allow the connection to most automation systems. A single cable with two twisted conductors replaces complex conventional cabling while reducing cost and increasing the reliability of the entire system.

− Profibus

− CANopen

− DeviceNet

− ControlNet

− Modbus RTU

− Ethernet IP

− Modbus TCP

− EtherCAT

− ProfiNet

I/O extension modules:

The pluggable I/O modules extend the basic I/O’s.

− RDIO-01 Digital extension module 3 x DI, 2 x DO

− RAIO-01 Analogue extension module 2 x AI, 2 x AO Control panel: High level of convenience included

The assistant control panel is part of the basic unit. It offers a multi-language alpha-numeric display (EN, DE, ES, FR, IT)

Fieldexciter connection

DCS550 Control panel

Analog output, 2 x AO

Analog input, 4 x AI

Tacho input /10 ... 270 V

Armature Connection

3ADW000374R0101 | DCS550 Product flyer

DCS550 converter module

R-Fieldbus module

R-IO extension module

R-IO extension module

Encoder interface

Digital input, 8 x DI

Digital output, 4 x D0

Digital output, Relay

AC Connection

Drive tools

Useful features

DriveWindow Light

The user-friendly start-up and maintenance tool for the world of ABB-drives supports both ABB’s DC-drives and AC-drives.

DriveWindow Light is a PC-software for easy and fast startup and maintenance of DCS550 converters and is part of the basic package. In offline-mode, all parameters can be set from the user’s office desk. The parameter browser can both display and save parameters on the computer. A comparison feature can compare and align current values with a stored set of parameters. With the “Local”-feature, the drive can be controlled, as well. At the same time, up to four display values can be visualised graphically. DriveWindow Light also includes an assistant for guided start-up, winder functions as well as the

AP-tool for block programming.

supports the start-up of serial communication (fieldbus) and winder functions. The context sensitive help function is always available.

“Adaptive Programming” (AP):

Adaptive Programming is included in the basic package.

With the help of 16 functional blocks users can develop, test and document their own programs easily in a graphic manner.

The „Adaptive Programming“ (AP) function allows the implementation of additional features.

Modifications can be configured with either the control panel or with the help of the graphic interface of DriveWindow Light AP.

The main features of DriveWindow Light AP are:

Start-up assistant

The DWL start-up assistant for the DCS550 provides valuable support during commissioning via an interactive dialogue.

The individual steps of the start-up process are pre-defined in the right order and all required parameters are displayed.

The “Basic”-feature captures motor and connection data and adjusts the controller automatically. The “Advanced”-feature

− 16 programmable function blocks

− Available functions:

– Logical: AND, OR and XOR

– Mathematical: add, mul, div, abs, max and min

– Other: timer, switch, comparator, filter, SR, PI and

user-defined warnings or faults

− Freely definable execution order

− Easy documentation

Start-up Assistant Adaptive Programming Speed Controller Autotuning

Winder Macros Winder Assistant Trending

Integrated winder function

Integrated winder functions

The DCS550 is equipped with a winder function with predefined macros for the four most commonly used winder types: drive as an analog actual value. The DCS550 is equipped with a free PID-controller that can be integrated into the control loop with the “Tension Control” macro.

Velocity control

Calculates the diameter and rotation speed set value.

The diameter is used to adjust the speed controller to all winding sizes. There is no tension control. All other macros are included in this basic structure.

Dancer control

Controls the tension with the weight of the dancer roll

(closed loop).

The dancer has to be kept in the right position with additional speed set values. The PID-controller of the DCS550 can also control the positioning of the dancer roll. The position of the dancer roll is transmitted to the controller as an analog actual value.

Indirect tension control

Controls the tension with the help of preset charts for friction and moment of inertia (open loop).

This structure provides a very robust control behaviour because no physical tension measurement is required.

Direct tension control

Closed loop for physical value of tension

The tension is measured with a load cell and transferred to the

Commissioning assistant

For an easy winder set-up, all different winder types can be configured and commissioned using a graphical assistant.

The assistant is part of DriveWindows Light PC-tool.

The rating for friction and inertia can be determined by auto tuning.

