ABB | DCS800 | User manual | ABB DCS800 User manual

DCS800
Hardware Manual
DCS800 Drives (20 to 5200 A)
DCS800 Single Drive Manuals
E
D
Language
I
ES
F
CN
DCS 800 Quick Guide (191 + CD)
DCS 800 converter module
Flyer DCS800
Flyer DCS800 E Panel solution
Catalogue DCS800
Hardware Manual DCS800 00S
Firmware Manual
Installation according to EMC
Technical Guide
Service Manual DCS800
Planning and Start-up for12-Pulse converters
CMA-2 Board
Flyer Hard - Parallel
Public. number
3 ADT 645 0 ??
RES
NN
3 ADW 000 190
3 ADW 000 0??
3 ADW 000 192
3 ADW 000 194
3 ADW 000 193
3 ADW 000 032
3 ADW 000 163
3 ADW 000 195
3 ADW 000 196
3 ADW 000 136
3 ADW 000 153
x
x
p
p
p
p
x
x
x
x
x
p
p
p
p
p
p
p
p
p
p
p
p
p
p
p
p
p
p
p
JF
JF
JF
TW
TV
TW
TW
NN
NN
TW
UW
Tools + optical link
DriveWindow 2.x
DriveOPC
Optical DDCS Communication Link
DDCS Branching unit User´s manual
NETA Remote diagnostic interface
3 BFE 645 60981
3 BFE 000 73846
3 AFE 639 88235
3 BFE 642 85513
3 AFE 546 05062
x
x
x
x
x
CoDeSys2.3
3ADW000199
3 ADW 000 058
x
x
x
3 ADW 000 198
3 ADW 000 091
p
p
p
p
3 ADW 000 007
3 ADW 000 197
p
p
p
3AFE 644 84567
3AFE 644 85733
3AFE64661442
x
x
x
TV
TV
TV
x
x
vdB
vdB
vdB
vdB
DCS800 Application
1131Programming Tool +Libary
1131 DCS800 target +tool description
Winding with the DCS 800XXXXX
Winder application description
Flyer magnetic application
Magnetic application description
DCS800 00A Enclosed
Flyer DCA 800
System description DCS800 00A
Installation of DCS800 00A
DCR 500 rebuild system
Flyer DCR
DCR Manual
DCS500/DCS600 upgrade manual
Hardware Extension
RAIO-01 Analogue IO Extension
RDIO-01 Digital IO Extension
AIMA R-slot extension
Serial interfaces
Drive specific serial communication
Installation and Start-up GuideRPBA-12 (PROFIBUS)
Fieldbus Adapter with DC Drives RPBA- (PROFIBUS)
3 AFE 645 04215
Fieldbus Adapter with DC Drives RCAN-02 (CANopen)
p
UW
UW
UW
UW
UW
vdB
vdB
vdB
vdB
vdB
vdB
vdB
UW
UW
UW
TW
TW
TW
vdB
Fieldbus Adapter with DC Drives RCNA-01 (ControlNet)
3 AFE 645 06005
x
vdB
Fieldbus Adapter with DC Drives RDNA- (DeviceNet)
3 AFE 645 504223
x
vdB
Fieldbus Adapter with DC Drives RMBA (MODBUS)
3 AFE 644 98851
x
vdB
Fieldbus Adapter with DC Drives RETA (Ethernet)
x -> existing
p -> planned
vdB
DCS800 Drives
20 to 5200 Amps
Hardware Manual
3ADW000194R0201 Rev B
EFFECTIVE: 05.10.2005
¤ 2005 ABB Automation Products GmbH. All rights reserved.served.
3ADW000194R0201 DCS800 Hardware Manual e b
3ADW000194R0201 DCS800 Hardware Manual e b
5
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
To which products this chapter applies
This chapter applies to the DCS800... Size D1 to D7and field exciter units DCF800...
Use of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment. They also tell you how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Safety instructions
3ADW000194R0201 DCS800 Hardware Manual e b
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death.
Only qualified electricians are allowed to install and maintain the drive.
•
Never work on the drive, motor cable or motor when main power is applied.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. Voltage between drive input phases U1, V1 and W1 and the frame is close to
0 V.
2. Voltage between terminals C1 and D1 and the frame is close to 0 V.
•
Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages inside the drive even when the main power on the drive is
switched off.
•
Do not make any insulation or voltage withstand tests on the drive or drive
modules.
•
When reconnecting the motor cable, always check that the C1 and D1 terminal
is correct.
Note:
•
The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
•
Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
may be present on the terminals of relay outputs SDCS-IOB-2, RDIO.
•
DCS800 with enclosure extension: Before working on the drive, isolate the
whole drive from the supply.
Safety instructions
3ADW000194R0201 DCS800 Hardware Manual e b
7
WARNING! The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
•
Ground the drive, motor and adjoining equipment to ensure personnel safety in
all circumstances, and to reduce electromagnetic emission and pick-up.
•
Make sure that grounding conductors are adequately sized as required by
safety regulations.
•
In a multiple-drive installation, connect each drive separately to protective
earth (PE).
•
Minimize EMC emission and make a 360° high frequency grounding of
screened cable entries at the cabinet lead-through.
•
Do not install a drive with EMC filter on an ungrounded power system or a high
resistance-grounded (over 30 ohms) power system.
Note:
•
Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
•
As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA
DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Safety instructions
3ADW000194R0201 DCS800 Hardware Manual e b
8
Fibre optic cables
WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4 in.).
Mechanical installation
These notes are intended for all who install the drive. Handle the unit carefully to
avoid damage and injury.
•
DCS800 Size D4...D7: The drive is heavy. Do not lift it alone. Do not lift the unit
by the front cover. Place the unit only on its back.
DCS800 Size D6/D7: The drive is heavy. Lift the drive by the lifting lugs only.
Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.
•
Make sure that dust from drilling does not enter the drive when installing.
Electrically conductive dust inside the unit may cause damage or lead to
malfunction.
•
Ensure sufficient cooling.
•
Do not fasten the drive by riveting or welding.
Safety instructions
3ADW000194R0201 DCS800 Hardware Manual e b
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
•
Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the base speed.
•
Do not activate automatic fault reset functions of the Standard Application
Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.
•
Do not control the motor with the disconnecting device (disconnecting switch);
instead, use the control panel keys
and
, or commands via the I/O
board of the drive.
•
Mains connection
You can use a switch disconnector (with fuses) in the power supply of the
thyristor power converter to disconnect the electrical components of the unit
from the power supply for installation and maintenance work. The type of
disconnector used must be a switch disconnector as per EN 60947-3, Class B,
so as to comply with EU regulations, or a circuit-breaker type which switches
off the load circuit by means of an auxiliary contact causing the breaker's main
contacts to open. The mains disconnector must be locked in its "OPEN"
position during any installation and maintenance work.
•
EMERGENCY STOP buttons must be installed at each control desk and at all
other control panels requiring an emergency stop function. Pressing the STOP
button on the control panel of the thyristor power converter will neither cause
an emergency motor stop, nor will the drive be disconnected from any
dangerous potential.
To avoid unintentional operating states, or to shut the unit down in case of any
imminent danger according to the standards in the safety instructions it is not
sufficient to merely shut down the drive via signals "RUN", "drive OFF" or
"Emergency Stop" respectively "control panel" or "PC tool".
•
Intended use the operating instructions cannot take into consideration every
possible system configuration, operation or maintenance. Thus, they mainly
give such advice only, which is required by qualified personnel for normal
operation of the machines and devices in industrial installations.
If in special cases the electrical machines and devices are intended for use in
non-industrial installations - which may require stricter safety regulations (e.g.
protection against contact by children or similar). These additional safety
measures for the installation must be provided by the customer during
assembly.
Safety instructions
3ADW000194R0201 DCS800 Hardware Manual e b
10
Note:
•
When the control location is not set to Local (L not shown in the PC tool status
row), the stop key on the control panel will not stop the drive.
Safety instructions
3ADW000194R0201 DCS800 Hardware Manual e b
11
Table of contents
DCS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
7
8
8
9
Table of contents
The DCS800
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The DCS800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Armature circuit converter DCS800 D1...D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Armature circuit converter DCS800 D5...D7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rebuild system DCR800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
16
17
17
18
19
Mechanical installation
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the converter module D6 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the converter module D7 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
22
22
22
22
22
23
24
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aspects of fusing for the armature-circuit and field supplies of DC drives . . . . . . . . . . . . . . .
25
25
25
25
28
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
12
Semiconductor type F1 fuses and fuse holders for AC and DC power lines . . . . . . . . . . . . .
Fuses F3.x and fuse holders for field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-phase Transformer T3 for field supply to match voltage levels . . . . . . . . . . . . . . . . .
Single-phase Commutating reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary transformer T2 for electronic system / fan supply . . . . . . . . . . . . . . . . . . . . . . . . . .
Residual current detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three-phase filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converters D1...D4 drive configuration using ’on board’ field exciter . . . . . . . . . . . . . . . . . . . . . . .
Converters D5 drive configuration using ’FEX-425-Int’ field exciter . . . . . . . . . . . . . . . . . . . . . . . .
Converters D5...D7 drive configuration using ’external’ field exciter DCF803, DCF804 . . . . . . . . .
START, STOP and E-STOP control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive configuration with reduced components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power section cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains cable (AC line cable) short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-sectional areas - Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DCS800 panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
31
32
32
32
32
33
38
39
40
41
42
44
46
46
47
48
48
49
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location R-Extension and Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Board Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse encoder receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the signal and control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSL Link Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
52
52
52
52
54
55
56
58
58
59
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan replacement (D6, D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
63
63
64
64
64
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
13
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Layout of the control board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Watchdog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seven segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital and analogue I/O connection of the SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface Board SDCS-COM-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DDCS Branching unit NDBU-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSL Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital I/O board SDCS-IOB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analogue and encoder I/O board SDCS-IOB-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Board SDCS-POW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface Board SDCS-PIN-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Armature circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Galvanic isolation - T90, A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC-DC transducer A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer T90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
65
67
68
68
69
69
69
69
70
70
72
73
76
78
79
81
83
84
84
85
85
86
86
88
92
94
95
Dimensional drawings
Module D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Module D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Module D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Module D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Module D5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Module D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Module D7 left-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Module D7 right-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuses installed inside the converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Accessories
DCF803-0035 and FEX 425 internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DCS LINK communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
106
106
106
107
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
RS232-Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Fuses and fuse holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Line chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Line chokes type ND 01...ND 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Line chokes type ND 07...ND 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Line chokes type ND 401...ND 413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Autotransformer T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Line choke L3 for SDCS-FEX-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Supply transformer T2 for electronics and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Optical cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
15
The DCS800
What this chapter contains
This chapter describes briefly the operating principle and construction of the drive in
short.
The DCS800
The DCS800 size D1...D7 are intended for controlling DC motors.
Size D1...D4
20...1000 A
Size D5
900...2000 A
Size D6
1900...3000 A
Size D7
2050...5200
The DCS800
3ADW000194R0201 DCS800 Hardware Manual e b
16
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. DCS800-S012005). The optional selections are given thereafter, on the name plate by plus code.
The main selections are described below. Not all selections are available for all
types.
Type code D C S 8 0 0 - A A X - Y Y Y Y - Z Z - plus code
A X
Y
Z B
Position
Position
Plus code
Product series
DCS800
A
Type
S0 = Converter module IP00
R0 = Rebuild system
E0 = Panel solution
A0 = Enclosed converter
X
Bridge type
1=
2=
Y
Rated current
YYYY = Rated current (e.g. 0025 = 25 amps)
ZZ
Rated voltage
(nominal rating in bold)
04 =
05 =
06 =
07 =
08 =
10 =
12 =
400 V
500 V
600 V
690 V
790 V
990 V
1200 V
B
Power connection
- =
L=
R=
Standard D1...D6
Left side D7
Right side D7
+S163
+0S163
0=
A=
with internal field exciter (only D5)
without internal field exciter (only D1...D4)
+S171
+S172
+S173
Standard
230 V / 1-ph
400 V / 500 V / 790 V at D6 = 400-500 V / 3-ph
600 V / 690 V
at D6 = 600-690 V / 3-ph
115 V (only D4)
400-500 V; D6 converter
600-690 V; D6 converter
+S199
+0S199
SDCS-DSL board
no SDCS-DSL board
Control panel
0J400
no control panel
Fieldbus
K...
I/O and DDCS
L...
Internal field exciter
configuration
Fan voltage
SDCS-DSL board
Single bridge 2-Q
Double bridge 4-Q
+ plug-in options
The DCS800
3ADW000194R0201 DCS800 Hardware Manual e b
PC +
-NDPA-02
(PCMCIA)
-NDPC-12
-NISA-03 (ISA)
DriveWindow
Master/
Follower
NDBU95
3ADW000194R0201 DCS800 Hardware Manual e b
NDBU95
CoDeSys
DWL
RS232
3
5
IOB-3
DCS link
T
T
twisted pair
L1
M
K1
M
Legend
K3
T3
F3
Power
supply
to field
7.1
DCS8_sys_ovw_a.dsf
- detailed description see chapter 7.1
CON x - short designation of components
digital input / output
analogue input / output
alternative
* see Technical Data
K5
On Board FEX PIN 4
8
7
X7
Q1
F1
DCF 803 / 804
8
IOB-2x
8
X6
X53
PIN-4
230 V (115V)
EMC filter
Earth-fault monitor
Three-phase field supply
PC +
3
X5
DSL
DSL
X51X52
24V-
X10
4
X11
X4
Slot 3
X34
Slot 4
Slot 2
X3
X1
Memory Card
X20
Advant
control
Ch0
X2
RDIO
RAIO
Slot3
optical fibre
Slot2
Fieldbus
interface R...
Ch1
CON-4
F2
T2
DCS800 D1...D4
X9
Ch2
X19
Ch3
Panel
X33
PLC
Slot 1
Slot1
RJ45
Panel
CDP 312
Door
mounting
kit
500V
500V
1000V
17
Main circuit and control
Armature circuit converter DCS800 D1...D4
COM-8
optical fibre
NAMIA
The DCS800
PC +
-NDPA-02
(PCMCIA)
-NDPC-12
-NISA-03 (ISA)
DriveWindow
Master/
Follower
NDBU95
NDBU95
NAMIA
The DCS800
3ADW000194R0201 DCS800 Hardware Manual e b
CoDeSys
DWL
RS232
3
5
IOB-3
DCS link
T
T
twisted pair
M
L3
Legend
** only D5 types
* three-phase D6 and D7
Power
supply
to field
COM-8
optical fibre
7.1
DCS8_sys_ovw_a.dsf
- detailed description see chapter 7.1
CON x - short designation of components
digital input / output
analogue input / output
alternative
* see Technical Data
M
*
FEX 425 internal **
8
7
X7
PIN-41
PIN-41
K5
K3
T3
F3
DCF 803 / 804
8
IOB-2x
8
X6
X53
PIN-51
L1
K1
F1
Q1
Earth-fault monitor
EMC filter
Three-phase field supply
PC +
3
X5
DSL
DSL
X51X52
24V-
X10
4
X11
X4
Slot 3
X34
Slot 4
Slot 2
X3
X1
Memory Card
X20
Advant
control
Ch0
X2
RDIO
RAIO
Slot3
optical fibre
Slot2
X9
Ch1
CON-4
POW-1
T2
F2
DCS800 D5...D7
Fieldbus
interface R...
Ch2
X19
Ch3
X33
Panel
PLC
Slot 1
Slot1
RJ45
Panel
CDP 312
Door
mounting
kit
500V
1000V
18
Armature circuit converter DCS800 D5...D7
-NDPA-02
(PCMCIA)
-NDPC-12
-NISA-03 (ISA)
DriveWindow
PC +
Master/
Follower
NDBU95
3ADW000194R0201 DCS800 Hardware Manual e b
NDBU95
CoDeSys
DWL
RS232
3
5
IOB-3
DCS link
-
T
T
PIN-41
REB-3
PIN-41
NPSM-01
twisted pair
~
M
L1
L1
M
M
L3
Legend
K3
T3
F3
Power
supply
to field
7.1
DCS8_sys_ovw_a.dsf
- detailed description see chapter 7.1
CON x - short designation of components
digital input / output
analogue input / output
alternative
* see Technical Data
K5
FEX 425 internal
8
7
X7
REB-2
REB-1
PIN
1x
PIN-51
-
K1
Q1
K1
F1
Existing part
Q1
DCF 803 / 804
8
IOB-2x
8
X6
X53
~
POW
1
POW-1
T2
F2
EMC filter
Earth-fault monitor
Three-phase field supply
PC +
3
X5
DSL
DSL
X51X52
24V-
X10
4
X11
X4
Slot 3
X34
Slot 4
Slot 2
X3
X1
Memory Card
X20
Advant
control
Ch0
X2
RDIO
RAIO
Slot3
optical fibre
Slot2
DCR800
X9
Ch1
CON-4
Fieldbus
interface R...
Ch2
X19
Ch3
X33
Panel
PLC
Slot 1
Slot1
RJ45
Panel
CDP 312
Door
mounting
kit
500V
1000V
19
Rebuild system DCR800
COM-8
optical fibre
NAMIA
The DCS800
20
The DCS800
3ADW000194R0201 DCS800 Hardware Manual e b
21
Mechanical installation
Unpacking the unit
• open box
• take out shock dampers
• separate manual and accessories
• do not lift the drive by cover.
5
4
3
2
1
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC rating, UL, C-UL, CSA
and CE markings, a type code and a serial number, which allow individual
identification of each unit. The remaining digits complete the serial number so that
there are no two units with the same serial number.
Example labels are shown below.
Type designation label
Mechanical installation
3ADW000194R0201 DCS800 Hardware Manual e b
22
Before installation
The drive must be installed in an upright position with the cooling section facing a
wall. Check the installation site according to the requirements below. Refer to
Dimensional drawings for frame details.
Requirements for the installation site
See Technical data for the allowed operation conditions of the drive.
Wall
The wall should be as close to vertical as possible, of non-flammable material and
strong enough to carry the weight of the unit. Check that there is nothing on the wall
to inhibit the installation.
Floor
The floor/material below the installation should be non-flammable.
Free space around the unit
Required free space around the drive to enable cooling air flow, service and
maintenance see chapter Dimensional drawings.
Cabinet installation
The required distance between parallel units is five millimetres (0.2 in.) in
installations without the front cover. The cooling air entering the unit must not exceed
+40 °C (+104 °F).
Preventing cooling air recirculation
Unit above another
Prevent air recirculation inside and outside the cabinet.
HOT
Main air flow out
Air baffle plates
COOL AREA
max.+40 °C (+104 °F)
Air baffle plate
Main air flow in
Cooling w baffle.dsf
Airflow
Lead the exhaust cooling air away from the unit above.
Distances see chapter Dimensional drawings
Mechanical installation
3ADW000194R0201 DCS800 Hardware Manual e b
23
Mounting the converter module D6 inside an enclosure
50
50
~ 100
Cooling air entry
Free space around the conerter module
The cooling fan takes the air from the backside, both sides and from the area under- optimum
compromise
neath the converter module.
50
~ 100
View from: the right side
the back
the left side
Top view
air flow
air flow
A6_li_air_inlet.dsf
21.8
25
W
A6_li_air_inlet_a.dsf
352
372
312
272
175
The figure below gives an example, how the right angle
busbars can be mounted in case all cable connections
are still made at the left side of the converter module.
This results in four layers for the power cables.
A6_cable_term_busb.dsf
When mounting the right angle busbars or connecting
cables directly please make sure the correct bolts are
used. The converter module is equipped with a thread
hole at its end. Because of that the length of the
remaining threads is limited to 35 mm (see drawing
below).
max.
35mm
468.2
136
V
140
U
control cables
250
pressure
converter fan
switch
(left and right side)
do not unscrew these bolts !
125
0
0
D
75
Ø14
Cooling air outlet
To avoid circulating air inside the enclosore it is recommended to make sure the exhaust air leaves the enclosure.
In case the AC or DC connection or perhaps both of
them have to be made at the right side of the converter
module use the space behind the converter and move
the power terminals via a right angle busbar up to that
point where the final connection is most suitable. In this
case the busbars need to be fixed at the cubicle /
enclosure, not at the converter module! The figures
below give a rough example, how a right side connection can be made.
100
72.2
75
C
Power cable connection
The power cable connection is performed via Terminal
option 01 for A6. This option consists of one right
angle copper busbar. The mechanical details are
shown by the figure below.
25
electronics power supply
Cable entries
Top view
air flow
air flow
air flow
air flow
Example right side connection
Mechanical installation
3ADW000194R0201 DCS800 Hardware Manual e b
24
Mounting the converter module D7 inside an enclosure
converter fan control cables
pressure
switch
air flow
electronics power supply
Cable entries
The cable entries are existing symmetrically on both
sides. Nevertheless only the entries on the left side
should be used for cables going to the electronics
power supply (SDCS-POW-1) or the controller board
(SDCS-CON-x).
air
flo
w
air flow
Cooling air entry
The cooling fan takes the air from the backside, both
sides and from the area underneath the converter
module.
left side / (right side)
View from front
View from bottom
Free space around the conerter module
Do not place the converter module in a corner. In case
the fan cannot take the air through the bottom plate of
the enclosure non of the remaining entires has to be
blocked.
A7_re_air_inlet.dsf
>20
50
Air entry through bottom plate
Make sure the converter module gets clean air,
because there is no air filter in front of the fan at the
converter.
Cooling air outlet
To avoid circulating air inside the enclosore it is recommended to make sure the exhaust air leaves the
enclosure.
Mechanical installation
3ADW000194R0201 DCS800 Hardware Manual e b
25
Planning the electrical installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive system. Always
follow local regulations.
Note: If the recommendations given by ABB are not followed, the drive may
experience problems that the warranty does not cover.
Reference: Technical Guide - publ. no.: 3ADW000163
To which products this chapter applies
This chapter applies to the DCS800 Size D1...D7.
Options for the drive
Line reactors
for armature (DCS800) and field (DCF800) supply.
When thyristor power converters operate, the line voltage is short-circuited during
commutation from one thyristor to the next. This operation causes voltage dips in the
mains PCC (point of common coupling). For the connection of a power converter
system to the mains, one of the following configurations can be applied:
Line
PCC
(Pcc)
uk LR > 1%
Configuration A
When using the power converter, a minimum of impedance is
required to ensure proper performance of the snubber circuit. A line
reactor can be used to meet this minimum impedance requirement.
The value must therefore not drop below 1% uk (relative impedance
voltage). It should not exceed 10% uk, due to considerable voltage
drops at converter output.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
26
Configuration B
Line
If special requirements have to be met at the PCC (standards like EN
61 800-3, DC and AC drives at the same line, etc), different criteria
must be applied for selecting a line reactor. These requirements are
often defined as a voltage dip in percent of the nominal supply
voltage.
LLine
PCC
(P )
LLRcc
The combined impedance of ZLine and ZLR constitute the total series
impedance of the installation. The ratio between the line impedance
and the line reactor impedance determines the voltage dip at the
connecting point. In such cases line chokes with an impedance
around 4% are often used.
Example calculation with Uk Line=1%;
Uk LR=4%; Voltage Dip = ZLine/(ZLine+ZR)=20%. Detailed calculation
see Technical Guide.
Configuration C
Line
If an isolation transformer is used, it is possible to comply with certain
connecting conditions per Configuration B without using an additional
line reactor. The condition described in Configuration A will then
likewise be satisfied, since the uk is >1 %.
PCC
(Pcc)
Configuration C1
Line
PCC
(Pcc)
LLR
LLR
LLR
....
If 2 or more converters should be supplied by one
transformer the final configuration depends on the
number of drives in use and their power capability.
Configuration A or B has to be used which are based on
commutation chokes, if the drive system consists of any
of the converters (D1, D2, D5, D6, D7). In case only two
converters type D7 are involved no commutation chokes
are necessary because the design of these converters is
adapted to that wiring.
Netzdr_f.dsf
With reference to the power converter:
The line reactors listed in table below
• have been sized to the units nominal current
• are independent of converter's voltage classification; at some converter types the
same line choke is used up to 690 V line voltage
• are based on a duty cycle
• can be used for DCS800 as armature converter as well as field converter but
rated line choke current must be considered.
You will find further information in publication:
Technical Guide chapter: Line reactors
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
27
Line reactors L1
DCS Type
400V-690V
50/60 Hz
Line choke
Design
Line choke
Design
type for
Fig.
type for
Fig.
configur. A
configur. B
2-Q Converter
4-Q Converter
DCS800-S01-0020-04/05
DCS800-S02-0025-04/05
ND01
1
ND401
4
DCS800-S01-0045-04/05
DCS800-S02-0050-04/05
ND02
1
ND402
4
DCS800-S01-0065-04/05
DCS800-S02-0075-04/05
ND04
1
ND403
5
DCS800-S01-0090-04/05
DCS800-S02-0100-04/05
ND06
1
ND404
5
DCS800-S01-0125-04/05
DCS800-S02-0140-04/05
ND06
1
ND405
5
DCS800-S01-0180-04/05
DCS800-S02-0200-04/05
ND07
2
ND406
5
DCS800-S01-0230-04/05
DCS800-S02-0260-04/05
ND07
2
ND407
5
DCS800-S01-0290-06
DCS800-S02-0320-06
ND08
2
on request
-
DCS800-S01-0315-04/05
DCS800-S02-0350-04/05
ND09
2
ND408
5
5
DCS800-S01-0405-04/05
DCS800-S02-0450-04/05
ND10
2
ND409
DCS800-S01-0590-06
DCS800-S02-0650-06
ND13
3
on request
-
DCS800-S01-0500-04/05
DCS800-S02-0550-04/05
ND10
2
ND410
5
DCS800-S01-0610-04/05
DCS800-S02-0680-04/05
ND12
2
ND411
5
DCS800-S01-0740-04/05
DCS800-S02-0820-04/05
ND13
3
ND412
5
DCS800-S01-0900-04/05
DCS800-S02-1000-04/05
ND13
3
ND413
5
DCS800-S01-0900-06/07
DCS800-S02-0900-06/07
ND13
3
on request
-
DCS800-S01-1200-04/05
DCS800-S02-1200-04/05
ND14
3
on request
-
DCS800-S01-1500-04/05/06/07 DCS800-S02-1500-04/05/06/07
ND15
3
on request
-
DCS800-S01-2000-04/05
ND16
3
on request
-
ND16 *
3
on request
-
DCS800-S02-2000-04/05
DCS800-S01-2000-06/07
* with forced cooling (1m/s)
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
28
Aspects of fusing for the armature-circuit and field supplies of DC drives
General
Unit configuration
Protection elements such as fuses or overcurrent trips are used whenever
overcurrents cannot entirely be ruled out. In some configurations, this will entail the
following questions: firstly, at what point should which protective element be
incorporated? And secondly, in the event of what faults will the element in question
provide protection against damage?
AC supply: public mains / plant's mains
Cabinet
2
3
M
The figure shows the arrangement of the
switch-off elements in the armature-circuit
converter
.
.
.
.
.
2
For field supply
see Fig. 2.6/2
You will find further information in
publication:
Technical Guide chapter: Aspects
for fusing
Conclusion for the armature supply
In some cases standard fusing is used instead of semi-conductor fusing in order to
save money on installation. If every possible fault scenario could be ruled out, this
would be acceptable. However this is seldom the case.
In the event of a fault condition, the small amount of money saved can cause
exploding power semi-conductor or other devices and could also cause fires.
Adequate protection against short-circuit and earth fault, as depicted in the
EN50178 standard, is possible only with appropriate semiconductor fuses.
Semiconductor
fuses
Semiconductor
fuses
DCS converter
DCS converter
2-Q non-regen.
4-Q resp.
2-Q regenerative
Semiconductor
fuses
M
M
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
29
Conclusion for the field supply
Basically, similar conditions apply for both field supply and armature-circuit supply.
Depending on the power converter used (diode bridge, half-controlled bridge, fully
controlled 4-quadrant bridge), some of the fault sources may not always be
applicable. Due to special system conditions, such as supply via an autotransformer
or an isolating transformer, new protection conditions may additionally apply.
The following configurations are very often used:
In contrast to the armature-circuit supply, fuses are never used on the DC side for
the field supply, since a fuse trip might under certain circumstances lead to greater
damage e.g. (small, but long-lasting overcurrent; fuse ageing; contact problems;
etc.).
Semiconductor fuse F3.1 (super-fast acting) should be used, if conditions similar to
those for armature-circuit supply are to apply, like for example protection of the field
supply unit and the field winding.
F3.1
ND30 /
built-in
2
Configuration for field supplies
The F3.2 and F3.3 fuse types serve as line protectors and cannot protect the field
supply unit. Only pure HRC fuses or miniature circuit-breakers may be used.
Semiconductor fuses would be destroyed, for example, by the transformer’s starting
current inrush.
F3.2
F3.1
2
F3.3
F3.1
Configurations for field supplies
ND30 /
built-in
2
FF_ASP_b.dsf
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
30
Semiconductor type F1 fuses and fuse holders for AC and DC power lines
(DCS800-S01 / DCS800-S02)
The converter units are subdivided into two groups:
• Unit sizes D1, D2, D3 and D4 with rated currents up to 1000 A require external
fuses.
• In unit sizes D5, D6 and D7 with rated currents of 900 A to 5200 A, the branch
semiconductor fuses are installed internally (no additional external semiconductor
fuses are needed).
The third column of the table below assigns the AC fuse type to the converter type.
In case the converter should be equipped with DC fuses according to the hints, use
the same type of fuse as on AC side at DC side (C1, D1). Blade type fuses are used
for all the converters construction type D1...D4 except the converters
(610 A, 680 A, 740 A, 820 A, 900 A, 1000 A).
Type of converter
2-Q Converter
DCS800-S01-0020-04/05
DCS800-S01-0045-04/05
DCS800-S01-0065-04/05
DCS800-S01-0090-04/05
DCS800-S01-0125-04/05
DCS800-S01-0180-04/05
DCS800-S01-0230-04/05
DCS800-S01-0315-04/05
DCS800-S01-0405-04/05
DCS800-S01-0500-04/05
DCS800-S01-0610-04/05
DCS800-S01-0740-04/05
DCS800-S01-0900-04/05
4-Q Converter
DCS800-S02-0025-04/05
DCS800-S02-0050-04/05
DCS800-S02-0075-04/05
DCS800-S02-0100-04/05
DCS800-S02-0140-04/05
DCS800-S02-0200-04/05
DCS800-S02-0260-04/05
DCS800-S02-0350-04/05
DCS800-S02-0450-04/05
DCS800-S02-0550-04/05
DCS800-S02-0680-04/05
DCS800-S02-0820-04/05
DCS800-S02-1000-04/05
Type
Fuse holder
170M 1564
170M 1566
170M 1568
170M 1568
170M 3815
170M 3816
170M 3817
170M 5810
170M 6811
170M 6811
170M 6163
170M 6163
170M 6166
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 1 S3
OFAX 1 S3
OFAX 1 S3
OFAX 2 S3
OFAX 3 S3
OFAX 3 S3
3x 170H 3006
3x 170H 3006
3x 170H 3006
DCS800-S01-0290-06
DCS800-S01-0590-06
DCS800-S02-0320-06
DCS800-S02-0650-06
170M 5810
170M 6813
OFAX 2 S3
OFAX 3 S3
Fuses and fuse holders (details see chapter Technical Data)
Fuses F3.x and fuse holders for field supply
Depending on the protection strategy different types of fuses are to be used. The
fuses are sized according to the nominal current of the field supply device. If the field
supply unit is connected to two phases of the network, two fuses should be used; in
case the unit is connected to one phase and neutral only one fuse at the phase can
be used. Table below lists the fuse currents with respect to the table above.
The fuses can be sized according to the maximum field current. In this case take the
fuse, which fits to the rated field current levels.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
31
Field conv.
Field
current
DCF803-0035
IF ≤ 6 A
FEX-425-Int
IF ≤ 12 A
DCF803
IF ≤ 16 A
DCF804
DCF803
IF ≤ 30 A
DCF804
DCF803
IF ≤ 50 A
DCF804
Type of protection
elements
F3.1
F3.2
170M 1558 * OFAA 00 H10
170M 1559 * OFAA 00 H16
170M 1561 * OFAA 00 H25
F 3.3
10 A
16 A
25 A
170M 1564
OFAA 00 H50
50 A
170M 1565
OFAA 00 H63
63 A
Semiconduct. LV HRC type circuit breaker
type fuse for for 690 V; fuse for 500 V or
fuse holder hold. OFAX 00
690 V
type OFAX 00
* F3.1 Fuse KTK25 included in FEX-425-Int
Fuses and fuse holders for 2-phase field supply
Single-phase Transformer T3 for field supply to match voltage levels
The field supply units’ insulation voltage is higher than the rated operating voltage
(see Chapter Field supplies), thus providing an option in systems of more than 500 V
for supplying the power section of the converter directly from the mains for purposes
of armature supply, and using an autotransformer to match the field supply to its
rated voltage. Moreover, you can use the autotransformer to reduce the voltage
ripple. Different types (primary voltages of 400...500 V and of 525...690 V) with
different rated currents each are available.
Field converter type for field current Transformer
type 50/60 Hz
≤500 V; 50/60 Hz
IF
external supply
Uprim = ≤500 V
≤6A
T 3.01
DCF803-0035
≤12
A
T 3.02
FEX-425-Int
≤16 A
T 3.03
DCF803/4-0050
≤30 A
T 3.04
DCF803/4-0050
≤50 A
T 3.05
Uprim = ≤600 V
≤6A
T 3.11
DCF803-0035
≤12
A
T
3.12
FEX-425-Int
≤16 A
T 3.13
Uprim = ≤690 V
DCF803/4-0050
≤30 A
T 3.14
DCF803/4-0050
≤50 A
T 3.15
Autotransformer.dsf
T3 autotransformer
Autotransformer data (details see chapter Technical Data)
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
32
Single-phase Commutating reactor
For DCF803-0035 and FEX-425-Int field power converter with external supply must
be connected via additionally commutating reactor because of EMC considerations if
the supply has a separate mains. With DCF803/804 field power converters, it is
already installed.
Converter
≤500 V; 50/60 Hz
for field
current
IF
Reactor
DCF803-0035 (16 A)
16 A
ND 30
FEX-425-Int
>16A
*
1ph_reactor.dsf
* 3-phase operation and 3-phase line choke recommended
Commutating reactor (for more information see chapter ??)
Auxiliary transformer T2 for electronic system / fan supply
The converter unit requires various auxiliary voltages, e.g. the unit’s electronics
require 115 V/1-ph or 230 V/1-ph, the unit fans require 230 V/1-ph or 400 V/690 V/3ph, according to their size. The T2 auxiliary transformer is designed to supply the
unit’s electronic system and all the single-phase fans including the fan of the D5
converter
.
Input voltage: 380...690 V/1-ph; 50/60 Hz
Output voltage: 115/230 V/1-ph
Power:1400 VA
Residual current detection
This function detects current to ground. If needed, the analogue input AI4 of the
SDCS-IOB-3 board has to be activated, a current signal of the three phase currents
should be supplied to AI4 by a current transformer.
EMC filters
Filter in a grounded line (earthed TN or TT network)
The filters are suitable for grounded lines only, for example in public European 400 V
lines.
According to EN 61800-3 filters are not needed in insulated industrial networks with
own supply transformers. Furthermore they could cause safety risks in such floating
lines (IT networks).
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
33
According to EN 61800-3 filters are not needed in industrial zone (Second
Environment) for DCS800 drives above 100 A rated current. For rated currents
below 100 A the filter requirement is identical to Light Industry (First Environment).
Three-phase filters
EMC filters are necessary to fulfil the standard for emitted interference if a converter
shall be run at a public low voltage line, in Europe for example with 400 V between
the phases. Such lines have a grounded neutral conductor. ABB offers suitable
three-phase filters for 400 V and 25 A...600 A and 500 V filters for 440 V lines
outside Europe. The filters can be optimized for the real motor currents:
IFilter = 0.8 • IMOT max ; the factor 0.8 respects the current ripple.
Lines with 500 V to 1000 V are not public. They are local networks inside factories,
and they do not supply sensitive electronics. Therefore converters do not need EMC
filters if they shall run with 500 V and more.
Type of converter
Constr. Filter type f. y=4
type
2-Q Converter
DCS800-S01-0020-0y
DCS800-S01-0045-0y
DCS800-S01-0065-0y
DCS800-S01-0090-0y
DCS800-S01-0125-0y
DCS800-S01-0180-0y
DCS800-S01-0230-0y
DCS800-S01-0315-0y
DCS800-S01-0405-0y
DCS800-S01-0500-0y
DCS800-S01-0610-0y
DCS800-S01-0740-0y
IDC [A]
20A
45A
65A
90A
125A
180A
230A
315A
405A
500A
610A
740A
DCS800-S01-0900-0y
DCS800-S01-0900-0y
DCS800-S01-1200-0y
DCS800-S01-1500-0y
DCS800-S01-2000-0y
900A
900A
1200A
1500A
2000A
≤ 3000A
4-Q Converter
DCS800-S02-0025-0y
DCS800-S02-0050-0y
DCS800-S02-0075-0y
DCS800-S02-0100-0y
DCS800-S02-0140-0y
DCS800-S02-0200-0y
DCS800-S02-0260-0y
DCS800-S02-0350-0y
DCS800-S02-0450-0y
DCS800-S02-0550-0y
DCS800-S02-0680-0y
IDC [A]
25A
50A
75A
100A
140A
200A
260A
350A
450A
550A
680A
DCS800-S02-0820-0y
DCS800-S02-1000-0y
DCS800-S02-0900-0y
DCS800-S02-1200-0y
DCS800-S02-1500-0y
DCS800-S02-2000-0y
820A
1000A
900A
1200A
1500A
2000A
≤ 3000A
D1
D1
D1
D1
D1
D2
D2
D3
D3
D3
D4
D4
D4
D4
D5
D5
D5
D5
D6
NF3-440-25
NF3-440-50
NF3-440-64
NF3-440-80
NF3-440-110
NF3-500-320
NF3-500-320
NF3-500-320
NF3-500-600
NF3-500-600
NF3-500-600
NF3-500-600
NF3-690-1000 ➀
NF3-690-1000 ➀
NF3-690-1000 ➀
NF3-690-1000 ➀
NF3-690-1600 ➀
NF3-690-1600 ➀
NF3-690-2500 ➀
Filter type f. y= 5
NF3-500-25
NF3-500-50
NF3-500-64
NF3-500-80
NF3-500-110
NF3-500-320
NF3-500-320
NF3-500-320
NF3-500-600
NF3-500-600
NF3-500-600
NF3-500-600
NF3-690-1000 ➀
NF3-690-1000 ➀
NF3-690-1000 ➀
NF3-690-1000 ➀
NF3-690-1600 ➀
NF3-690-1600 ➀
NF3-690-2500 ➀
➀ Filter only available on request
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
34
Single-phase filters for field supply
Many field supply units are single-phase converters for up to 50 A excitation current.
They can be supplied by two of the three input phases of the armature supply
converter. Then a field supply unit does not need its own filter.
If the phase to neutral voltage shall be taken (230 V in a 400 V line) then a separate
filter is necessary. ABB offers such filters for 250 V and 6...30 A.
Converter type of
field supply unit
dc current
[A]
Filter type ➀
Umax = 250 V
DCF803-0035 *
FEX-425-Int *
8
NF1-250-8
16
NF1-250-20
DCF803-0050
50
NF1-250-55
DCF804-0050
50
NF1-250-55
➀ The filters can be optimized for the real field cur-
further filters for
12
NF1-250-12
30
NF1-250-30
rents: IFilter = IField
* single-phase operation
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
35
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
36
EMC filters
You will find further information in publication:
Technical Guide chapter:
EMC Compliant Installation and Configuration for a
Power Drive System
The paragraphs below describe selection of the electrical components in conformity with the EMC Guideline.
The aim of the EMC Guideline is, as the name implies,
to achieve electromagnetic compatibility with other
products and systems. The guideline ensures that the
emissions from the product concerned are so low that
they do not impair another product's interference immunity.
In the context of the EMC Guideline, two aspects must
be borne in mind:
•the product's interference immunity
•the product's actual emissions
The EMC Guideline expects EMC to be taken into
account when a product is being developed; however,
EMC cannot be designed in, it can only be quantitatively measured.
Note on EMC conformity
The conformity procedure is the responsibility of both
the power converter's supplier and the manufacturer of
the machine or system concerned, in proportion to their
share in expanding the electrical equipment involved.
First environment (residential area with light industry) with restricted distribution
Not applied, since general distribution sales channel excluded
Not applicable
satisfied
satisfied
Medium-voltage network
Medium-voltage network
Supply transformer for a residential
area (rating normally 1,2 MVA)
Residential area
Supply transformer for a residential
area (rating normally 1.2 MVA)
Light industry
Residential area
Earthed
neutral
Converter
M
M
Operation at public
low-voltage network
together with other
loads of all kinds.
An isolating transformer
with an earthed screen
and earthed iron core
renders mains filter and
line reactor superfluous.
Line reactor +
Y-capacitor
Converter
M
To other loads, e.g. drive systems
Mains filter
Line reactor
Line reactor
Converter
Converter
Converter
M
M
M
M
M
Operation at public
low-voltage network
together with other
loads of all kinds.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
Operation at public
low-voltage network
together with other
loads of all kinds.
To other loads which have to be protected from the system disturbances caused by
power converters (HF interference and commutation notches)
Converter
Mains filter
alternative
Line reactor
Earthed public 400-V
network with neutral
conductor
Earthed public 400-V
network with neutral
conductor
alternative
Mains filter
To other loads which have to be protected from the system disturbances caused by
power converters (HF interference and commutation notches)
To other loads, e.g. drive systems
Earthed public 400-V
network with neutral
conductor
To other loads, e.g. drive systems
Earthed
neutral
An isolating transformer
with an earthed screen
and earthed iron core
renders mains filter and
line reactor superfluous.
37
For compliance with the protection objectives of the
German EMC Act (EMVG) in systems and
machines, the following EMC standards must be satisfied:
Product Standard EN 61800-3
EMC standard for drive systems (PowerDriveSystem), interference immunity and emissions in residential areas, enterprise zones with light industry
and in industrial facilities.
This standard must be complied with in the EU for
satisfying the EMC requirements for systems and
machines!
For emitted interference, the following apply:
EN 61000-6-3
Specialised basic standard for emissions in light industry can
be satisfied with special features (mains filters, screened power
cables) in the lower rating range *(EN 50081-1).
EN 61000-6-4
Specialised basic standard for emissions in industry *(EN
50081-2)
For interference immunity, the following apply:
EN 61000-6-1
Specialised basic standard for interference immunity in residential areas *(EN 50082-1)
EN 61000-6-2
Specialised basic standard for interference immunity in industry.