Example: direct tension control (closed loop)

DCS550 Product flyer | 3ADW000374R0101

Technial data

Mains connection

Mains

Rated frequency

Field exciter

3-phase 230 V

50 Hz or 60 Hz

AC

- 525 V

AC

; -15 % / +10 %

Supply voltage

Hardware

Internally connected to the mains

Completely integrated 3-phase OnBoard field exciter

Operating conditions

Degree of protection

EMC

IP 00

Fulfilling EN 61800-3 in accordance with

3ADW 000 032

CE, cULus Compliance

Control interfaces

Auxiliary voltages

PC-tools

DCS550 Control Panel

115 V

AC

, 230 V

AC

, 230 V

DC

DriveWindow Light, DWL AP, start-up assistant, winder assistant, help function

As standard, several languages, start-up assistant, help function

Status display

Analog I/O

Seven-segment display as standard

4 AI (15 bit + sign);

3 AO (11 bit + sign; two are freely programmable, one is fixed for armature current)

8 DI, 5 DO (one for mains breaker) Digital I/O

Motor temperature

Analog tacho input

Encoder input

1 PTC

As standard

As standard for 5 V and 24 V encoders

Option slots two slots for analog and digital I/O plug-in options

Special firmware functions

Adaptive Program

PID controller

Macros winder macros

Control and communication options

16 freely programmable function blocks

Freely usable PID controller

10 pre-defined macros for fast commissioning

4 pre-defined winder macros

Analog & digital plug-in options

1 * RAIO

2 * RDIO

Classic fieldbusses

RCAN-01

RCNA-01

RDNA-01

RMBA-01

2 AI, 2 AO

3 DI, 2 DO each

CANopen

ControlNet

DeviceNet

Modbus (RTU)

Profibus RPBA-01 Profibus

Ethernet fieldbusses

RECA-01

RETA-01

REPL-01

RETA-02

*= in preparation

EtherCat*

Ethernet/IP and Modbus/TCP

Ethernet Powerlink*

Profinet* t

T

8

10

X4:1

5

6

3

4

8

9

10

X3:1

2

SDCS-CON-F

X1:1 ±90...±270 V

2

±30...±90 V

3

±8...±30 V

S1

3

1

S1

6 4

5

6

S2

3 4 250

S3

3 4 250

-

-

+

-

+

+

-

+

ATACH

AI1

AI3

10

X2:1

5

6

3

4

-

+

AI4

GND

+10V

-10V

GND

Firmware

I-act

GND

121 100nF

10k

121 100nF

10k

121 100nF

10k

1 2

4 5

7 8

ChA

3

S4

ChA

-

+

ChB

6

S4

ChB

-

+

ChZ

9

S4

ChZ

-

+

GND

Sense 0 V

Sense 5 V

Power

10

S4

11

12

DI1

5V

24V

DI3

DI4

9

10

X5: 1

230V

K1

4

8

SDCS-PIN-F

X96:1

Control Connections

DO1

DO4

GND

Con-F_I_O_2_a.dsf

3ADW000374R0101 | DCS550 Product flyer

Technial data, dimensions and weights

Single bridge (2-Q Drive)

Mains [V] I

A

[A]

230 – 525

–15 / +10 %

315

405

470

610

740

900

135

180

225

270

20

45

65

90

I

F

[A]

1 - 12

1 - 18

2 - 25

2 - 35

Fan supply no fan internal internal internal

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

230 V

230 V

230 V

Double bridge (4-Q Drive)

Mains [V] I

A

[A]

230 – 525

–15 / +10 %

350

450

520

680

820

1000

25

50

75

100

150

200

250

300

I

F

[A]

1 - 12

1 - 18

2 - 25

2 - 35

Fan supply no fan internal internal internal

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

115 / 230 V

230 V

230 V

230 V

Dimensions h x w x d [mm]

370 x 270 x 220

370 x 270 x 270

459 x 270 x 310

644 x 270 x 345

Dimensions h x w x d [mm]

370 x 270 x 220

370 x 270 x 270

459 x 270 x 310

644 x 270 x 345

Weight

[kg]

11

16

25

38

Weight

[kg]

11

16

25

38

Type code

DCS550-S01-0020-05

DCS550-S01-0045-05

DCS550-S01-0065-05

DCS550-S01-0090-05

DCS550-S01-0135-05

DCS550-S01-0180-05

DCS550-S01-0225-05

DCS550-S01-0270-05

DCS550-S01-0315-05

DCS550-S01-0405-05

DCS550-S01-0470-05

DCS550-S01-0610-05

DCS550-S01-0740-05

DCS550-S01-0900-05

Size

F1

F2

F3

F4

Type code

DCS550-S02-0025-05

DCS550-S02-0050-05

DCS550-S02-0075-05

DCS550-S02-0100-05

DCS550-S02-0150-05

DCS550-S02-0200-05

DCS550-S02-0250-05

DCS550-S02-0300-05

DCS550-S02-0350-05

DCS550-S02-0450-05

DCS550-S02-0520-05

DCS550-S02-0680-05

DCS550-S02-0820-05

DCS550-S02-1000-05

Size

F1

F2

F3

F4

For more information please contact:

ABB Automation Products

Wallstadter Straße 59

68526 Ladenburg

Germany

Phone +49(0)6203-71-0

Fax +49(0)6203-71-7609 www.abb.com/motors&drives

E-Mail: [email protected]

© Copyright 2010 ABB. All rights reserved.

Specifications subject to change without notice.