If this standard is satisfied, then the EN 61000-6-1 standard is
automatically satisfied as well *(EN 50082-2).
* The generic standards are given in brackets
Second environment (industry) with restricted distribution
Not applicable
satisfied
on customer's request
satisfied
Medium-voltage network
satisfied
Medium-voltage network
Supply transformer for a
residential area (rating
normally 1.2 MVA)
Industrial zone
Standards
EN 61800-3
EN 61000-6-3
EN 61000-6-4
EN 61000-6-2
EN 61000-6-1
Classification
Converter
transformer
with earthed
Industrial zone
Converter
transformer
Earthed
neutral
M
Converter
M
Line reactor
alternative
M
M
Operation at low-voltage network together with
other loads of all kinds, apart from some kinds
of sensitive communication equipment.
M
For power converters without additional components,
the following warning
applies:
This is a product with
restricted distribution
under IEC 61800-3. This
product may cause radio
interference in residential areas; in this case, it
may be necessary for the
operator to take appropriate action (see adjacent
diagrams).
Converter
The field supply is not
depicted in this overview
diagram. For the field current cables, the same rules
apply as for the armaturecircuit cables.
alternative
Converter
alternative
M
I > 400 A
and/or
U > 500 V
To other loads, e.g. drive systems
Case-referenced EMC analysis
Line reactor
alternative
Converter
To other loads, e.g. drive systems
Mains filter
Line reactor +
Y-capacitor
iron core
(and earthed
screen where
appropriate)
Earthed 400-V network
with neutral conductor;
3~ 400 A
The following overview utilises the terminology and
indicates the action
required in accordance with
Product Standard
EN 61800-3
For the DCS 500B series,
the limit values for emitted
interference are complied
with, provided the action
indicated is carried out. This
action is based on the term
Restricted Distribution used
in the standard (meaning a
sales channel in which the
products concerned can be
placed in the stream of
commerce only by suppliers, customers or users
which individually or jointly
possess technical EMC
expertise).
M
M
Operation with separate power converter transformer. If there
are other loads at the same secondary winding, these must be
able to cope with the commutation gaps caused by the power
converter. In some cases, commutating reactors will be
required.
Legend
Screened cable
Unscreened cable with restriction
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
2
ON
V2
OUT1
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
4
3
V1
IN1
X3: 1
V6
OUT3
K6
13
F6
14
6
7
8
AI2
_ +
9
2
AI4
_
+
10 X4: 1
5 6
AI3
_ +
S1
K8
K3
4
5
K1
X96:2
EMER.
STOP
K15
2
1
K15
6
0V
7
9
10
0V
e.g. Pressure
switch at D7
module
8
AO1 AO2 IACT
2
S1
1
F5
2
1
DO8
X96: 1
2
F8
2
1
K8
X6: 1
K6
2
K1
3
4
6
2
S1
1
5
K20
7
K21
8
9
10
0V
2
1
3
5
4
K11
2
3
4
5
6
7
+
_
T
the polarities are shown for motoring
K10
X7: 1
K8
1
X2: 1
M
~
2
3
2
4
3
8
0V
T
X5: 1...10
depending on the unit type
an other configuration is possible
X2: 4
690V
660V
600V
575V
F2
525V
500V
450V
415V
400V
380V
DO1 DO2 DO3 DO4 DO5 DO6 DO7
Power supply
(POW-1)
2
115V
X99: 1
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V
Control board (CON-4)
K11
+10V -10V
3
0V
X2:5
X2:4
if there are intermediate terminals
5
K21
K10
Communication
board (COM-8x)
AI1
_ +
V5
AITAC
_ +
K20
K21
IN3
X33
K20
START
K1
STOP
OFF
X96:1
F7
T2
230V
F1
+
L1
K1
3
V1
4
M
D1
_
+
X1: 5
3
_
K6
F6
E
3
5
U
2
1
2
W
M
3~
V
4
3
4
6
5
6
I> I> I>
1
L1 L2 L3
DCS8_ans_1_1.dsf
'on board' field exciter
Voltage levels
see description
W1 PE
6
5
L3
DCS800
Converter
module
C1
U1
2
1
C
L2
L1
A
L1 N
14
13
38
Converters D1...D4 drive configuration using ’on board’ field exciter
Wiring the drive according to this diagram offers the highest degree of standard
monitoring functions done by the drive.
3ADW000194R0201 DCS800 Hardware Manual e b
2
V2
OUT1
4
3
V1
IN1
X3: 1
V6
OUT3
K6
13
F6
14
6
7
8
AI2
_ +
9
2
AI4
_
+
10 X4: 1
5 6
AI3
_ +
S1
K8
K3
4
5
K1
X96:2
X96:1
EMER.
STOP
K15
2
1
K15
6
0V
7
9
10
0V
e.g. Pressure
switch at D7
module
8
AO1 AO2 IACT
2
S1
1
F5
2
1
DO8
X96: 1
2
F8
2
1
K8
X6: 1
K6
2
K1
3
4
6
2
S1
1
5
K20
7
K21
8
9
10
0V
2
1
5
4
3
K11
2
3
4
5
6
7
+
_
T
the polarities are shown for motoring
K10
X7: 1
M
~
2
1
X2: 1
K8
2
4
3
3
8
0V
T
X5: 1...10
depending on the unit type
an other configuration is possible
X2: 4
690V
660V
600V
575V
F2
525V
500V
450V
415V
400V
380V
DO1 DO2 DO3 DO4 DO5 DO6 DO7
Power supply
(POW-1)
2
115V
X99: 1
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V
Control board (CON-4)
K11
+10V -10V
3
0V
X2:5
X2:4
if there are intermediate terminals
5
K21
K10
Communication
board (COM-8x)
AI1
_ +
V5
AITAC
_ +
K20
K21
IN3
X33
K20
START
ON
K1
STOP
OFF
F7
230V
T2
+
L1
K1
F1
V1
4
3
M
D1
_
D
2
1
L1 N
T3
7
4
3
365V
350V
265V
250V
90V
60V
30V
500V
460V
415V
400V
+
X1: 5
3
_
Field exciter unit
FEX-425-Int
X1: 1
L3
K3
F3
Voltage levels
see description
W1 PE
6
5
L3
DCS800
Converter
module
C1
U1
2
1
C
L2
L1
A
L1 N
3
5
U
2
1
2
W
M
3~
V
4
3
4
6
5
6
I> I> I>
1
DCS8_ans_1_2.dsf
K6
F6
E
L1 L2 L3
14
13
39
Converters D5 drive configuration using ’FEX-425-Int’ field exciter
Wiring the drive according to this diagram gives the most flexibility and offers the
highest degree of standard monitoring functions done by the drive. Field converters
FEX-425-Int are equipped with their own synchronization and can be supplied from
an independent net. For drives up to 500 V mains voltage FEX-425-Int can be
supplied internally (3-phase).
Planning the electrical installation
2
V2
OUT1
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
4
3
V1
IN1
X3: 1
V6
OUT3
K6
13
F6
14
6
7
8
AI2
_ +
9
2
AI4
_
+
10 X4: 1
5 6
AI3
_ +
S1
K8
K3
4
5
K1
X96:2
EMER.
STOP
K15
2
1
K15
6
0V
7
9
10
0V
e.g. Pressure
switch at D7
module
8
AO1 AO2 IACT
2
S1
1
F5
2
1
DO8
X96: 1
2
F8
2
1
K8
X6: 1
K6
2
K1
3
4
6
2
S1
1
5
K20
7
K21
8
9
10
0V
2
1
3
5
4
K11
2
3
4
5
6
7
_
T
+
the polarities are shown for motoring
K10
X7: 1
K8
1
X2: 1
M
~
2
3
2
4
3
8
0V
T
X5: 1...10
depending on the unit type
an other configuration is possible
X2: 4
690V
660V
600V
575V
F2
525V
500V
450V
415V
400V
380V
DO1 DO2 DO3 DO4 DO5 DO6 DO7
Power supply
(POW-1)
2
115V
X99: 1
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V
Control board (CON-4)
K11
+10V -10V
3
0V
X2:5
X2:4
if there are intermediate terminals
5
K21
K10
Communication
board (COM-8x)
AI1
_ +
V5
AITAC
_ +
K20
K21
IN3
X33
K20
START
ON
K1
STOP
OFF
X96:1
F7
T2
230V
F1
+
L1
K1
V1
4
3
M
D1
_
D
2
1
L1 N
T3
7
4
3
365V
350V
265V
250V
90V
60V
30V
500V
460V
415V
400V
+
X1: 5
3
_
Field exciter unit
DCS803
DCS804
X1: 1
L3
K3
F3
Voltage levels
see description
W1 PE
6
5
L3
DCS800
Converter
module
C1
U1
2
1
C
L2
L1
A
L1 N
3
5
U
2
1
2
W
M
3~
V
4
3
4
6
5
6
I> I> I>
1
DCS8_ans_1_3.dsf
K6
F6
E
L1 L2 L3
14
13
40
Converters D5...D7 drive configuration using ’external’ field exciter
DCF803, DCF804
Wiring the drive according to this diagram gives the most flexibility and offers the
highest degree of standard monitoring functions done by the drive. Field converters
DCF803 / DCF804 are equipped with their own synchronization and can be supplied
from an independent net. DCF803-0035 can be supplied wit 3-phase aux. supply.
41
START, STOP and E-STOP control
The relay logic can be split into three parts:
a: Generation of the ON/OFF and START/STOP command:
The commands represented by K20 and K21 (latching interface relay) can be e.g. generated by a
PLC and transferred to the terminals of the converter either by relays, using galvanic isolation or
directly via 24V signals. There is no need to use hardwired signals. These commands can be as well
transferred via serial communucation. Even a mixed solution can be realized by selecting different
possibilities for the one or the other signal (see parameter group 11).
MCW (7.01)
ON
RUN
RESET
PC tool or panel
ON
RUN
RESET
USED MCW
7.04
used
Main Control Word
HW I/O
ON
RUN
RESET
local /
remote
command
location (10.01)
gen_ctrl_cmd.dsf
b: Generation of control and monitoring signals:
The main contactor K1 for the armature circuit is controlled by a dry contact (DO 8) located on the
SDCS-PIN-4, Status of fans and fans klixon can be monitored by means of fans ack signals:
MotFanAck (10.06) and ConvFanAck (10.20).
c: OFF2, OFF3 Stop function:
Beside ON/OFF and START/STOP the drive is equipped with two additional stop functions OFF2 and
OFF3 according Profibus standard. OFF3 is a scalable stop function (rampstop, max torque stop,
dynamic braking …) to perform stop category 1. This function should be connected to the E-STOP
button without any time delay. In case of ramp stop selection the K 15 timer relay must be set longer
than EStopRamp (22.04). For COAST selection the drive opens the main contactor immediately.
OFF2 switches off DC current as fast as possible and prepares the drive for losing main contactor or
mains supply. For a normal DC motor load the time to switch OFF the DC current is below 20 ms. This
function should be connected to all signals and safety functions opening the main contactor. This
function is important for 4-quadrant drives. Do not open main contactor during regenerative current.
The correct sequence is
1. switch off regenerative current
2. then open the main contactor
In case of E-STOP is hit, the information is transferred to the converter via digital input 5. In case of
(rampstop, or max torque selection) the converter will decelerate the motor and then open main
contactor.
If the drive has not finished the function within the K15 timer setting, the drive must get the command
to switch OFF the current via K16. After K16 timer set has elapsed the main contactor is opened
independent of the drives status.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
42
E-STOP
K16
ELEC.
DISCONN.
speed
1
EMER.
STOP
S1
Timer K15
K15
2
K15
Timer K16
K16
Block current control
K1 main contactor
CON-2
DIx X6:9
K15
E-Stop ramp
Coast
Stop-Mode.dsf
E-Stop reaction
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
3ADW000194R0201 DCS800 Hardware Manual e b
2
3
4
AITAC
_ +
6
7
8
AI2
_ +
S1
9
2
AI4
_
+
10 X4: 1
4 5
AI3
_ +
if there are intermediate terminals
5
AI1
_ +
K21
K20
K21
3
0V
4
5
+10V -10V
6
0V
7
8
9
AO1 AO2 IACT
10
0V
F5
2
1
DO8
X96: 1
2
F8
2
1
X6: 1
2
K1
3
4
5
6
K20
7
K21
8
9
2
X7: 1
2
3
4
X2: 1
5
6
7
8
0V
T
_
+
the polarities are shown for motor operation
10
0V
5
M
~
2
3
T
X5: 1...10
depending on the unit type
another configuration is possible
X2: 4
DO1 DO2 DO3 DO4 DO5 DO6 DO7
Power supply
(PIN-4)
X99: 1
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V
Control board (CON-4)
K1
X96:2
X96:1
2
1
MP
+
L1
K1
F1
C1
U1
2
1
W1 PE
6
5
L3
M
D1
_
DCS800
Converter
module
V1
4
3
L2
400V 50Hz
L1
+
X1: 5
3
D5:
FEX-425-Int field exciter, supplied internal
* D1-D4: On board field exciter (PIN-4)
U
2
I>
1
5
V
W
M
3~
4
6
I> I>
3
DCS8_ans_2.dsf
_
(PIN-4) On board
or
FEX-425-Int (D5)
* Field exciter unit
F6
Selection of components: The wiring diagram is valid for a DCS800 converter construction type D1...D4 ≤ 525 V and D5
≤ 500 V. The ’on board’ field exciter (D1...D4) can be used at line voltages up to 525 V and will give field currents up to 6 /
15 / 20 / 25 A. For higher field currents, use the next larger field supply units DCF803/804 or a 3-phase field supply DCS800.
X3: 1
K20
START
ON
K1
STOP
OFF
F7
L1
Aux. supply
14
13
43
Drive configuration with reduced components
Converters D1...D4 (400...500V) using ’on board’ field exciters
Converters D5 (400...500V) using FEX-425-Int field exciter
Wiring the drive according to this diagram gives the same control performance, but a lower degree of
flexibility. Dynamic Braking keeps the main contactor K1 in state ON during braking.
Planning the electrical installation
44
Power section cooling
Fan assignment for DCS800
Converter type
Model
Configuration
Fan type
DCS800-S0x-0045-y1 ...
DCS800-S0x-00140-y1
D1
1
2x CN2B2
DCS800-S0x-0180-y1 ...
DCS800-S0x-0260-y1
D2
1
2x CN2B2
DCS800-S0x-0315-y1 ...
DCS800-S0x-0350-y1
D3
1
2x CN2B2
DCS800-S0x-0405-y1 ...
DCS800-S0x-0550-y1
D3
2
4x CN2B2
DCS800-S0x-0610-y1 ...
DCS800-S0x-0820-y1
D4
3
1x W2E200 (230 V)
DCS800-S0x-0610-y1 ...
DCS800-S0x-0820-y1
D4
Pluscode E171
3
1x W2E200 (115 V)
DCS800-S0x-0900-y1 ...
DCS800-S0x-1000-y1
D4
3
1x W2E250 (230 V)
DCS800-S0x-0900-y1 ...
DCS800-S0x-1000-y1
D4
Pluscode E171
3
1x W2E250 (115 V)
DCS800-S0x-0900-y1 ...
DCS800-S0x-2000-y1
D5
4
D2E 160
DCS800-S0x-1900-y4/5/8 ...
DCS800-S0x-3000-y4/5/8
D6
5
GR31M
400...500 V
DCS800-S0x-1900-y6/7 ...
DCS800-S0x-3000-y6/7
D6
5
GR31M
500...690 V
DCS800-S0x-3300-y1...
DCS800-S0x-5200-y1
D7
5
GR35C
400 V / 690 V
Fan Data for DCS800
Fan
CN2B2
W2E200
W2E 200
W2E 250 W2E 250
Rated voltage [V]
115; 1~
230; 1~
115; 1~
115; 1~
230; 1~
Tolerance [%]
±10
+6/-10
+6/-10
±10
+6/-10
Frequency [Hz]
50
60
50
60
50
60
50 60 50 60
Power consumption [W]
16
13
64
80
64
80
120 165 135 185
Current consumpt. [A]
0.2 0.17 0.29 0.35
0.6
0.7
1.06 1.44 0.59 0.82
Blocking current [A]
< 0.3 < 0.26 < 0.7 < 0,8 < 1.5
< 1.8 < 1.8 < 1.8 < 0.9 < 0.9
Air flow [m3/h] freely blowing
156 180 925 1030 925
1030 1835 1940 1860 1975
Air flow [m3/h]
at working point
Max. ambient temperature [° C]
< 60
< 75
< 75
60
60
Useful lifetime of grease
appr.
appr.
appr. 45000h/60°
appr.
appr.
40000 h/60° 45000 h/60°
40000 h
40000 h
Protection
Impedance
Temperatur detector: internal connected
➀
➀ Increased losses due to increased current with a blocked rotor will not result in a winding temperature, higher than permissible for the insulation class being involved.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
45
Fan
D2E 160
Rated voltage [V]
230; 1~
GR31M
380... 500 V
400...450 ∆
450...500
Tolerance [%]
Frequency [Hz]
Power consumption [W]
±10
50
60
653 860
Current consumpt. [A]
2.50
Blocking current [A]
3.75
Air flow [m3/h] freely blowing
Air flow [m3/h]
at working point
400...500 ∆
±10
±10
50
60
800 ∆
700
3.4
4.5
800 750
2.5 A 3.2 A
GR31M
525... 690 V
500...690 500...690
500
∆
1340 ∆
50
800
60
1200
1.45 ∆
0.91
2.0 ∆
0.9
1.2
at 450 V ∆
8.5
at 500 V ∆
8.5
at 690 V
400...500 ∆
600...690
+5/-10
50
±10
60
2900 ∆
2200
3600 ∆
3300
6.5 ∆
2.3
4.9 ∆
3.0
at 500 V ∆ at 400 V ∆ at 400 V ∆
8.5
>25
>30
4.4
-
-
1500
1.26 A
(450V ∆)
Max. ambient temperature [° C]
Useful lifetime of grease
Protection
GR35C
400 / 690 V
1600
1.6 A
(500V ∆)
1500
0.7 A
(690V )
1600
1.65 A
(500V ∆)
4200
3.6 A
(400V ∆)
4250
4.1 A
(400V ∆)
< 55
appr. 30000 h/40°
Temperatur detector: UN ≤ 230 V~; IN ≤ 2.5 A~
Fan connection for DCS800
|-------------------------------------- Terminals on top of converter housing --------------------------------------|
N
3
4
5
either 230 Vac
or 115 Vac
3
4
5
X99: 1
2
3
4
5
X99: 1
2
3
4
5
X99: 1
2
3
4
5
X99: 1
2
L
N
M
~
M55
M
~
M
~
M56
M55
M
~
N
2
L
L
X99: 1
M
~
3
4
5
X2: 1
M55
2 3
N
4
TW TW
5
6
gray
2
gray
L
X99: 1
115 Vac
brown
white
blue
white
black
5
green/yellow
4
N
3
L
115 Vac
230 Vac
2
N
X99: 1
L
L
230 Vac
N
Converter housing
U1
V1
W1
U2 V2 W2 PE TK TK
M
~
M
~
M56
at
Fan_con_c.dsf
Connection
U1-W2
V1-U2
W1-V2
U2-V2-W2
M
~
M57
Configuration 1
M
~
M58
Configuration 2
Configuration 3
Configuration 4
Configuration 5
Monitoring the DCS800 power section
a.The size D1...D5 power section is likewise monitored by an electrically isolated
PTC thermistor detector, which is installed on the heat sink in an isolated
configuration. Evaluation of the resistance and the protection effect correspond to
max. temperature of type code.
b.The size D6 and D7 power section isolated PTC thermistor is used for air entry
temperature. The detector thus measures the power section’s radiated heat and any
changes in the cooling air temperature and volume. Since the cooling air volume can
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
46
only be detected indirectly, a differential-pressure switch has been additionally
installed at the unit’s housing, always located close to the power terminals.
The resistance change proportional to the temperature is acquired and evaluated in
the unit’s software. If the temperature rises above the preset value, then first an
alarm will be signaled, and - if the temperature continues to rise - an error message.
The value to be set for this parameter must not be more than 5 degrees above the
permissible ambient temperature.
The differential-pressure switch compares the pressure inside the unit with the
normal atmospheric pressure. If the fan has been switched on and the unit door
closed (and no unit casings have been removed), the pressure switch will signal
“Cooling conditions ok”, which means the drive may be enabled. There is no need to
set any specific differential pressure (recommendation: center setting).
Thermal overload and short-circuit protection
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive.
Mains cable (AC line cable) short-circuit protection
Always protect the input cable with fuses. Size the fuses according to local safety
regulations, appropriate input voltage and the rated current of the drive (see chapter
Technical Data).
High-speed semiconductor fuses provide short-circuit protection, but don’t provide
thermal overload protection.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
47
Cross-sectional areas - Tightening torques
Recommended cross-sectional area to DINVDE 0276-1000 and DINVDE 0100-540
(PE) trefoil arrangement, up to 50°C ambient temperature.
Converter type
C1, D1 (AM1, KM1)
U1, V1, W1(AK1, AK3, AK5)
(2.)
IDC
[A-]
[mm²]
[mm²]
Iv
[A~]
[mm²]
[mm²]
DCS800-S0x-0050-xx
50
1 x 10
-
41
1x
6
-
1x 6
1 x M6
DCS800-S0x-0075-xx
75
1 x 25
-
61
1 x 25
-
1x 16
1 x M6
6
DCS800-S0x-0100-xx
100
1 x 25
-
82
1 x 25
-
1x 16
1 x M6
6
DCS800-S0x-0140-xx
140
1 x 35
-
114
1 x 35
-
1x 16
1 x M6
6
DCS800-S0x-0200-xx
200
2 x 35
1 x 95
163
2 x 25
1 x 95
1x 25
1 x M8
13
DCS800-S0x-0260-xx
260
2 x 35
1 x 95
204
2 x 25
1 x 95
1x 25
1 x M8
13
DCS800-S0x-0???-xx
270
2 x 35
1 x 95
220
2 x 25
1 x 95
1x 25
1 x M8
13
DCS800-S0x-0350-xx
350
2 x 70
-
286
2 x 50
1x 50
1 x M8
13
DCS800-S0x-0450-xx
450
2x
95
-
367
2 x 95
-
1x 50
1 x M10
25
DCS800-S0x-0550-xx
550
2x
95
-
424
2 x 95
-
1x 50
1 x M10
25
DCS800-S0x-0680-xx
680
2 x 120
-
555
2 x 120
-
1x120
1 x M12
50
DCS800-S0x-0820-xx
820
2 x 150
-
669
2 x 120
-
1x120
1 x M12
50
DCS800-S0x-0900-6/7
900
4x
3 x 150
734
4 x 70
3 x 95
1x150
2 x M12
50
DCS800-S0x-1000-xx
1000
2 x 185
-
816
2 x 150
-
1x150
1 x M12
50
95
1
PE
1
(2.)
[mm²]
[Nm]
6
DCS800-S0x-1200-xx
1200
4 x 120
-
979
4 x 95
3 x 120
1x185
2 x M12
50
DCS800-S0x-1500-xx
1500
4 x 185
-
1224
4 x 150
-
2x150
2 x M12
50
-
2x240
2 x M12
50
3x120
4 x M12
50
3x120
4 x M12
50
DCS800-S0x-2000-xx
2000
8 x 120
6 x 185
1632
4 x 240
DCS800-S0x-1900-xx ➁
1900
8 x 120
6 x 185
1550
4 x 240
DCS800-S0x-2050-xx ➁
2050
8 x 120
6 x 185
1673
6 x 120
5 x 150
DCS800-S0x-2500-xx ➁
2500
7 x 185
-
2040
8 x 120
6 x 185
4x120
4 x M12
50
DCS800-S0x-2600-xx
2600
7 x 185
-
2122
8 x 120
6 x 185
4x120
4 x M12
50
DCS800-S0x-3000-xx ➁
3000
8 x 185
-
2448
7 x 185
-
4x150
4 x M12
50
DCS800-S0x-3300-xx
3300
8 x 185
-
2693
7 x 185
-
4x150
4 x M12
50
DCS800-S0x-4000-xx
4000
7 x 300
-
3264
8 x 240
-
4x240
4 x M12
50
DCS800-S0x-4800-xx ➀
4800
8 x 300
-
3876
6 x 300
-
3x300
4 x M12
50
DCS800-S0x-5200-xx ➀
5200
8 x 300
-
4202
6 x 300
-
3x300
4 x M12
50
➀Reduced ambient temperature 40°C
➁Option for more flexible cable connection available
You will find instructions on how to calculate the PE conductor’s cross-sectional area
in VDE 0100 or in equivalent national standards. We would remind you that power
converters may have a current-limiting effect.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
48
Selecting the control cables
All control cables except 220 V or 115 V must be shielded.
Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables,
Finland or BELDEN type, USA) for analogue signals. This type of cable is
recommended for the pulse encoder signals also. Employ one individually shielded
pair for each signal. Do not use common return for different analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (Figure b) is also usable.
a
A double-shielded twisted
pair cable
b
A single-shielded twisted
multipair cable
Run analogue and digital signals in separate, shielded cables.
Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals be run as twisted pairs.
! Never mix 24 VDC and 115/230 VAC signals in the same cable.
DCS800 panel cable
The cable connection of the DCS800 panel to the drive must not exceed 3 meters
(10 ft). The cable type tested and approved by ABB is used in control panel option
kits.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
49
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either nonconductive or conductive but not connected to the protective earth.
To fulfill this requirement, the connection of a thermistor (and other similar
components) to the inputs of the drive can be implemented by three alternate ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
50
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
51
Electrical installation
What this chapter contains
This chapter describes the electrical installation procedure of the drive.
WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive was already connected to the mains, wait for 5 min.
after disconnecting mains power.
Reference: Technical Guide - publ. no.: 3ADW000163
Checking the insulation of the assembly
Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage
tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the
drive. Check the insulation of the assembly as follows.
WARNING! Check the insulation before connecting the drive to the mains. Make
sure that the drive is disconnected from the mains (input power).
1. Check that the motor cable is disconnected from the drive output terminals C1,
D1, F+ and F-.
2. Measure the insulation resistances of the motor cable and the motor between
each circuit (C1, D1) or (F+, F-) and the Protective Earth by using a measuring
voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm.
C1, D1
M
ohm
F+, FPE
ohm
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
52
IT (ungrounded) systems
Don’t use EMC filters.
The screen winding of dedicated transformers must be grounded.
For installation without low voltage switch (e.g. contacter, air-circuit-breaker) use
overvoltage protection.
The voltage shift of isolated supply must be limited of a range of an earth fault.
Supply voltage
Check supply voltages of:
Aux
X99
Fan
Terminals
AC voltage for field circuit
U1, V1, W1 (if used)
AC voltage for armature circuit
U1, V1, W1
Connecting the power cables
Grounding and sreening of power cables see manual Technical Guide, see
Reference
Cross sectional areas and tightening torques of power cable see chapter Planning
the electrical installation
Location R-Extension and Interface Modules
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
53
Connect the signal cables as described below. Tighten the screws to secure the
connection.
DCS800
Panel connector
X33:
SLOT 1
R IO Extension module
or
R-Fieldbus module
SLOT 2
R IO Extension module
Interface connector
X2: SDCS-IOB-3
X1: SDCS-IOB-2
SLOT 3
R IO Extension module
or
R DDCS interface
board
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
54
I/O Board Configuration
In-/output signals
The converter can be connected in four different ways to a control unit via analogue/
digital signals. Only one of the four choices can be used at the same time. .
SDCS-CON-4
SDCS-CON-4
X2:
X1:
X2:
X1:
X3:
X4:
X6:
X5:
X3:
X7:
X4:
X5:
X3: X1:
SDCS-IOB-2
I/O´s via SDCS-CON-4
I/O´s via SDCS-CON-4 and SDCS-IOB-2
Analogue I/O´s:
Digital I/O´s:
Encoder input:
Analogue I/O´s:
digital I/O´s:
standard
not isolated
not isolated
standard
all isolated by means
of optocoupler/relay,
the signal status is
indicated by LED
SDCS-CON-4
X2:
X1:
X2:
X1:
X6:
IO_poss_b.dsf
SDCS-CON-4
X7:
X1: X2:
X1: X2:
SDCS-IOB-3
SDCS-IOB-3
X3: X1:
SDCS-IOB-2
I/O´s via SDCS-CON-4 and SDCS-IOB-3
I/O´s via SDCS-IOB-2 and SDCS-IOB-3
Analogue I/O´s:
Analogue I/O´s:
Standard + one
channel for residual
current measurement
digital I/O´s:
not isolated
encoder input:
isolated
current source for: PT100/PTC element
Standard + one
channel for residual
current measurement
digital I/O´s:
all isolated by means of
optocoupler/relay, the
signal status is
indicated by LED
current source for: PT100/PTC element
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
55
Pulse encoder connection
Connecting a pulse encoder to the DCS800 converter
The connection diagram for a pulse encoder to the electronics of a DCS converter is
quite similar, if the SDCS-CON-4 or the SDCS-IOB-3 is used. The basic difference
between these 2 boards is the galvanically isolated circuit and pulse receivers via
opto coupler on the SDCS-IOB-3 board.
Power supply for incremental encoder
SDCS-CON-4 and SDCS-IOB-3 board have jumpers to select a supply voltage. V17
LED on SDCS-IOB-3 indicates supply is OK.
Hardware configuration
Encoder supply
SDCS-CON-4
supplied by PIN-4
SDCS-CON-4
supplied by POW-1/POW-4
SDCS-IOB-3
5V
sense controlled
sense controlled
sense controlled
12 V
-
no sense
sense controlled
24 V
no sense
no sense
no sense
Sense feedback connection is recommended when power supply level for
differential pulse encoder is 5 V. The wiring is shown on figure below.
Commissioning hint
DIFFERENTIAL
A
A
B
B
Z
Z
+U
0V
= twisted
pair
Note:
X5:1
ChA+
X5:1
X5:2
ChA-
X5:2
X5:3
ChB+
X5:3
X5:4
ChB-
X5:4
X5:5
ChZ+
X5:5
X5:6
ChZ-
X5:6
X5:7
Power source
X5:10
X5:8
Sense power
X5:9
X5:9
Sense GND
X5:8
X5:10
SINGLE-ENDED
A
A
B
B
Z
Z
+U
0V
CON-4
IOB-3
X5:7
GND
CON-4
IOB-3
X5:1
ChA+
X5:1
X5:2
ChA-
X5:2
X5:3
ChB+
X5:3
X5:4
ChB-
X5:4
X5:5
ChZ+
X5:5
X5:6
ChZ-
X5:6
X5:7
Power source
X5:9
X5:9
X5:8
GND
If with a positive reference the
TACHO_PULSES signal does not
look like the illustration below, then
tracks A & must be mutually
exchanged with encoders with
inverted signals, and tracks A and B
with encoders without inverted
signals.
X5:10
X5:8
X5:10
If the drive’s direction of rotation is
correct (if necessary, correct by
exchanging the field connections), the
Tacho error message may appear
during start-up.
X5:7
IOB3x3_f.dsf
If the TACHO_PULSES signal is
missing or non-linear, the encoder’s
pulses are not being read correctly.
Possible reasons for this may be the
encoder supply, the encoder itself, or
the wiring.
65535
Forward
0
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
56
Pulse encoder receiver
Two different incremental encoder connections are available.
-differential connection; pulse encoders generating either voltage or current signals
can be used
-single-ended (push pull) connection; voltage signals
Restrictions using jumper S4 (CON-4): or S10 (IOB-3): depending on the board
Line termination via S4/S10 should not be used at 12 V or 24 V encoders, because
of the power consumption taken from the encoder. If a pulse encoder with a build in
current source is used a burden resistor of 120 Ω is activated via jumper S4/S10: 1-2
a.s.o.
Pulse encoder connection principles
single ended
open collector
n.c.
SDCS-IOB-3
e.g. CH A
X5:1
120
S10
3
2
1
6
+
X5:1
n.c.
+24V
5 10k
4
SDCS-CON-4
e.g. CH A
120
1 2 3
S4
+
+
10k
+24 V
+
X5:2
X5:2
single ended
push pull
+U
SDCS-IOB-3
e.g. CH A
X5:1
120
-U
S10
3
2
1
6
+
+U
X5:1
120
+24V
5 10k
4
SDCS-CON-4
e.g. CH A
+
X5:2
-U
R
+
1 2 3
S4
10k
+24 V
+
X5:2
R
GND
GND
In case of a single ended 5 V encoder the jumpers S4 / S10 will be set to a neutral position. To get a threshold lower than 5 V each
terminal X5:2 / X5:4 / X5:6 must be connected via a resistor R to GND according to the table below.
R
1 kΩ
1.5 Ω
2.2 kΩ
U thresh
1.2 V
1.8 V
2.3 V
Make sure the threshold is half of the supply voltage and the minimum voltage of the encoder output (saturation voltage UCE of a
transistor).
differential
CH+
X5:1
SDCS-IOB-3
e.g. CH A
120
S10
CH-
3
2
1
6
+
+24V
5 10k
4
+
X5:2
iob14_e.dsf
CON-4
IOB-3
5V
12/24 V
5V
12/24 V
differential S4
S4
S10
S10
voltage source
1-2
3=park
2-3
4-5
4-5
6=park
8-9
10-11
7-8
9=park
14-15
16-17
differential
S10
current source
1-2
7-8
13-14
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
57
The distance between pulse encoder and interface board is dependent on the
voltage drop on the connecting lines and on the output and input configuration of the
used components. If cables are used according to the table below the voltage drop
caused by the cable can be compensated by the voltage regulator.
Cable length
parallel wires for
power source & GND
Cable used
0 ... 50 m
1x 0.25 mm²
12x 0.25 mm²
50 ... 100 m
2x 0.25 mm²
12x 0.25 mm²
100 ... 150 m
3x 0.25 mm²
14x 0.25 mm²
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
58
Connecting the signal and control cables
The cables for digital signals, which are longer than 3 m and all cables for analogue
signals, must be screened. Each screen must be connected at both ends by metal
clamps or comparable means directly on clean metal surfaces, if both earthing points
belong to the same earth line. Otherwise a capacitor must be connected to earth on
one end. In the converter cubicle this kind of connection must be made directly on
the sheet metal as close as possible to the terminals and if the cable comes from
outside also on the PE bar. At the other end of the cable the screen must be well
connected with the housing of the signal emitter or receiver.
Connection of a cable
screen with the aid of
metal clamp to the metal surface of the PCB
carrier at a DCS converter
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the
grounding electrodes. Aluminium tray systems can be used to improve local
equalizing of potential.
A diagram of the cable routing is shown below.
Control cable duct
24 V 230 V
24 V
230 V
Motor cable
Drive
Power cable
Input power cable
min 200 mm (8 in.)
min 300 mm (12 in.)
Motor cable
90 °
min 500 mm (20 in.)
Control cables
Not allowed unless the 24 V
cable is insulated for 230 V or
insulated with an insulation
sleeving for 230 V.
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
Lead 24 V and 230 V
control cables in separate
ducts inside the cabinet.
59
DSL Link Wiring
DSL Link is a 800 KBaud serial communcation between:
• Drive to drive or
• Drive to Field exciter
based on CAN hardware and twisted pair cabling.
The topology of the bus must be: Bus
Switched OFF nodes can remain in the bus and do not disturb the serial
communucation.
The bus is designed for cable length up to 50 meters. A repeater with additional
hardware based on POF cable is available on request.
The function of the interface is predefined:
1 Mailbox function for peer to peer communication
2 Communication to field exciter DCF 804, DCF803 and three-phase field
supply of DCS800
3 Communication for12-pulse operation, DCS800 to DCS800
Cabling
Every bus node requires the setting of Node number.
The bus termination of twisted pair cable is performed with a pre-designed
termination resistor 120 Ohm inside Drive / field exciter.
The termination resistance of 120 Ohm is selected for typical twisted pair cable and
must be located in both ends.
Preferred cable type:
DEVICENET PUR
Supplier: Helu Kabel, Germany type 81910
•••
Node 1
Node n
CAN_H
120 ohm
1%, 1/4 W
120 ohm
1%, 1/4 W
CAN_L
CAN_Bus_termination.dsf
The bus must be isolated but can be ground terminated at one end only.
Example of two DCS800 D5 converters with FEX-425-Int internal field supply.
DCS800 D5 Converter
FEX-425-Int
X3
SDCS-DSL
X51
Set bus
termination ON
DCS800 D5 Converter
X52
Termination OFF
SDCS-DSL
X51
X52
Termination OFF
FEX-425-Int
X3
Set bus
termination ON
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
60
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
61
Installation checklist
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. (See Mechanical installation, current ratings
Ambient conditions.)
The unit is fixed properly on a vertical non-flammable wall. (See Mechanical installation.)
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the electrical
installation)
All screen terminals are checked for tightness.
All cable connections are seated properly.
ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)
The drive is grounded properly.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.
Appropriate mains (input power) fuses and disconnector are installed.
The motor connections at C1, D1 and F+, F- and their tightening torques are OK.
Proper function of E_Stop circuit and relay..
Fan power wiring connected.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Drive, motor connection box and other covers are in place.
Installation checklist
3ADW000194R0201 DCS800 Hardware Manual e b
62
Installation checklist
3ADW000194R0201 DCS800 Hardware Manual e b
63
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Reference: Service manual - publ. no.: 3ADW000195
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance
Interval
Instruction
Heatsink temperature check
and cleaning
Depends on the dustiness of
the environment (every 6 to 12
months)
See Heatsink.
Cooling fan change
Every six years
See Fan.
Maintenance
3ADW000194R0201 DCS800 Hardware Manual e b
64
Heatsink
The heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. In a “normal”
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section Fan).
2. Blow clean compressed air (not humid, no oil) from bottom to top and
simultaneously use a vacuum cleaner at the air outlet to trap the dust. Note: If
there is a risk of the dust entering adjoining equipment, perform the cleaning in
another room.
3. Replace the cooling fan.
Fan
The cooling fan lifespan of the drive is about 50 000 operating hours. The actual
lifespan depends on the drive usage and ambient temperature.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB specified spare parts.
Fan replacement (D6, D7)
Maintenance
3ADW000194R0201 DCS800 Hardware Manual e b
65
Technical data
What this chapter contains
This chapter contains the technical specifications of the drive, e.g. the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and other
markings and warranty policy.
Reference:
Hardware extension
RAIO Analog I/O Extension
Hardware extension
RDIO Digital I/O Extension
DCS800 1131 Programming target
Branching units NDBU-95
publ.no.:3AFE64484567
publ.no.:3AFE64485733
publ.no.:3ADW000199
publ.no.:3ADW000100
Environmental Conditions
System connection
Voltage, 3-phase:
Voltage deviation:
Rated frequency:
Static frequency deviation:
Environmental limit values
Permissible cooling air temperat.
- at converter module air inlet:
with rated DC current:
w. different DC curr. acc. Fig.
below:
- Options:
Relative humidity (at 5...+40°C):
Relative humidity (at 0...+5°C):
Change of the ambient temp.:
230 to 1000 V acc. to IEC 60038
±10% continuous; ±15% short-time *
50 Hz or 60 Hz
50 Hz ±2 %; 60 Hz ±2 %
Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz
df/dt:
17 % / s
* = 0.5 to 30 cycles.
Please note: Special consideration must be taken for voltage deviation in regenerative mode.
Degree of protection
Converter Module and
options (line chokes, fuse
holder,
field supply unit, etc.):
Enclosed converters:
Paint finish
Converter module:
Enclosed converter:
Size
IP 00
IP 20/21/31/41
D5
D6
D7
Vibration class D1...D4
D5...D7
Site elevation
<1000 m above M.S.L.:
>1000 m above M.S.L.:
NCS 170 4 Y015R
light grey RAL 7035
Sound pressure level LP (1 m distance)
as module
enclosed conv.
55 dBA
?? dBA
55 dBA
?? dBA
60 dBA
?? dBA
66...70 dBA,
77 dBA
depending on fan
73 dBA
78 dBA
75 dBA
73 dBA
82 dBA
80 dBA
D1
D2
D3
D4
Storage temperature:
Transport temperature:
Pollution degree (IEC 60664-1,
IEC 60439-1):
0 to +55°C
0 to +40°C
+30 to +55°C
0 to +40°C
5 to 95%, no condensation
5 to 50%, no condensation
< 0.5°C / minute
-40 to +55°C
-40 to +70°C
2
3M3
3M1
100%, without current reduction
with curr. reduct., see Fig. below
Vibration
as module
0.5 g, 5...55 Hz
1 mm, 2...9 Hz
0.3 g, 9...200 Hz
Effect of the site elevation above sea level on the converter’s load capacity
100
Effect of the ambient temperature on the converter module load capacity
110
90
100
80
90
70
80
60
50
1000
70
2000
3000
4000
5000 m
Current reduction to (%)
30
35
40
45
50
55°C
Current reduction to (%) for converter modules
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
66
Regulatory Compliance
The converter module and enclosed converter components are designed for use in industrial environments. In EEA countries,
the components fulfil the requirements of the EU directives, see table below.
European Union Directive
Manufacturer's Assurance
Harmonized Standards
Converter module
Enclosed converter
Machinery Directive
98/37/EEC
Declaration of Incorporation
EN 60204-1
EN 60204-1
93/68/EEC
[IEC 60204-1]
[IEC 60204-1]
Low Voltage Directive
73/23/EEC
Declaration of Conformity
EN 60146-1-1
EN 60204-1
93/68/EEC
[IEC 60146-1-1]
[IEC 60204-1]
EN 50178 [IEC --]
EN 60439-1
see additional
[IEC 60439-1]
IEC 60664
EMC Directive
89/336/EEC
93/68/EEC
Declaration of Conformity
EN 61800-3 ➀
[IEC 61800-3]
(Provided that all installation
instructions concerning cable
➀ in accordance with
selection, cabling and EMC filters 3ADW 000 032
or dedicated transformer are followed.)
North American Standards
In North America the system components fulfil the requirements of the table
below.
Rated supply voltage
Standards
Converter module
Enclosed converter
UL/CSA types: on request
to 600 V
UL 508 C
Power Conversion Equipment
CSA C 22.2 No. 14-95
Industrial Control Equipment,Industrial Products
Available for converter
modules including field
exciter units.Types with UL
mark:
• see UL Listingwww.ul.com / certificate no.
E196914
• or on request
>600 V to 1000 V
EN / IEC xxxxx see table
EN / IEC types: on
above.
request(for details see
Available for converter
table above
modulesincluding field
exciter units.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
EN 61800-3 ➀
[IEC 61800-3]
➀ in accordance with
3ADW 000 032/3ADW 000
091
67
Current ratings
The current ratings for the DCS800 with 50 Hz and 60 Hz supplies are given below. The symbols are
described below the table.
Power converter module currents with corresponding load cycles.
The characteristics are based on an ambient temperature of max. 40°C and an elevation of max.
1000 m a.s.l.
Unit type
IDC I
2-Q converters
400 V / 500 V
DCS800-S01-0020-04/05
DCS800-S01-0045-04/05
DCS800-S01-0065-04/05
DCS800-S01-0090-04/05
DCS800-S01-0125-04/05
DCS800-S01-0180-04/05
DCS800-S01-0230-04/05
DCS800-S01-0315-04/05
DCS800-S01-0405-04/05
DCS800-S01-0500-04/05
DCS800-S01-0610-04/05
DCS800-S01-0740-04/05
DCS800-S01-0900-04/05
DCS800-S01-1200-04/05
DCS800-S01-1500-04/05
DCS800-S01-2000-04/05
DCS800-S01-2050-05
DCS800-S01-2500-04/05
DCS800-S01-3000-04/05
DCS800-S01-3300-04/05
DCS800-S01-4000-04/05
DCS800-S01-5200-04/05
600 V / 690 V
DCS800-S01-0290-06
DCS800-S01-0590-06
DCS800-S01-0900-06/07
DCS800-S01-1500-06/07
DCS800-S01-2000-06/07
DCS800-S01-2050-06/07
DCS800-S01-2500-06/07
DCS800-S01-3000-06/07
DCS800-S01-3300-06/07
DCS800-S01-4000-06/07
DCS800-S01-4800-06/07
790 V
DCS800-S01-1900-08
DCS800-S01-2500-08
DCS800-S01-3000-08
DCS800-S01-3300-08
DCS800-S01-4000-08
DCS800-S01-4800-08
990 V
DCS800-S01-2050-10
DCS800-S01-2600-10
DCS800-S01-3300-10
DCS800-S01-4000-10
1190 V
IDC II
continuous
[A]
20
45
65
90
125
180
230
315
405
500
610
740
900
1200
1500
2000
2050
2500
3000
3300
4000
5200
100 %
15 min
IDC III
150 %
60 s
100 %
15 min
18
40
54
78
104
148
200
264
320
436
490
596
700
888
1200
1479
1550
1980
2350
2416
2977
3800
27
60
81
117
156
222
300
396
480
654
735
894
1050
1332
1800
2219
2325
2970
3525
3624
4466
5700
290
590
900
1500
2000
2050
2500
3000
3300
4000
4800
240
470
684
1200
1479
1520
1940
2530
2416
3036
3734
1900
2500
3000
3300
4000
4800
2050
2600
3300
4000
IDC IV
150 %
120 s
100 %
15 min
18
37
52
72
100
144
188
250
310
418
482
578
670
872
1156
1421
1480
1880
2220
2300
2855
3669
27
56
78
108
150
216
282
375
465
627
723
867
1005
1308
1734
2132
2220
2820
3330
3450
4283
5504
18
38
55
66
94
124
178
230
308
380
454
538
620
764
1104
1361
1450
1920
2280
2277
2795
3733
36
76
110
132
188
248
356
460
616
760
908
1076
1240
1528
2208
2722
2900
3840
4560
4554
5590
7466
360
705
1026
1800
2219
2280
2910
3795
3624
4554
5601
225
472
670
1104
1421
1450
1840
2410
2300
2900
3608
337
708
1005
1656
2132
2175
2760
3615
3450
4350
5412
205
434
594
1104
1361
1430
1880
2430
2277
2950
3700
410
868
1188
2208
2722
2860
3760
4860
4554
5900
7400
1500
1920
2500
2655
3036
3734
2250
2880
3750
3983
4554
5601
1430
1820
2400
2540
2889
3608
2145
2730
3600
3810
4334
5412
1400
1860
2400
2485
2933
3673
2800
3720
4800
4970
5866
7346
1577
2000
2551
2975
2366
3000
3827
4463
1500
2250
1900
2850
2428
3642
2878
4317
Data on request
1471
1922
2458
2918
2942
3844
4916
5836
[A]
[A]
Size
internal
field curr.
D1
6A
D2
15 A
D3
20 A
D4
25 A
D5
25 A *
D6
-
D7
-
D3
D4
-
D5
25 A *
D6
-
D7
-
D6
-
D7
-
D7
-
200 %
10 s
[A]
* as option
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
68
Unit type
IDC I
4-Q converters
400 V / 500 V
DCS800-S02-0025-04/05
DCS800-S02-0050-04/05
DCS800-S02-0075-04/05
DCS800-S02-0100-04/05
DCS800-S02-0140-04/05
DCS800-S02-0200-04/05
DCS800-S02-0260-04/05
DCS800-S02-0350-04/05
DCS800-S02-0450-04/05
DCS800-S02-0550-04/05
DCS800-S02-0680-04/05
DCS800-S02-0820-04/05
DCS800-S02-1000-04/05
DCS800-S02-1200-04/05
DCS800-S02-1500-04/05
DCS800-S02-2000-04/05
DCS800-S02-2050-05
DCS800-S02-2500-04/05
DCS800-S02-3000-04/05
DCS800-S02-3300-04/05
DCS800-S02-4000-04/05
DCS800-S02-5200-04/05
600 V / 690 V
DCS800-S02-0320-06
DCS800-S02-0650-06
DCS800-S02-0900-06/07
DCS800-S02-1500-06/07
DCS800-S02-2050-06/07
DCS800-S02-2500-06/07
DCS800-S02-3000-06/07
DCS800-S02-3300-06/07
DCS800-S02-4000-06/07
DCS800-S02-4800-06/07
790 V
DCS800-S02-1900-08
DCS800-S02-2500-08
DCS800-S02-3000-08
DCS800-S02-3300-08
DCS800-S02-4000-08
DCS800-S02-4800-08
990 V
DCS800-S02-2050-10
DCS800-S02-2600-10
DCS800-S02-3300-10
DCS800-S02-4000-10
1190 V
IDC II
continuous
[A]
25
50
75
100
140
200
260
350
450
550
680
820
1000
1200
1500
2000
2050
2500
3000
3300
4000
5200
100 %
15 min
IDC III
150 %
60 s
100 %
15 min
23
45
66
78
110
152
214
286
360
436
544
664
766
888
1200
1479
1550
2000
2330
2416
2977
3800
35
68
99
117
165
228
321
429
540
654
816
996
1149
1332
1800
2219
2325
3000
3495
3624
4466
5700
320
650
900
1500
2050
2500
3000
3300
4000
4800
256
514
684
1200
1520
1940
2270
2416
3036
3734
1900
2500
3000
3300
4000
4800
2050
2600
3300
4000
IDC IV
150 %
120 s
100 %
15 min
22
43
64
75
105
148
206
276
346
418
538
648
736
872
1156
1421
1480
1930
2250
2300
2855
3669
33
65
96
113
158
222
309
414
519
627
807
972
1104
1308
1734
2132
2220
2895
3375
3450
4283
5504
21
38
57
67
99
126
184
265
315
380
492
598
675
764
1104
1361
1450
1790
2080
2277
2795
3733
42
76
114
134
198
252
368
530
630
760
984
1196
1350
1528
2208
2722
2900
3580
4160
4554
5590
7466
384
771
1026
1800
2280
2910
3405
3624
4554
5601
246
508
670
1104
1450
1870
2190
2300
2900
3608
369
762
1005
1656
2175
2805
3285
3450
4350
5412
235
462
594
1104
1430
1740
2030
2277
2950
3700
470
924
1188
2208
2860
3480
4060
4554
5900
7400
1500
1910
2250
2655
3036
3734
2250
2865
3375
3983
4554
5601
1430
1850
2160
2540
2889
3608
2145
2775
3240
3810
4334
5412
1400
1710
2000
2485
2933
3673
2800
3420
4000
4970
5866
7346
1577
2000
2551
2975
2366
3000
3827
4463
1500
2250
1900
2850
2428
3642
2878
4317
Data on request
1471
1922
2458
2918
2942
3844
4916
5836
[A]
[A]
Size
internal
field curr.
D1
6A
D2
15 A
D3
20 A
D4
25 A
D5
25 A *
D6
-
D7
-
D3
D4
-
D5
25 A *
D6
-
D7
-
D6
-
D7
-
D7
-
200 %
10 s
[A]
* as option
Sizing
Note 1: The ratings apply at ambient temperature of 40 °C (104 °F). In lower temperatures the D5, D6,
D7 ratings are higher (except Imax).
Note 2: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is
below 40 °C (104 °F) or the drive is loaded cyclically.
Derating
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
69
Control Board SDCS-CON-4
Layout of the control board SDCS-CON-4
247
Jumper coding
X300
2
1
Jumper parking position
No filter; Normal DC Tacho
1
2
Filter for AC Tacho with rectifier
X37
Jumper parking position;
no grounding of Tacho input
H2500
D2001
Tacho input X3:4 connected with 0 V / GND
D2001
2
1
D1000
1
Tacho input 2 at X2:23 and X2:24 at
SDCS-IOB-3 / PS5311
8
7
2
1
8
7
2
1
8
7
2
1
8
7
*
*
AI2 - X3:7-8: RIN = 200 kOhm
Range -10V...0V...+10V
AI2 - X3:7-8: RIN = 250 Ohm
Range I IN = -20mA...+20mA
X20
S3 21
X17
Jumper parking position 5-6
Pull-up resistor 4.74 kOhm activated at X3:7
for PTC temperature sensor
1
2
X2
25
26
1
12 Encoder mode: differential; RC load with
11
*
10 R = 121 Ohm and C = 100 nF activated
3
2
1
3
2
1
12 Encoder mode: single ended; Pull-up resistors
11
4.75 kOhm activated
10
12 Encoder supply 5 V, sense X5:8-9 are active
11
*
10
3
2
1
12
11
10
S5 21
2
1
4
3
4
3
S121
1
X3
9
8
7
X34
1
2
S24
2
1
Jumpers shown in default position
1
2
X1
25
26
3
S4 23
X10
2
3 1
1
1
26
AI1 - X3:5-6: RIN = 250 Ohm
Range IIN = -20mA...+20mA
2
X11
X12
4
3
1
2
2
1
2
1
AI1 - X3:5-6: RIN = 200 kOhm
Range -10V...0V...+10V
*
230
4
3
30
D2100
Tacho input 1 at X3:4 and X3:1/2/3 at
SDCS-CON-4
1
1
S2 21
X9
X33
X13
1
3
2
1
3
2
1
3
2
1
3
2
1
3
2
1
9
8
*
7
9
8
7
9
8
*
7
9
8
7
9
8
*
7
9
8
7
2
1
S1 23
S38
3
2
7 1
X4
12
11
10
5
S4
1
6
1
9
X5
1
S5
2
1
4
3
1
X8
2
X6
1
X7
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8
Encoder supply 24 V, uncontrolled
Step 1: Preparation for download operation
*
Step 2: download + normal program execution
* default value
Con4_layout.dsf
Memory circuit
SDCS-CON-4 board is equipped with FlashPROM which contains the firmware plus the stored
parameters. Parameters handled by DCS800 panel or DWL, PCtool or by Serial communication
parameter service are stored immediately in the FlashPROM.
Parameters handled by cyclic serial communication (dataset table Group 90 - 92) are not stored in the
Flash PROM. They must be stored by means of ParApplSave (16.6) service.
The faultlogger entries are stored in the FlashPROM during power down (auxiliary power supply OFF).
Watchdog function
The control board has an internal watchdog. The watchdog controls the running of the control board
program. If the watchdog trips, it has the following effects:
•
•
•
•
Writing to FPROM is disabled.
Thyristor firing control is reset and disabled.
Digital outputs are forced low.
Programmable analogue outputs are reset to zero, 0V.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
70
Seven segment display
A seven segment display is located on the control board SDCS-CON-4 and it shows the state of drive.
0.7s 0.7s 0.7s
E01
E02
E03
E04
E05
E06
internal FlashPROM error (check sum)
external FlashPROM error (check sum)
RAM error
RAM error
no Firmware
watchdog error
Program is not running
Normal situation
Download firmware; S5=1-2
Request + download Firmware step 2; S5=3-4
Alarm
Fault
7seg_DCS8.dsf
Terminal description
X37: Connector is used for supply of SDCS-CON-4 from SDCS-POW-1, SDCS-POW-4, SDCS-PIN-4
supply voltage can be measured to ground.
X37:3= 48V
X37:5=24V
X37:7=15V
X37:11=-15V
X37:13=5V encoder
X37:23=5V CPU
Supply voltage monitoring
5V CPU is monitored by 4.75 V and forces CPU to reset. In parallel the CPU monitors Powerfail signal
from power supply (SDCS-PIN-4 or SDCS-POW-1).
X12: and X13: connector are used for measurement voltage, current and temperature and firing
thyristors of SDCS-PIN-51/PIN-41, SDCS-PIN-4.
see chapter Technical data
X17: and X300: are routine test connectors.
X1: and X2: are used to connect SDCS-IOB-2 and SDCS-IOB-3 board.
see chapter Technical data
X33: is used to connect DCS800 Panel. It can be connected direct via 40 mm jack or via CAT 1:1 cable
(RJ45).
X34: is used for download firmware and for DWL and IEC1131 programming connection.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
71
The RS232 interface is normally used for setting parameter in the drive via the PC Tool.
The default settings of this interface are as follows:
Signal level:
RS232 (+12V / -12V)
Data format:
UART
Message format:
Modbus-Protocol
Transmission method:
half-duplex
Baudrate:
DriveWindow Light: variable
CodeSys download: 38.4 kBaud
FDT firmware download: self-adapting
Number of Data bits:
8
Number of Stop bits:
1
Parity-Bit:
odd
X34:
Description
1
not connected
2
TxD
3
RxD
4
not connected
5
SGND Signal ground
6...9
not connected
1
5
X34:
9
6
X8: is need for SDCS-DSL-4 board which provides the serial communication interface to field exciters,
12-pulse converters, master-follower and mailbox to other converters.
X9:, X10: and X11: are used for extension IO modules and serial communication interface adapter.
For detailed description see manual Hardware extension RAIO Analog I/O Extension
Hardware extension RDIO Digital I/O Extension
DCS800 1131 Programming target
see chapter SDCS-COM-8 board
X20 (Slot 4) is used for Memory Card, see description IEC1131 Programming.
Prepared function of:
Slot 1
Slot 2
Slot 3
Slot 4
X9:
X10:
X11:
X20:
RDIO / RAIO
x
x
x
R... Fieldbus adapter
x
SDCS-COM-8
Second fieldbus RMBA
x
x
Memory Card
x
x
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
72
Digital and analogue I/O connection of the SDCS-CON-4
Resolution
[bit]
2
3
4
±90...±270 V
39k2
±30...±90 V
±8...±30 V
S1 3
5
6
7
8
12k8
1
5k
S1 6
4
GND
S2
3 4 250
5
4k75
S3 6
8
7
S3
3 4 250
Firmware
X2:
X3:1
SDCS-IOB-3
(PS5311)
SDCS-CON-4
-
ATACH2
+
8
9
ATACH
7
S1
-
1k66
+
+10V
9
10
+
X4:1
-
2
+
3
GND
4
+10V
5
-10V
6
GND (AOx)
100
7
-10...0...+10 V
Firmware
±15 V
AI2
(3.3 ms)
15 + sign
-10...0...+10 V
Firmware
±15 V
AI3
(10 ms)
15 + sign
-10...0...+10 V
Firmware
±15 V
AI4
(10 ms)
15 + sign
-10...0...+10 V
Firmware
±15V
47.5
AO1
AO2
8
11 + sign
11 + sign
9
10
-10...0...+10 V
-10...0...+10 V
-10...0...+10 V
X
GND
+/- I-act
X5:1
2
3
4
5
6
7
ChA
121 100nF 1 2 3
10k
121 100nF 4 5 6
S4
10k
121 100nF 7 8 9
10k
S4
+
ChB
ChZ
+
ChZ
GND
+
Encoder supply
-
S4
10
11
Power
2k21 221k
4k75
47nF
Firmware
Firmware
Firmware
+ Hardw.
≤ 5 mA
≤ 5 mA
≤ 5 mA 3 V -> nom.??
motor curr.
Remarks
Inputs not isolated
Impedance = 120 Ω, if selected
max. frequence ≤300 kHz
-
Sense 5 V
9
10
Power
≤ 5 mA for ext. use
≤ 5 mA e.g. refer. pot.
-
ChA
ChB
Sense 0 V
8
X6:1
S4
Remarks
±15 V
15 + sign
+10 V
-10 V
100n
Common
mode
range
AI1
(3.3 ms)
+
Scaling
by
±90...270 V ¿
±30...90 V Firmware
±8...30 V
15 + sign
ATACH1
+
-
Input/output
values
Hardware
5V
Z15
12
≤ 250 mA
≤ 200 mA
Sense lines for GND and supply to
correct voltage drops on cable (only if
5 V encoder is in use).
Input value
Signal definition by
Firmware
Remarks
5V
24 V
-
DI1
+
2
= 10 ms
DI2
3
= 10 ms
DI3
4
5
= 10 ms
= 10 ms
DI4
DI5
6
= 10 ms
DI6
7
8
= 3.3 ms
DI7
DI8
= 3.3 ms
9
5V
24 V
0...7.3 V
7.5...50 V
-> “0“ status
-> “1“ status
+24 V; 125 mA
X1:
10
X7: 1
2
Relay driver
DO1
Relay driver
DO2
3
DO3
4
Relay driver
Relay driver
5
Relay driver
DO5
6
Relay driver
DO6
7
Relay driver
DO7
8
DO4
GND
Con4_I_O.dsf
Output
value
Signal definition by
50 * mA
22 V at no
load
Firmware
Remarks
Current limit for all 7
outputs = 160 mA
Do not apply any reverse
voltages!
* short circuit protected ➀ gain can be varied in 15 steps between 1
and 4 by software parameter
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
73
Interface Board SDCS-COM-8
This board must be used together with a DCS800 to provide same serial communication DDCS options
as ACS800.
Furthermore the board is equipped with four optical channels (max. data transmission speed is 4 Mb for
each optical channel):
•
•
•
•
Channel 0 is used to communicate data from the overriding control (FCI, APC2, AC80, Nxxx-xx
(adapter modules for fieldbus), AC800M) or via adapter modules from other controllers) to the
DCS600-drive.
Channel 1 is used for DDCS I/O extension. AIMA-01 board see separate documentation.
Channel 2 (Master-Follower) is used to operate two or more drives dependent on each other.
Channel 3 is prepared to connect the PC tool for commissioning and maintenance (DriveWindow).
Connector X19 is used for CDP 312 panel as well as interface board NDPI.
148
SDCS-COM-8
D100
D200
V6
TxD
RxD
TxD
RxD
grey
blue
grey
ey
k gr
dar
e
u
l
b
86
CH 0
CH 1
RxD
TxD
grey
CH 2
RxD
dark
grey
V1
dark
grey
TxD
X19
grey
CH 3
D400
COM_8_layout.dsf
Type
optical components
Channel 0 used for
Ch 0
Ch 1
Ch 2
Ch 3
SDCS-COM-81
10 Mb
5 Mb
10 Mb
10 Mb
other interfaces
SDCS-COM-82
5 Mb
5 Mb
10 Mb
10 Mb
Fieldbus adapter
modules Nxxx-xx
Color of optical components:
5 Mb -> blue
driver current maximum 30 mA
10 Mb -> dark grey driver current maximum 50 mA
Remark:
Only channels with the same components (e.g. 10 Mb component) may be connected to
each other.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
74
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
75
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
76
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
77
DDCS Branching unit NDBU-95
DDCS Branching Unit (DBU) is used (for DCS 600/DCS800) to implement the star topology of DDCS
link. This allows a slave unit to fail or become unpowered without disabling the communication. The
NDBU receives messages from the master (PC) and sends them to all the slave units simultaneously.
Each slave unit has an individual address and only the addressed slave unit sends a reply message to
the master. It is also possible to use NDBU thus enabling peer-to-peer communication.
NDBU-95 DDCS Branching Unit has nine output channels where messages from the master are sent.
The reply message sent by one slave unit is delivered to the master and it can be delivered also to other
slaves if necessary. Several NDBU-95s can be used in parallel, in series or in any combination of these.
The maximum distance between the master and NDBU-95 as well as between two NDBU-95s, see
manual Branching units NDBU-95.
Technical specifications
Optical links:
Master channels
Slave channels
Data rate
Driving current
Monitoring
Transmission device
Layout of the NDBU-95 branching unit
1 DDCS input and 1 DDCS output
9 DDCS inputs and 9 DDCS outputs
1 - 4 MBd, programmable
20 mA, 30 mA, 50 mA + channel
disabling, programmable
a green LED for each channel,
switched on when NDBU is receiving messages
10 Mb component for each channel
DBU
94
NDBU-95
TXD
V120
CH8
Power supply:
Input voltage
Input current
Monitoring
DDCS
BRANCHING
UNIT, 8+1 CH
RXD
V119
+24 VDC ± 10%
300 mA
a green LED switched on when the
output voltage is normal
TXD
V118
CH7
Operating temperature: +0 ... +50 °C
PCB dimensions:
s. diagram beside
Only channels with the same components (e.g.
10 Mb component) may be connected to each
other.
ADDRESS
8
RXD
V117
S1
TXD
1
V116
CH6
Remark:
41
1
0
RXD
V115
TXD
V114
CH5
RXD
MBIT/S
++ ++
+ + + + X12
1 2 4
V113
TXD
V112
CH4
RXD
V111
For further information see Appendix D in the DriveWindow
User's Manual.
TXD
V110
CH3
264
RXD
V109
Note
For addressing and automatic node numbering of the
drives and branching units see DriveWindow documentaion.
TXD
V108
CH2
RXD
V107
TXD
V106
CH1
TRANSM
SETTING
+ + + + X2+ + + + X11
RXD
V105
DIS
LONG
MEDIUM
SHORT
TXD
V104
CH0
RXD
V103
TXD
V102
MSTR RXD
V101
+5V OK
X1
1
2
24 V DC
0V
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
78
DSL Board
The DSL board provides a drive to drive communication. The communication hardware and protocol is
based on CAN bus.
This communication can be used 12-pulse operation, communication to field exciter either single phase
or three phase field exciter.
The communication hardware is equipped with an isolated supply and isolated transmitter. The
terminator can be set by Jumper S2 and S1selection of termination see chapter DSL wiring
77
3
1
2
3
1
2
3
3
4
2
S2
1 2
1
X54
3
2
X53
2
1
X52
1
X51
S1
30
SDCS-DSL-4
DSL-4_drw.dsf
Jumper coding
S1 Bus termination
3
2
120 Ohm
1
3
2
*
1
S2
*
no termination, park position
Ground termination
2
4
1
3
2
4
1
3
2
4
1
3
200 kOhm R-C ground
termination
0 Ohm R-C ground
termination
*
no termination, park position
default value
.
SDCS-DSL-4
Software
X8: CON-4
X51:1
Supply
24 V
≤ 200 mA
24 V / 200 mA
2
X52:1
2
S1
2
1 3
X53:1
2
CANL
CANH
3
S1
3 4
1 2
GNDB
Termination 200 kOhm
3
X54:1
2
3
Remarks
24 V grounded supply for FEX425
internal and DCF803-0035 field
exciter units; short circuit protected
250 mA
TxD
RxD
DSL communication
Bus termination
S1
1-2
2-3
Ground termination
S2
1-3
2-4
3-4
RS 485 communication
DSL-4_dia.dsf
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
Remarks
120 ohm
no termination; park position
200 kOhm R-C ground termination
0 Ohm ground termination
no termination; park position
Remarks
no isolation
79
Digital I/O board SDCS-IOB-2
As described at the beginning of the chapter, there are
various options for configuring the inputs/outputs.
I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
SDCS-CON-4
SDCS-CON-4
The board IOB-2x has 8 digital inputs and 8 digital
outputs.
X2:
There are three different types existing, which differ at
the input voltage level:
X2:
X1:
X3:
X1: X2:
The inputs are filtered and galvanically isolated by
using optocouplers. Inputs can form two galvanically
separated groups by using either X7:1 or X7:2.
X1:
X5:
X3: X1:
X3: X1:
SDCS-IOB-2
SDCS-IOB-3
SDCS-IOB-21 24...48V DC
SDCS-IOB-22 115 V AC
SDCS-IOB-23 230 V AC
X4:
SDCS-IOB-2
The cable length between X1:/X1: and X2:/X2: is max.
1.7 m and between X1:/X3: is max. 0.5 m because of
EMC reasons.
If these boards are in use, they have to be mounted
outside the DCS module. They must be mounted in a
way, that the conductive supports have a good connection to ground of the installation.
Layout and jumper settings of the SDCS-IOB-2x board
DI2
DI3
DI4
DI6
S7
2
4
3
W16
DI7
2
1
W14
W12
W10
DI5
DI8
1
1
X5
X4
5
Line potential !
R4
R5
R6
R7
1
4*
R8
W15
R3
W13
R2
1
X6
4
70
70
R1
W11
K8
W9
K5
W7
K4
W5
K3
W3
K2
W1
K1
97.5
S8
DI1
3 4
DO7
1
DO6
W8
DO8
DO5
DO3
W6
SDCS-IOB-2x
X1
DO4
DO2
W4
X3
DO1
W2
W100 **
233.5
X7
5
4
Jumper coding
supports are conductive
diameter of all supports: 4.3 mm
time constant
input 2ms
10ms
S7
DI 7
S8
DI 8
*
2
4
2
4
1
3
1
3
2
4
2
4
1
3
1
3
*
*
default value
* this dimension may vary (4/5 mm)
depending on revision
(** W100 as printed circuit ) ?
iob2x1_c.dsf
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
80
Note:
When the SDCS-CON-4 control board with the SDCS-IOB2 I/O board is installed, terminals X6: and X7: on the
SDCS-CON-4 must not be used.
SDCS-IOB-2x
Software
DOx
X4:1
DO1
K1
2
3
Output value Signal definition by
K1...K5, K8
Firmware
potential-isolated by relays
(NO contact element)
Contact ratings:
AC: ≤250 V~/ ≤3 A~
DC: ≤24 V-/ ≤3 Aor ≤115/230 V-/ ≤0.3 A-)
MOV-protected (275 V)
K6, K7
Firmware
potential-isolated by optocoupler
Switching capacity: ≤50 mA
external voltage: ≤24 V-
DO2
K2
4
5
DO3
K3
6
7
DO4
K4
8
X5:1
DO5
K5
2
DO6
3
4
66V
5
6
DO7
66V
DO8
7
K8
8
681
X6:1
+
R1
100n
W1
2
R3
DI3
W6
R4
DI4
W8
R5
W9
6
DI2
W4
W7
5
DI1
R2
W5
4
+
681
W2
W3
3
-
DIx
DI5
W10
R6
DI6
W11 W12
7
R7
W13
8
DI7
W14
R8
W15
X4:, X5: are screw-clamp terminal types for leads up to 4 mm² crosssectional area.
Default values are shown within the software diagrams.
The ground potential of the digital outputs may vary within ±100 V to
each other.
Input value Signal definition by
Channel
Firmware
1...8
IOB-21
0...8 V
18...60 V
IOB-22
0...20 V
60...130 V
IOB-23
Firmware
0...40 V
90...250 V
Remarks
potential-isolated by optocoupler
(24...48V-) R1...R8 = 4.7 kΩ
-> "0 signal"
-> "1 signal"
(115V~)
R1...R8 = 22 kΩ
-> "0 signal"
-> "1 signal"
(230 V~)
R1...R8 = 47 kΩ
-> "0 signal"
-> "1 sig."
including tolerance; absolute
max. values
X6: / X7: are screw-clamp terminal types for leads up to 4 mm² crosssectional area
Input resistance: see diagram.
Input smoothing time constant: see diagram.
Smoothing time constant of channel 7 and 8 can be changed; see
fig. before.
DI8
W16
X7:1
W100
2
3
Remarks
up to revision D
4
from
revision E on
+48V
conductive support
iob2x2_b.dsf
Power supply for digital inputs: 48V / ≤ 50mA; not galv. isolated
from the DCS electronics!
If the inputs are supplied from the internal +48 V (X7:3 and/or X7:4) a
connection must be done from either X7:1 and/or X7:2 to ground of
the DCS 500 module. In default condition ground is identical to the
converter's frame.
If the inputs are supplied by any external source (+48 V DC, 115 V AC
or 230 V AC) the neutral line / - line must be connected to either X7:1
or X7:2. If the inputs should be controlled with the same voltage level,
but from two different voltage sources, having probably two different
ground levels, the first neutral line should be connected to X7:1 and
the second to X7:2. In this case the jumpers Wx connecting the inputs
to X7:2, but controlled by the source, connected to X7:1, must be cut
off.
The same method is needed for the other jumpers Wx.
High frequency grounding is done by 100 nF capacitor.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
81
Analogue and encoder I/O board SDCS-IOB-3
As described at the beginning of the chapter, there are
various options for configuring the inputs/outputs.
I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
SDCS-CON-4
The board SDCS-IOB-3 consists of the 5 analogue
inputs, 3 analogue outputs, the galvanical isolated
pulse encoder interface and a current source for temperature measuring devices.
X2:
SDCS-CON-4
X1:
X2:
X1:
X6:
X1: X2:
If these boards are in use, they have to be mounted
outside the DCS module. They must be mounted in a
way, that the conductive supports have a good connection to ground of the installation.
X3: X1:
SDCS-IOB-2
SDCS-IOB-3
X7:
X1: X2:
SDCS-IOB-3
The cable length between X1:/X1: and X2:/X2: is max.
1.7 m and between X1:/X3: is max. 0.5 m because of
EMC reasons.
Layout and jumper settings of the SDCS-IOB-3x board
233.5
conductive supports
V17
SDCS-IOB-3
X2
2
14
1
13
S1*
8
7
8
7
2
1
2
1
S2*
70
T1
S10 *
S5 *
R110
3
2
1
2
4
1
3
S3*
1
12
12
1
X3
S4
24
23
22
*
X1
1
2
11
12
85
70
10
1
X4
X5
5
5
iob3_c.dsf
4
4
Jumper coding
Functionallity of analogue inputs
S1
S2
S3
activation of
gain = 1
500 between
input terminal -10V..+10V
YES
AITAC S1:1-2
*
Ch
AI1 S1:3-4
-1V..+1V
S4 Pulse encoder supply
Sum I AC
not equal
to 0
5V
*
1
3
5
7
9
11
YES
AI2 S1:5-6
S2
8
6
4
2
7
5
3
1
S3 8
7
5
3
1
AI3 S1:7-8
6
4
2
AI4 S1:9-10
S10
gain = 10
8
6
4
2
7
5
3
1
S3 8
7
5
3
1
S2
6
4
2
YES
S5
24 V *
12 V
2
4
6
8
10
12
2
4
6
8
10
12
1
3
5
7
9
11
1
3
5
7
9
11
2
4
6
8
10
12
Temperature sensor supply
PTC
1.5 mA
1
3
PT100
5 mA *
2
4
1
3
2
4
S1:11-12
S1:13-14
Characteristics for pulse encoder inputs
single ended:
3
2
1
5V
differential:
5V
3
2
1
*24
12/24 V
23
22
3
2
1
24
23
22
3
2
1
24
23
22
12/24 V
*
24
23
22
13 mA
3
2
1
24
23
22
* default value
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
82
-
X1:1
81-270V
2
25-90V
TG
3
+
4
Note:
When the SDCS-CON-4 control board with the SDCS-IOB-3 I/O
board is installed, analogue tacho input at SDCS-CON-4 should
be used:
X2:3
8-33V
4
X2:3
5
R9
5
X2:4
PS5311
7
6
6
7
8
Terminals X3:, X4: and X5: on the SDCS-CON-4 must not be used.
X2:
8
SDCS-IOB-3
-
X3:1
2
3
4
5
6
7
8
+
-
11
12
500
100k
1n
100k 1n
100k
+
+
S2
5 6
x10
+
7 8
x10
-
S3
9 10
+
12
11
~
S1
Input/output
values
Hardware
15 + sign
-10...0...+10 V Firmware
ComRemarks
mon
mode
range
±20 V ➀➁➂➅
AI1
3.3 ms
15 + sign
-10...0...+10 V Firmware
±20 V ➀➁➂
AI2
3.3 ms
15 + sign
-10...0...+10 V Firmware
±40 V ➀➁➂➃➄
AI3
10 ms
15 + sign
-10...0...+10 V Firmware
±40 V ➀➁➂➃➄
AI4
10 ms
15 + sign
-10...0...+10 V Firmware
±40 V ➀➁➂
AO1
11 + sign
-10...0...+10 V Firmware
Power
≤ 5 mA*
AO2
11 + sign
-10...0...+10 V Firmware
≤ 5 mA*
analogue
-10...0...+10 V R110
≤ 5 mA* gain: 0.5...5
SDCS-CON-x Software
100k
3 4
9
10
S1
1 2
Resolution
[bit]
14
13
Scaling
by
AITAC
100
~
100
X4:1
47.5
100n
2
0V
3
4
100
5
47.5
x
100n
6
0V
+/- I-act
R110
0V
3 V = I NDC
Ri = 3 Ω
+10V
7
≤ 5 mA* for external use
≤ 5 mA* e.g. reference pot.
0V
8
9
100
10
-10V
1 2
11
1.5 mA
5 mA
1.5 mA
5 mA
S5
3 4
0V
Curr. source for
PTC or PT100
12
S10
4 5 6
S10
+24V 1 2 3
10 11 12
+24V 7 8 9
16 17 18
+24V 131415
X5:1
2
3
ChA ChB +
4
5
Encoder supply
ChA +
ChB -
6
7
8
9
10
5V
12 V / 24 V
ChZ +
≤ 250 mA *
≤ 200 mA *
ChZ V17
Sense Power +
Remarks
Inputs not isolated
Impedance = 120 Ω, if selected
max. frequence ≤300 kHz
Sense lines for GND and supply to
correct voltage drops on cable (only if
5V/12V enc. is in use)
PowerSource
Sense GND
S4
GND
iob3x2 e.dsf
➀
➁
➂
➃
total smoothing time ≤2 ms
-20...0...+20 mA by setting S1
4...20 mA by ➁ + Software function
-1...0...-1 V by setting S2/S3 (CMR ±10 V)
-2...0...-2 mA by setting S2/S3 + S1 (CMR ±10 V)
➄ designated for PT100 evaluation per firmware and
hardware
➅ If the input is used for tacho feedback and the tacho
voltage needs to be scaled, the board PS5311 must be
ordered separate. If this input is used for feedback
signals, there is a need for additional margin for
overshoot measurement. This margin is set by software
and results e.g. in the 8 to 33 volts at PS5311.
* short circuit proof
➆Residual current detection is selected as default. The jumpers S1:11-12 and S1:13-14 are set, inputs X3:9 and X3:10
and jumper S1:9-10 must not be used and inputs X3:11 and X3:12 serve as input for the current signal taken from a
current transformer. This detection is based on a sum current transformer where the secondary is connected through a
diode bridge to 100 W resistor . Voltage will appear across the resistor, if the sum of the 3-phase current is not zero. In
case AI4 should be used for a different purpose, use the inputs/jumpers accordingly and take the block diagram as a
help.
Restrictions using jumper S1, S2 or S3:
The selection for the burden resistor across the input terminals can be done independent from S2 or S3 settings for inputs
AITAC, AI1, AI2, AI3 and AI4.
If the gain is set to 10 by using S2 or S3 and the 500 W burden resistor is activated, the input signal level is changed to -2
mA...0...+2 mA.
For input AI4 there are the following configurations available:
- input range ”20mA” , or
- input range ”10V”, or
- earth fault monitoring by Isum not equal to zero via X3:11 and X3:12
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
83
Power Supply Board SDCS-POW-4
The SDCS-POW-4 board is designed for DCS800 converter modules D5...D7 and is mounted on the
electronic support. This board is used for all types of modules independent from current or voltage
range.
The SDCS-POW-4 works on a switched mode basis in fly back configuration. It generates all necessary
DC voltages for the SDCS-CON-4 and all other electronic boards. The input voltage automatically is
detected either to 230 V AC or to 115 V AC. The following figure shows the instructions for the selection
of the AC input voltage and for the selection of the encoder supply voltage.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
84
Interface Board SDCS-PIN-4
General
The SDCS PIN4 board is designed for DCS800 Converter modules sizes D1 up to size D4 (20 A...1000
A) the board has three different functions:
1. Power supply of CON-4 board and the connected options
2. Control of armature bridge and measurement
3. Control of on-board field exciter and field current measurement
The board is mounted conducting ground at points (
) inside the module.
The board is used for supply voltages from 230 V up to 525 V, 600 V.
The converter identification is made by TYPECODE 97.01 (and not by hardware)!
The converter identification manages the burden resistor setting and 2-Q or 4-Q bridges operation.
Armature firing
Power supply
X18
X16
X17
X12
X13
6A 5x
25A 1x
X15
T100
X37
High voltage
Field current measurement
X22
+
X4
X3
S1
X31
X2
X1
X8
X95
SDCS-PIN-4
X7
X9
1
2
3
1-2 = 230 V
2-3 = automatic
F101
F100
K301
F102
X12
X5
High voltage
Field firing
-
K400
X10
F400
-
+
X24
C1
U1
X21
X25
V1
X23
W1
X20
D1
X96
F300
X99
conducting point
Pin4_layout.dsf
Different functional areas on SDCS-PIN-4
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
85
Power supply
The power supply (X99:) operates on fly back configuration. The internal DC link voltage is 310 V.
The power supply automatically adapts the supply input voltage between 230 V and 115 V and switches
relays K301.
In case of oscillating 230 V input voltage (e.g. generator network) the operation must be clamped to
230 V by Jumper S1= 2-3 230 V operation
Technical data
AC Supply voltage
Backup supply
Supply voltage
115 V AC
230 V AC
Tolerence
-15%/+10%
-15%/+10%
Frequency
45 Hz ... 65 Hz
45 Hz ... 65 Hz
Power consumption
120 VA
120 VA
Power loss
≤60 W
≤60 W
Inrush current
20 A / 20 ms
10 A / 20 ms
Mains buffering
min 30 ms
min 30 ms
Powerfail
85 V
170 V
The terminal X95 are used to add additional
capacitance to the existing ones to increase
the mains buffering time. More detailed data
is available on request via your ABB
representative.
S1
2-3 -> 230 V operation fix
1-2 -> automatic detection of input voltage range (default)
X96: Output DO8
Isolated relay (NO contact)
X96:
Contact rating:AC: 230 V~/ <3 A~
DC: 24 V-/ <3 Aor 115/230 V-/ <0.3 A-)
PIN4_in-output_circuit.dsf
Input circuit PIN-4
275 V
Filtering
X99:
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
86
Armature circuit interface
The function for armature circuit interface consist of:
• Firing the armature bridge of 6 or 12 thyristors.
• High ohmic measurement of DC and AC voltage.
• Interface for AC current transformer for current measurement.
• Snubber circuit for the thyristor protection together with resistor R1 on heatsink.
• Interface for heatsink temperature measurement with a PTC resistor.
• Fuses for overvoltage protection and field circuit.
The same board can be used for 3 phase field exciters without modification.
The current measurement is adjusted by TYPECODE parameter 97.01 and automatic adjusted by rated
motor current.
Field circuit interface
The On board fieldexciter is located internally. The firing pulses are synchronized from mains circuit
L1,L2,L3 and SDCS-CON-4 board. The pulses are amplified on PIN4 board. The hardware structure is
a three phase half controlled bridge supplied direct from mains circuit U1, V1 , W1 via fuses F100,
F101, F102.
If the On board field exciter is not needed it can be switched OFF by firmware.
The function of field circuit interface consists of:
•
•
•
•
Firing the field bridge three phase half controlled bridge.
Measurement of DC field current, the scaling is automatically selected via rated motor field current.
Snubber circuit are shared with armature bridge.
Fuses F101, F102, F103 for cable and motor field protection.
Ratings
AC voltage range
110...500 V (525 V)
AC insulation voltage
500 V
Frequency
50 Hz / 60Hz
AC input current
< field current
Minimum Current
?300 mA
Size
D1
D2
D3
D4
6A
15A
20A
25A
max. cross sectional area
16 mm²
AWG 6
16 mm²
AWG 6
16 mm²
AWG 6
16 mm²
AWG 6
min. cross sectional area
1 mm²
AWG 16
2.5 mm²
AWG 12
4 mm²
AWG 10
6 mm²
AWG 8
DC output current
Fuse type
KTK - 25
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
X12:
11,12
2
5
7
15
4
14
16
6
ANTC
HWCOD3
HWCDD5
UA -
UU
UV
VW
UA +
NC
NC
3ADW000194R0201 DCS800 Hardware Manual e b
14
6
8
+24 V
+15 V
Pin4.dsf
-15 V
12
GND 24, 22,
20, 18, 10
2
4
+24 V
+48 V
X99: 1
FORWARD
8,6
SR1
GNDI
X13:
+ 48 V1
11
BZP6
10
9
BZP5
4,2
7
BZP4
SR2
3
5
BZP3
+48 V1
2
3
BZP2
2
X96: 1
2
Firing pulse channels
6
5
4
1
AC/DC voltage measuring circuits
1
REVERSE
0V
5M / 6M
Armature circuit interface
Armature current measuring resistances
BZP1
X13:
3
8,13
GNDI
9,10
STWA
IDC
Control board
IDCM
X6:
X5:
19
17
31
29
3
1
35
33
11
9
27
25
19
17
31
29
3
1
35
33
11
9
27
25
K
G
K
G
K
G
K
G
K
G
K
G
G
K
G
K
G
K
G
K
G
K
G
X13: 13 15 16 12
1.6
2.5
1.4
2.3
1.2
2.1
2.6
1.5
2.4
1.3
2.2
1.1
X31:
R1
X30:
X7:
X2:
X1:
V1??
POWER INTERFACE BOARD SDCS-PIN-4
F101
X12:1
3
D1
C1
W1
V1
U1
F- F+
X8: X9:
T100
Field circuit
interface
16A
F103
F102
3
1
3
1
3
1
X22: 1
X5:
X4:
X3:
1.5
2.2
1.3
2.6
1.1
2.4
G
K
G
K
G
K
G
K
G
K
G
K
C1 (+)
X24:
X23:
X21:
X20:
R57
V15
V22
V13
V26
V11
V24
S2
S1
S2
S1
S2
S1
N/1
P1
T52 P2
N/1
P1
T53
1.2
2.5
1.6
2.3
1.4
2.1
25A...275A
276A...800A
N/1
801A...1200A
P1
U1 V1 W1
T51 P2
only in case of 4-Q converters
PE
K
G
K
G
K
G
K
G
K
G
K
G
D1 (-)
V12
V25
V16
V23
V14
V21
1500:1
3000:1
4500:1
87
Typical armature circuit thyristor converter diagram with SDCS-PIN-4 board
Technical data
88
Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x
The Power Interface of DCS converter modules model D5/D6/D7 from 900 A up to 5200 A consists of
two boards - the Measuring board SDCS-PIN-51 and the Pulse transformer board SCDS-PIN-41.
The following figures show the different connections between the SDCS-PIN-41 and SDCS-PIN-51
board depending on the application 2- or 4-quadrant and the construction type.
Converters delivered from middle 2005 will be equipped with SDCS-PIN-48, which is a full replacement
for converters already in use.
X24
X25
U1
X22 X122 X23
V14
V11
V16
V13
V12
G
G
G
G
G
X313 S
X413 S
B
X113
S2
S1
C
C
C
G
C
D
C
E
F
SDCS-PIN-46/PIN-48
X313
X413
X213
X113
X13
X513
C1
C
A
SDCS-PIN-5x
D1
X13
X13 S
X12 S
X12
W1
X12
V1
C
V15
X213
SDCS-CON-x
2-Quadrant application, no parallel thyristors - Construction type D5/D6/D7
2q_c34_b.dsf
4-Quadrant application, no parallel thyristors - Construction type D5/D6/D7
X25
X313 S
C
T6
C
C
T3
D
T2
E
SDCS-PIN-46/PIN-48
F
F
X113
S2
S1
C
X313
X413
X213
X113
X513
X13
C
T1
B
X113
X413 S
X13 S
X12 S
X12
D1
X13
C
T4
A
SDCS-PIN-5x
C1
W1
X12
V1
C
X213
X24
U1
X22 X122 X23
X213
SDCS-CON-x
SDCS-PIN-46/PIN-48
V25
V12
V23
V16
V21
V14
G
G
G
G
G
G
V11
V26
V13
V22
V15
V24
C
C
C
C
C
C
G
G
G
G
G
G
4q_c3a_b.dsf
Pulse transformer board SDCS-PIN-46/PIN-48
Layout of the SDCS-PIN-46/PIN-48 pulse transformer board
270
X1
A
X113
G
C
G
C
B
C
G
C
D
G
C
E
SDCS-PIN-4x
G
C
Gate
Cathode
X2
F
X213
Pin4x.dsf
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
100
G
C
The board consists of six
pulse transformers with
amplifiers.
89
Measuring board SDCS-PIN-51
This board is always used together with SDCS-PIN-41 board. On
this board there are the circuits located needed for current, voltage
and temperature measuring and for hardware coding.
The voltage measurement uses 5 resistor:
U1:W1
to W5
The current is measured by current transformers at the main AC
inputs, rectified by a diode bridge and scaled with burden resistors.
The nominal current is adjusted by cutting out resistors (R1 ... R21)
from the board according to the current coding table. The resistors
R22 ... R26 are used for the current equal to zero detection. These
resistors must be cut off too, according to the current coding table.
V1:W6
to W11
W1:W12 to W16
C1(+):W17 to W21
D1(-):W22 to W26
Voltages (U1, V1, W1 and C1(+) and D1(-)) are measured by using
high ohm resistor chains. Scaling of AC and DC voltage is done by If there is a need for voltage adaptation, all 5 chains must be hanactivating 1 MΩ resistors (= cutting out short circuit wires, which are dled in the same way.
represented by low ohmic resistors).
Note! Actual voltage signals U1, V1, W1, C1(+) and D1(-) of the
main circuit are not galvanically isolated from the control board.
Because of that a current of less than 1 mA will flow to earth.
When galvanically isolated measurement is needed, please contact
your ABB representative..
Layout of the SDCS-PIN-51 board
line potential !
R123
W2
W1
S3
W1
C1
Isolating
supports
W21
D1
W9
W16
W8
W15
W20
W26
W19
W25
W7
W14
W18
W24
W6
W13
W12
W10 W70
W71
W72
W80
W81
W82
X24 2
1
R1
1 X25 2
.......
R21
R22
X12S
X413S
W83
X13S
X313S
R26
W17
W23
X13
W11
X12
100
V1
1 X23 2
X22 X122
4 Two PTC
3
1
2 One PTC
W22
X313
W3
X413
W4
X213
W5
X113
U1
Conductive
supports
see diagram
power part
PTC
X513
W5
S2
S1
SDCS-PIN-51
305
Layout of the SDCS-PIN-52
U1
S3
X12
V1
W1
C1
D1
In the past some converters for
line voltages lower/equal 500 V
had been equipped with SDCSPIN-52 boards. The SDCS-PIN51 board serves as a spare part
for those converters.
SDCS-PIN-52
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
90
Settings of the SDCS-PIN-51 board if a DCS converter is equipped with it by ABB
Current coding
2000
1900
D6
2500:1
2050 2500
3000
2050
2600
3300
D7
4000:1
4000 4800
5200
Rated current scaling
900
D5
2500:1
1200 1500
Zero current
detection
Construction type
Current transf. ratio
Rated current [A DC]
18
R1-R4
18
R5
18
R6
18
R7
18
R8
18
R9
18
R10
18
R11
18
R12
18
R13
18
R14
18
R15
18
R16
33
R17
68
R18
120
R19
270
R20
560
R21
47
R22
47
R23
47
R24
47
R25
100
R26
code_tab_PIN1_PIN20_PIN51_d.dsf
Voltage coding
D5
D6 / D7
Construction type
Conv. nom. voltage [V] Y=4 (400V) Y=6 (600V) Y=7 (690V) Y=4 (400V) Y=6 (600V) Y=7 (690V) Y=8 (790V)
Y=5 (500V)
Y=5 (500V)
➀ U1 [V AC]
Value f. conv. nom. volt
500
600
690
800
0 = HW type coding
at SET(TINGS) block
Measuring board SDCS PIN-51
PIN-51
PIN-51
PIN-51
PIN-51
PIN-51
PIN-51
W1, 6, 12, 17, 22
W2, 7, 13, 18, 23
W3, 8, 14, 19, 24
W4, 9, 15, 20, 25
W5, 11, 16, 21, 26
D7
Y=9
(990V)
D7
Y=1
(>1000V)
1000
PIN-51
see
chapter
Galvanic
isolation
➀ the converters can be used at lower line voltage then specified by the y-value without hardware modifications, if
the nominal line voltage applied to the converter is not lower than 45% for y=5...9 and not lower than 55% for y=4.
Temp. sensor coding
R 57 as a temp. sensor for D5, D6, D7
S3
3
4
2
1
Board used as a spare part:
•
•
2 Q - 4 Q coding
2-Q
W10
indicates a removed jumper
default: all jumpers Wxx, Rxx are in
condition
ensure the correct converter type related settings
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
4-Q
3
4
14
16
6
15
2
UU
UV
VW
UA +
UA -
ANTC
B5
B4
5
7
9
BZP3
BZP4
BZP5
3ADW000194R0201 DCS800 Hardware Manual e b
A7,A8
A5,A6
A4
4,2
8,6
10
13
15
SR2
SR1
+48 V1
ACOD1
ACOD2
B5
7
1
HWCDD5
HWCIN4
B8
X12:
B6
X12:
HWCOD3 5
B1
NC
1k5
W10
820R
W80
1k5
1k5
820R
W81
W70
3k3
1k5
W82
W71
HW-coding jumpers
0V
W72
8k2
3k3
W83
1.4
SDCS-PIN-48
A4,B4
A4,B4
A2
A1,B1
A2
A1,B1
p41_51_A7.dsf
A2
A1,B1
A3,B3
A4,B4
A9,B9
A6,B6
A6,B6
A3,B3
A7,B7
A8,B8
A8,B8
A3,B3
A8,B8
A7,B7
A6,B6
A10,B10
A5,B5
A9,B9
X113:
A5,B5
X213:
A10,B10
CF
A3,B3
A4,B4
A9,B9
A7,B7
A8,B8
A7,B7
A9,B9
A5,B5
X213:
A10,B10
CE GF
A2
2.1
A1,B1
A1,B1
CD GE
A2
A3,B3
A3,B3
1.6
A1,B1
A4,B4
A2
A6,B6
A4,B4
6
5
A6,B6
A10,B10
X213:
A5,B5
CF
Fast-on
S1
1.5
A6,B6
CC GD
CE GF
A8,B8
2.3
2.2
SDCS-PIN-48
CD GE
A8,B8
CB GC
1.3
A7,B7
1.2
CC GD
3
1
D1
C1
W1
V1
A9,B9
CA GB
2.6
X22:
2
1
2
1
2
1
U1
A7,B7
2.5
CB GC
1M
A9,B9
GA
1.1
W26
W21
W20
W25
W16
W15
W11
4
X113:
A10,B10
CA GB
W24
W19
W14
W9 1M
W5
3
X113:
A10,B10
W23
W22
2.4
W18
W17
GA
W13
W12
W8 1M
W4
X25:
X24:
X23:
SDCS-PIN-51
A5,B5
2
+ 48 V1
FWD
REV
0V
Firing pulse channels
R15 18R
A5,B5
1
501
W7 1M
R8 18R
W6 1M
*
B2
A2,A3
GNDI
B3
11
12,14
BZP6
B6
B7
3
BZP2
X13:
B8
0V
500
R12 18R
X13:
1
R21 560R
401
301
201
R10 18R
BZP1
R20 270R
A8
R19 120R
B1
R18 68R
A6
R17 33R
400
300
R13 18R
A1
R16 18R
AC/DC voltage measurement
R14 18R
200
R11 18R
101
R9 18R
5M
R7 18R
100
R6 18R
R26 100R
A2
0V
R5 18R
R25 47R
W3
R4 18R
R24 47R
W2
R3 18R
R23 47R
W1
R2 18R
A7
Armature current measurement
POWER INTERFACE BOARD
R22 47R
B7
A5,B2
A4,B4
X12:
A3,B3
R1 18R
Control board
8,13
GNDI
9,10
IDC
STWA
X12:
11,12
IDCM
R22
R15
R26
R13
R24
R11
K
G
K
G
G
K
K
G
K
G
F11
F14
V15
V22
V13
V26
V11
C22
C15
C25
C12
F12
C23
C26
F15
C16
F16
C21
C14
C13
F13
C24
C11
2.5
1.2
2.3
1.6
2.1
V16
V12
R25
R12 V25
R23
R16 V23
R21
R14 V21
V14
D1 (-)
K
G
K
G
G
K
K
G
K
G
G
K
1.4
G
V24
4000/1
S2 P1
S1
T52 P2
K
C1 (+)
1.5
2.2
1.3
2.6
1.1
2.4
R57
4000/1
S2 P1
S1
T51 P2
PE U1 V1 W1
91
Typical armature circuit thyristor converter diagram with SDCS-PIN-48 and SDCS-PIN-51 boards for a
4-Quadrant D7 type converter
Technical data
92
Galvanic isolation - T90, A92
The Galvanic isolation is an option for converters in
the current range 2050...5200 A and rated voltages
≤1000 V. For converters with a rated voltage of
1190 V and 12-pulse serial > 2x 500 V the galvanic
isolation is a standard equipment. It is used to
replace the high-ohmic resistance voltage
measurement and gives the advantage of a total
isolation from power part to electronic part.
The transformer T90 and the DC transducer A92 are
located outside the converter module. The internal AC
and DC voltage measurement channels are opened and
connected to the T90 and A92 units.
Hard and software settings:
Voltage coding on measuring board
D5 / D6 / D7
Construction type
Conv. nom. voltage [V] *
Rated mains voltage [V AC]
Value f. conv. nom. volt at
SET(TINGS) block *
Measuring board SDCS-
Y=4 (400V)
Y=5 (500V)
Y=6 (600V)
Y=7 (690V)
Y=8 (790V) Y=9 (1000V) Y=1 (1190V)
220…500
270…600
300…690
350…790
450…1000
530…1190
500
600
690
800
1000
1200
PIN-51
PIN-51
PIN-51
PIN-51
PIN-51
PIN-51
Resistors W1…W26
all resistors are 0 Ω
Galvanic isolation
Resistors Rx on PIN51
DC-DC transducer A92
27.4 kΩ
27.4 kΩ
27.4 kΩ
27.4 kΩ
27.4 kΩ
6 (810 V)
5 (945 V)
4 (1080 V)
2 (1350 V)
1 (1620 V)
2U2
2V2
2W2
2N
2U3
2V3
2W3
2N
2U4
2V4
2W4
2N
2U5
2V5
2W5
2N
2U6
2V6
2W6
2N
8680A1
7 (675 V)
Switch position RG *
27.4 kΩ
3ADT 745047
Transformer T90
Secondary Terminals *
2U1
2V1
2W1
2N
* 12-pulse serial and sequential have a different selection between S CONV NOM VOLT (42.08) and
the scaling of measurement channel. See 12-pulse manual for DCS 600.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
A6
B1
3
4
14
16
6
15
2
UU
UV
VW
UA +
UA -
ANTC
3ADW000194R0201 DCS800 Hardware Manual e b
1k5
A3,B3
A1,B1
A3,B3
A1,B1
13
15
ACOD1
ACOD2
B5
7
1
HWCDD5
HWCIN4
B8
X12:
B6
X12:
HWCOD3 5
B1
NC
+ 48 V1
A4
10
+48 V1
B2
FWD
A5,A6
8,6
SR1
W10
820R
W80
1k5
1k5
820R
W81
W70
3k3
1k5
W82
W71
HW-coding jumpers
REV
A7,A8
SR2
6
0V
A2,A3
4,2
GNDI
B3
11
12,14
BZP6
8k2
3k3
W83
A4,B4
A4,B4
0V
A6,B6
A6,B6
W72
A8,B8
A6,B6
A4,B4
A6,B6
A4,B4
A2
A1,B1
A2
A1,B1
A3,B3
A8,B8
A3,B3
A7,B7
A8,B8
A9,B9
A5,B5
X213:
A10,B10
A7,B7
A9,B9
A5,B5
X213:
A10,B10
A2
A7,B7
A7,B7
A8,B8
5
*
A2
A9,B9
A9,B9
X113:
A10,B10
W23
W22
GA
2.5
2.4
W18
W17
GA
W13
W12
4
X113:
A10,B10
501
W7 1M
3
B5
B6
B4
7
9
5
500
401
Rx
Rx
301
W2
A5,B5
2
BZP5
BZP3
Firing pulse channels
0V
R15 18R
A5,B5
1
BZP4
B7
R21 560R
3
R20 270R
BZP2
R19 120R
BZP1
R18 68R
X13:
B8
R17 33R
400
300
Rx
R10 18R
X13:
1
R16 18R
A8
R14 18R
AC/DC voltage measurement
R13 18R
A1
R12 18R
200
R11 18R
W6 1M
R8 18R
W1
R9 18R
101
CA GB
CA GB
1.2
1.1
W24
W19
W14
CB GC
CB GC
W8 1M
W3
R7 18R
Rx201
R6 18R
R26 100R
Rx
R5 18R
R25 47R
5M
R4 18R
R24 47R
100
R3 18R
R23 47R
A2
0V
2.3
2.6
CC GD
CC GD
1.3
1.6
2.2
1M
CE GF
2.1
CE GF
1.4
A2
A1,B1
A3,B3
A4,B4
A9,B9
A7,B7
A8,B8
A6,B6
A10,B10
X113:
A5,B5
CF
p41_51_A7.dsf
SDCS-PIN-48
CD GE
A2
A1,B1
A3,B3
A4,B4
A9,B9
A7,B7
A8,B8
A6,B6
A10,B10
3
1
D1
C1
W1
V1
X213:
A5,B5
CF
2
1
2
1
2
1
U1
Fast-on
S1
1.5
X22:
X25:
X24:
X23:
SDCS-PIN-51
SDCS-PIN-48
CD GE
W26
W20
W25
W21
W15
W11
W5
W16
W9 1M
W4
R2 18R
A7
R1 18R
Control board
A5,B2
8,13
GNDI
STWA
Armature current measurement
POWER INTERFACE BOARD
resistors, to be soldered in parallel to 5 M hybrid; values see table before
removed wires
R22 47R
B7
A4,B4
9,10
IDC
X12:
A3,B3
X12:
11,12
IDCM
Rx
R22
R15
R26
R13
R24
R11
K
G
K
G
K
G
K
G
K
G
G
K
C1 (+)
1.5
2.2
1.3
2.6
1.1
2.4
R57
2N
V15
V22
V13
V26
V11
V24
S
T90
4000/1
C22
C15
F15
C25
C12
F12
C23
C26
F16
C21
C14
F14
4000/1
S2 P1
S1
T52 P2
C16
P1
C13
F13
C24
C11
F11
S2
S1
T51 P2
PE U1 V1 W1
F90
2.5
1.2
2.3
1.6
2.1
1.4
V16
V12
R25
R12 V25
R23
R16 V23
R21
R14 V21
V14
D1 (-)
K
G
K
G
K
G
K
G
K
G
G
K
F11
20
=
10
17
=
9 1
=
X99:2
X99:1
SDCS-POW-1
A92
~
2
aux. supply
230 V AC
93
Typical armature circuit thyristor converter diagram with SDCS-PIN-48 and SDCS-PIN-51 boards for a
4-Q D7 type converter with galvanic isolation
Technical data
94
DC-DC transducer A92
Principle circuit diagram of the DC-DC transducer A92
17
6M
appr. 280nF
9
10nF
Input
voltage
OPAMP
20
RG
6M
appr. 3.9 k
10
TRANSDUCER
1:1
GAIN
7 STEPS
POWER SUPPLY
1
230 V AC
Output
voltage
+15V
0V
-15V
2
0V
Data
Selectable voltage gains:
675
810
945
1080
1215
1350
1620
Switch position
7
6
5
4
3
2
1
Output voltage:
9,84 V / 5 mA
Auxiliary power:
230 V ± 15 %; 50/60 Hz; 3 W
Clearance in air:
Auxiliary power to Output: >13 mm
V DC
Input/Output to Auxiliary power: >14 mm
Insulation voltage:
2000 V
Insulation test voltage:
5000 V
Ambient temperature range:
- 10 …+ 70 °C
Weight:
appr. 0.4 kg
The voltage gain and frequency response is especially designed for
DCS800 converters.
Dimensions in mm
Location of terminals
Side view
2.0
76.0
70.0
Snap-on mounting on DIN 46277 rail
20
17
80.0
100.0
10.0
7.0
112.0
Buttom view
Gain selector
RG
5.0
50.0
60.0
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
1
2
9
10
95
Transformer T90
Principle diagram of the transformer T90
1U
2N
2U6
2U5
2U4
2U3
2U2
2U1
1V
2V6
2V5
2V4
2V3
2V2
2V1
1W
2W6 2W5 2W4 2W3 2W2 2W1
1N
S
Data
Selectable transfer ratios Uprim:
502, 601, 701, 800,1000, 1200 V AC rms
Output voltage:
7.3 V AC rms
Insulation voltage:
1200 V
Isolation test voltage:
3500 V
Ambient temperature range:
- 10 …+ 70 °C
Weight:
- 10 …+ 70 °C
Weight:
2.1 kg
Dimensions in mm
Remark
max 116
max 110
The terminals on the primary side of the
transformer are in special design (lug terminals).
Handling hints: First turn the screw counterclockwise to the end stop, then swing out the
shrowding cover. Put in the cable lug, swing
in the shrowding cover and fasten the connection by turning the screw clockwise.
80
130
5.2 x 7.7
118....120
130
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
96
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
97
Dimensional drawings
Dimensional drawings of the DCS800 are shown below. The dimensions are given in
milllimeters.
Module D1
for size D1
for size D2...D3
DCS800-S01-0020
DCS800-S01-0045
DCS800-S01-0065
DCS800-S01-0090
DCS800-S01-0125
direction of air flow
screw M6
fan terminal
DCS800-S02-0025
DCS800-S02-0050
DCS800-S02-0075
DCS800-S02-0100
DCS800-S02-0140
Module D2
DCS800-S01-0180
DCS800-S01-0230
DCS800-S02-0200
DCS800-S02-0260
earthing
point
Size
screw
Weight
Module D3
Minimum
Top clearance
T1 = 150mm for size D1
T1 = 250mm for size D2/D3
T2 = 100mm for size D1
T2 = 150mm for size D2/D3
Field and power supply terminals
400 for size D3
Signal terminals
310 for size D1/D2
Mounting direction
DCS800-S02-0350
DCS800-S02-0450
DCS800-S02-0550
Minimum
Bottom clearance
DCS800-S01-0315
DCS800-S01-0405
DCS800-S01-0500
Power connection
D1toD3_dim_a.dsf
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
98
Module D4
for size D4
DCS800-S01-0610
DCS800-S01-0740
DCS800-S01-0900
DCS800-S02-0680
DCS800-S02-0820
DCS800-S02-1000
Weight appr. 38 kg
D4_dim_a.dsf
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
99
400
450
127.5
125
125
85.5
17 26
250
510
DCS800-S0x-0900
DCS800-S0x-1200
DCS800-S0x-1500
DCS800-S0x-2000
for M10
W1
22
V1
17
26
55
U1
Minimum Top
clearance
Module D5
Ø 14
34
773
775
820
1005
Weight appr. 110 kg
Support
Support
> 510
min. 480
69
*
D1
17.75
400
461
483
65.5
25
50
50
325.5
50
100
fan terminals
fan terminals
Minimum
Bottom clearance
80
276
44.5
102
C1
cable tray
with = 40 mm
earthing height =39 mm
M12
Ø 14
earthing M12
A5_dim_a.dsf
Busbars in mm:
AC 80 x 10
DC 60 x 5
Mounting the converter module A5 inside an
enclosure
Two supports should be mounted inside the
enclosure in such a way, that they can carry the
converter's weight when placing the converter
later on. The minimum distance between the
supports should not be less then 480 mm
because of electrical clearance (DC busbars).
A L-shape support as indicated will allow to
place the converter temporarily close to the front
end of the support (weight still taken by a lifting
device) and then push it back to the back plate
of the enclosure. The upper and lower holes in
the back plate of the converter should be used
to fix the converter in that position.
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
100
Module D6
458.2
425
375
DCS800-S0x-1900
DCS800-S0x-2050
DCS800-S0x-2500
DCS800-S0x-3000
20
250
409
Air outlet
10x20
Weight appr. 180 kg
C
200
C
D
225
D
M12
40
50
U
U
200
62
*
V
200
1725
1750
V
W
759.5
1079.5
W
63
10x20
Pressure switch
15
72
M10
100
355
385
445
A6_dim.dsf
468.2
Air entry
from the front, right, left and
136
back
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
101
230
for M10
200
DCS800-S0x-2050-xxL
DCS800-S0x-2600-xxL
DCS800-S0x-3300-xxL
DCS800-S0x-4000-xxL
DCS800-S0x-4800-xxL
DCS800-S0x-5200-xxL
530
350
25
Module D7
left-hand
Weight appr. 315 kg
200
1725
200
225
*
759.5
Pressure switch
for M10
Busbars in mm:
AC and DC 100 x 10
80 80 80 80
93
A7_dim_a.dsf
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
102
Module D7
right-hand
25
for M10
200
DCS800-S0x-2050-xxR
DCS800-S0x-2600-xxR
DCS800-S0x-3300-xxR
DCS800-S0x-4000-xxR
DCS800-S0x-4800-xxR
DCS800-S0x-5200-xxR
225
Weight appr. 315 kg
759.5
Pressure switch
for M10
A7_dim_a.dsf
Busbars in mm:
AC and DC 100 x 10
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
1725
200
200
*
103
Fuses installed inside the converter
Converter type
400 V / 500 V
DCS800-S0x-1200-04/05
DCS800-S0x-1500-04/05
DCS800-S0x-2000-04/05
DCS800-S0x-2050-51
DCS800-S0x-2500-04/05
DCS800-S01-3000-04/05
DCS800-S02-3000-04/05
DCS800-S0x-3300-04/05
DCS800-S0x-4000-04/05
DCS800-S0x-5200-04/05
600 V / 690 V
DCS800-S0x-0900-06/07
DCS800-S0x-1500-06/07
DCS800-S01-2000-06/07
DCS800-S0x-2050-06/07
DCS800-S0x-2500-06/07
DCS800-S01-3000-06/07
DCS800-S02-3000-06/07
DCS800-S0x-3300-06/07
DCS800-S0x-4000-06/07
DCS800-S0x-4800-06/07
790 V
DCS800-S0x-1900-08
DCS800-S0x-2050-08
DCS800-S0x-2500-08
DCS800-S01-3000-08
DCS800-S02-3000-08
DCS800-S0x-3300-08
DCS800-S0x-4000-08
DCS800-S0x-4800-08
1000 V
DCS800-S0x-2050-10
DCS800-S0x-2600-10
DCS800-S0x-3300-10
DCS800-S0x-4000-10
Model
Fuse F1
Size
Type
L1 L2 L3
D5
D5
D5
D6
D6
D6
D6
D7
D7
D7
800A 660V UR
1250A 660V UR
1600A 660V UR
1500A 660V UR
900A 660V UR ➀
1500A 660V UR ➀
1250A 660V UR ➀
2500A 660V UR
3000A 660V UR
3500A 660V UR
5
5
5
5
5
5
5
7
7
7
170M 6162
170M 6166
170M 6169
170M 6168
170M 6163
170M 6168
170M 6166
170M 7026
170M 7028
170M 7057
D5
D5
D5
D6
D6
D6
D6
D7
D7
D7
630A 1250V UR
1100A 1250V UR
1400A 1100V UR
700A 1250V UR ➀
1000A 1250V UR ➀
1100A 1250V UR ➀
1000A 1250V UR ➀
2500A 1000V UR
3000A 1000V UR
3000A 1000V UR
6
6
6
6
6
6
6
8
8
8
170M 6144
170M 6149
170M 6151
170M 6145
170M 6148
170M 6149
170M 6148
170M 7036
170M 7156
170M 7156
D6
D6
D6
D6
D6
D7
D7
D7
700A 1250V UR ➀
700A 1250V UR ➀
1000A 1250V UR ➀
1100A 1250V UR ➀
1000A 1250V UR ➀
2500A 1000V UR
3000A 1000V UR
3000A 1000V UR
6
6
6
6
6
8
8
8
170M 6145
170M 6145
170M 6148
170M 6149
170M 6148
170M 7036
170M 7156
170M 7156
D7
D7
D7
D7
1800A 1250V UR
1800A 1250V UR
2500A 1250V UR
2500A 1250V UR
9
9
9
9
170M 7976
170M 7976
170M 7978
170M 7978
F1x
F1x
F1x
F1x
F1x
F1x
➀ 12 fuses per bridge (2x per F1x)
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
104
Size 5, 6
Size 7...10
Indicator
15
33
4xM10
min 10 deep
Ø
max 105
Ø 56
max d
c
11
max 105
14
17
82.5
67.5
11
max d
108
Ø 11
139
b
b
a
A
8
25
25
6
100
Size
5
6
a
50
80
b
29
14
c
30
30
d
76
76
Size
7
8
9
10
A
62
90
105
120
Remark:
Given dimensions may be exceeded in some
cases. Please take them only for information.
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
105
Accessories
DCF803-0035 and FEX 425 internal
The field exciter DCF803 0035 and FEX425intern are half controlled three-phase field converter. Both
field converters are based on the same controller board SDCS FEX4. The board is equipped with own
synchronization and current control. The current measurement circuit is automatic scaled based on
rated motor field current. The field exciter is fully controlled and monitored via serial communication
from armature converter.
The field exciter is prepared to operate as three phase or single phase converter. Single phase
operation is provided with terminals U and W
measurement channel
5A
35 A
IFact
Setting of switchable burden
resistors by rated field current
U
V
W
Field
Fex4x1.dsf
Layout of the SDCS-FEX-4 board
X1
X110
1 2
240
T110
1
T113
X2
S800
X5
T111
D800
U730
S801
U731
1
2
V1
S1100
X71
U1
S2
R106
V110
X101
X7
1
3
W1
X6 X4
R107
R108
115
3
D1
T112
2 3
2
5A
X100
X3
35A
P1
P2
Fex4_layout.dsf
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
106
Electrical data
Power circuit
AC Field input voltage
110 V -15%...500 V +10% single or three-phase
AC input current
< DC output current
Frequency
same as DCS Converter module
AC isolation voltage
600 V
Line reactor
external or shared with D5 armature converter
Line fuses
KTK25 for FEX425 internal; external for DCF803-0035
DC output current
300 mA (min)...25 A= FEX425 internal; ...35 A = DCF803-0035
Powerloss
< 130 W ( at rated current)
Auxiliary supply
DC input voltage
24 V DC
Input current
< 200 mA supplied from SDC-DSL-4 X51
Buffering
10ms
Control unit
The control includes the following main blocks:
•
Micro controller H8 for current control synchronization and fault handling.
•
Two channel actual field current measurement of DC circuit.
•
H8 controller for serial communication based on CAN standard.
•
Driver circuit for firing of half control bridge.
•
The software is stored in the flash PROM memory. This software contains
PI current control for field circuit
Fault reset logic
Synchronization and PLL function
setting of current measurement channel
The setting and updating of all control parameters are set from armature converter via DCS link serial
communication. Actual field current reference, current control and status bits are cyclic sent via DCS
link serial communication.
The field exciter is equipped with an autoscaling function of burden resistor based on nominal field
current of motor.
Power section
The power section is a three-phase half controlled bridge with free-wheeling diode.
The external field exciter DCF803-0035 is the three-phase half controlled bridge including snubbers
based on SDCS-FEX-4 board. Line fuses and the line choke and transformer must be located outside
the housing.
The internal field exciter FEX425 is a ready installed field exciter in a D5 armature converter. The unit is
based on a SCDS-FEX-4 board and contains also line fuses and three-phase connection to armature
bridge. This internal supply can be removed and connected to an independent AC field supply.
The snubbers are designed to operate in parallel with armature bridge and shared the armature line
choke.
If the unit is used as a single phase supply the terminal U and W must be used. For single-phase supply
an autotransformer for voltage adaption is recommended.
Please see comparison of output voltage ripple between single-phase and three phase-supply.
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
107
Voltage ripple of UDC voltage depending on operation modes
1
single-phase half-controlled
Voltage ripple Vsec
0,75
0,5
0,25
three-phase half-controlled
0
0,1
0,4
0,7
1
U dc field
three-phase full-controlled
DCS LINK communication
The field converter is controlled from armature converter via DCS link serial communication based on
CAN hardware.
.
Fex4_DCSLink.dsf
X1:1
24 V / 200 mA
Supply
24 V
2
X3:1
S1100:1 CANL
2
CANH
3
GNDB
S1100:3
S1100:2
Termination 200 kOhm
Node address is set by: S800 digit 0
≤ 200 mA
DSL communication
Bus termination
S1100
:1 = ON
:1 = OFF
Ground termination
S1100
:2 = ON
:3 = ON
:2,:3 = OFF
Remarks
24 V grounded supply f. SDCS-FEX-4
Remarks
120 ohm
no termination
200 kOhm R-C ground termination
0 Ohm ground termination
no termination
(node adress 00 is not possible!)
S801 digit 10
Same node address must be selected in the corresponding armature converter.
example: node adress=13 ==> S800 = 3 and S801 = 1
Selection of communication speed is set by S1100
S1100:6 S1100:5
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
S1100:4 Baudrate
kBaud *
OFF
20
ON
50
OFF
125
ON
250
OFF
500
ON
800
OFF
888
ON
1000
Selection of armature
converter
0
1
2
3
4
5
6
7
* see Parameter 94.08, 94.09
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
108
Diagnosis
All messages are sent to armature converter and displayed by armature converter control panel. If
communication is broken or node numbers are mixed up a simple fault display on SDCS-FEX-4 board
can be used. Therefore the unit is equipped with two small LED.
U730 = Green
U731 = Yellow
Following messages are displayed:
both OFF
no 24V supply
green and yellow continues
No firmware
green blinking
25 A / 35 A output active, waiting for DCSLINK communication
green continues
25 A / 35 A output active, DCSLINK communication OK
yellow blinking
5A output active (X100:2), waiting for DCSLINK communicat.
yellow continues
5A output active (X100:2), DCSLINK communication OK
green and yellow toggling:
X times yellow
Y times green
X=1
Y=1
Alarm phase missed
Y=2
Alarm maximum temperature heatsink
X=2
Y=1
Fault
DCS link serial communication failed
Y=2
Fault
Synchronization fault
Y=3
Fault
Overcurrent
Y=5
Fault
Field AC supply voltage < 30V
Y=6
Fault
Field AC supply voltage < 650V
Y=9
Fault
maximum temperature heatsink
Y=12
Fault
Auxiliary voltage
Y=14
Fault
general hardware
No RESET
Y=15
Fault
general software
No RESET
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
109
RS232-Port
The RS232 interface is used for download the 'Field exciter firmware package'.
The default settings of this interface are as follows:
Signal level:
RS232 (+12V / -12V)
Data format:
UART
Message format:
Modbus-Protocol
Transmission method:
half-duplex
Baudrate:
9.600 Baud
Number of Data bits:
8
Number of Stop bits:
1
Parity-Bit:
odd
X2:
Description
1
not connectedßtext1
2
TxD
3
RxD
4
not connected
5
SGND Signal ground
6...9
not connected
1
5
9
6
The programming procedure is activated by setting S1:1-2 during auxiliary voltage is switched ON.
Setting for field exciter mode is S1:3-4 (default).
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
110
Fuses and fuse holders
Type
170M 1558
170M 1559
170M 1561
170M 1564
170M 1565
170M 1566
170M 1568
170M 3815
170M 3816
170M 3817
170M 3819
170M 5810
170M 6811
170M 6813
170M 6163
170M 6166
Resistance [mΩ]
30
21
15
6
4
3
1.8
0.87
0.59
0.47
0.37
0.30
0.22
0.15
0.15
0.09
Fuse F1
10A 660V UR
21A 660V UR
25A 660V UR
50A 660V UR
63A 660V UR
80A 660V UR
125A 660V UR
200A 660V UR
250A 600V UR
315A 660V UR
400A 660V UR
500A 660V UR
700A 660V UR
900A 660V UR
900A 660V UR
1250A 660V UR
Size
0
0
0
0
0
0
0
1
1
1
1
2
3
3
4
4
Fuse holder
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 00 S3L
OFAX 1 S3
OFAX 1 S3
OFAX 1 S3
OFAX 1 S3
OFAX 2 S3
OFAX 3 S3
OFAX 3 S3
170H 3006
170H 3006
L1 L2 L3
F1
Dimensions [mm] Size 0...4
Size 0...3
Indicator
c
a
Size
0
1
2
3
a
78,5
135
150
150
b
50
69
69
68
b
2
10
6
Fuse1_a.dsf
d
e
Size 4
30
76
11
Indicator
11
14
17
76
108
139
50
29
6
29
fuse2_a.dsf
Main dimensions of fuse holders
Fuse holder
OFAX 00 S3L
OFAX 1 S3
OFAX 2 S3
OFAX 3 S3
HxWxD [mm] Protection
148x112x111
IP20
250x174x123
IP20
250x214x133
IP20
265x246x160
IP20
OFAX ...
OFA X 2 S3
H
W
D
170H 3006 (IP00)
110
A-A
M8
M10
27
77
64
M8
A
A
60
85
205
40
Ø
9
180
170H3006_a.dsf
M10
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
c
35
45
55
76
d
21
45
55
76
e
15
20
26
33
111
Line chokes
Line chokes type ND 01...ND 16
Line chokes for use in industrial environment (minimum requirements), low inductive voltage drop, deep
commutation notches.
Line chokes ND01...ND06 are equipped with cables. The bigger ones ND07...ND16 are equipped with
busbars. When connecting them to other components, please take relevant standards into account in
case the materials are different. Don't use choke terminals as cable or busbar support!
Type
ND 01
ND 02
ND 03
ND 04
ND 05
ND 06
ND 07
ND 08
ND 09
ND 10
ND 11
ND 12
ND 13
ND 14
ND 15
ND 16
Choke
L
[µH]
Ipeak
[A]
rated
Voltage
[UN]
Weight
Irms
[A]
[kg]
Power loss
Fe
Cu
[W]
[W]
512
250
300
168
135
90
50
56.3
37.5
25.0
33.8
18.8
18.2
9.9
10.9
6.1
18
37
37
55
82
102
184
196
245
367
326
490
698
930
1163
1510
27
68
68
82
122
153
275
294
367
551
490
734
1047
1395
1744
2264
500
500
600
500
600
500
500
600
500
500
600
500
690
500
690
500
2.0
3.0
3.8
5.8
6.4
7.6
12.6
12.8
16.0
22.2
22.6
36.0
46.8
46.6
84.0
81.2
5
7
9
10
5
7
45
45
50
80
80
95
170
100
190
210
recommended
for armature
converter type
16
22
20
33
30
41
90
130
140
185
185
290
160
300
680
650
DCS...-0025
DCS...-0050
DCS...-0050
DCS...-0075
DCS...-0110
DCS...-0140
DCS...-0250
DCS...-0270
DCS...-0350
DCS...-0520
DCS...-0450
DCS...-0680
DCS...-0820
DCS...-1200
DCS...-1500
DCS...-2000
Line chokes type ND 01...ND 06
3
A
A
X
B
Y
X, Y, Z
C
Z
A, B, C
B
C
A, B, C
Y
0
100
Z
X, Y, Z
c
X
60
0
a
a1
d
b
Type
a1
a
b
c
d
e
f
g
ND 01
ND 02
ND 03
ND 04
ND 05
ND 06
120
120
148
148
148
178
100
100
125
125
125
150
130
130
157
157
157
180
48
58
63
78
78
72
65
65
80
80
80
90
116
116
143
143
143
170
4
4
5
5
5
5
8
8
10
10
10
10
mm²
6
10
10
16
25
35
g
e
ND1_to_6_a.dsf
f
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
112
Line chokes type ND 07...ND 12
I (6x)
H ±2
F ±0.3
E±2
A
C1
K
L
E ±2
A ±2
min 30 without varnish for
conduction to the mounting plate
G ±4
15
C ±1
3 AST4 78 2 23 D5
3AFE 10014603
0 .0 1 88 mH
4 90 A
I ma x 7 34 A
A
7
15
A-A
ND7_to_12_c.dsf
F ±0.3
B ±1
Type
ND 07, 08
ND 09
ND 10, 11
ND 12
A
285
327
408
458
B
230
250
250
250
C
86
99
99
112
C1
100
100
100
113
F
176
224
224
224
G
65
63
63
63
H
80
100
100
100
I
9x18
9x18
11x18
13x18
K
385
423
504
554
L
232
280
280
280
busbar
20x4
30x5
60x6
40x6
Line chokes type ND 15, 16
all busbars 60x10
151±2
140 ±2
90
100
45
45
140
45
30
20
100
ø13
30
60
15
15
150 ±2
A
40
A
ND13_14_c.dsf
15
30
140
390±1
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
147
(6x) 10x18
290 ±1
13
147
80
50
40
ø13
440 ±2
min 30 without varnish
for conduction to the
mounting plate
10
123 ±2
A-A
316 ±0.3
176 ±5
40
18
ø13
A-A
224 ±0.3
342 ±2
min 30 without varnish for
conduction to the mounting plate
154 ±4
30
18x13(3x)
Line chokes type ND 13, 14
all busbars 40x10
E
250
292
374
424
A
181±2
48
A
ND15_16_c.dsf
113
Line chokes type ND 401...ND 413
Line chokes for use in light industrial/residential environment, high inductive voltage drop, reduced
commutation notches.
These chokes are designed for drives which usually operate in speed control mode at 400 V or 500 V
networks. Because of that a duty cycle has been taken into account. The percentage taken into account
for that duty cycle is different for 400 V and 500 V networks:
- for Urated supply = 400 V, DC curr. 1 = 90% of nominal current
- for Urated supply = 500 V, DC curr. 1 = 72% of nominal current
For easier reading the maximum average DC load current is listed instead of the percentage in the next
table.
Line chokes ND401...ND402 are equipped with terminals. The bigger ones ND403...ND413 are
equipped with busbars. When connecting them to other components, please take relevant standards
into account in case the materials are different.
Type
ND 401
ND 402
ND 403
ND 404
ND 405
ND 406
ND 407
ND 408
ND 409
ND 410
ND 411
ND 412
ND 413
Choke
rated Weight
L
Irms
Ipeak Voltage
[mH] Line AC [A] [A]
[UN]
[kg]
1000
18.5
27
400
3.5
600
37
68
400
7.5
450
55
82
400
11
350
74
111
400
13
250
104
156
400
19
160
148
220
400
22
120
192
288
400
23
90
252
387
400
29
70
332
498
400
33
60
406
609
400
51
50
502
753
400
56
40
605
805
400
62
35
740
1105
400
75
Power loss
Fe
Cu
[W]
[W]
13
35
13
50
42
90
78
105
91
105
104
130
117
130
137
160
170
215
260
225
260
300
280
335
312
410
Load
DC curr. 1
(f. Usupply=400V)
22.6
45
67
90
127
179
234
315
405
495
612
738
900
Load
DC curr.2
(f. Usupply=500V)
18
36
54
72
101
143
187
252
324
396
490
590
720
Line chokes type ND 401...ND 402
Type
A B C D E F ØG ØH
ND 401 160 190 75 80 51 175 7
9
ND 402 200 220 105 115 75 200 7
9
A X
170
B Y
Terminals:
WAGO Type 202
UL File E45172
C Z
øH
tin-coated
Y
Z
A
B
C
A
X
D
øG
ø G+5
F±1
E±2
B
C
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
114
Line chokes type ND 403...ND 408
Type
ND 403
ND 404
ND 405
ND 406
ND 407
ND 408
A
220
220
235
255
255
285
B
230
225
250
275
275
285
C
120
120
155
155
155
180
D
135
140
170
175
175
210
E
100
100
125
125
125
150
F
77.5
77.5
85
95
95
95
ØG ØH
7
9
7
9
10 9
10 9
10 9
10 9
ØK
6.6
6.6
6.6
9
11
11
B
øH
tin-coated
X
Y
Z
A
øK AL
A
B
C
ø G+5
50
45
10
E ±2
F ±2
C
D
Line chokes type ND 409...ND 413
Type
ND 409
ND 410
ND 411
ND 412
ND 413
A
320
345
345
385
445
B
280
350
350
350
350
C
180
180
205
205
205
D
210
235
270
280
280
E
150
150
175
175
175
F
95
115
115
115
115
ØG
10
10
12
12
12
ØH
11
13
13
13
13
ØK
11
14
2x11
2x11
2x11
B
øH
tin-coated
A
B
C
X
Y
Z
A
øK AL
A
X
Y
B
C
Z
øG+6
12
F ±2
E ±2
C
D
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
115
Autotransformer T3
Type
for Field curr.
IF
T 3.01
T 3.02
T 3.03
T 3.04
T 3.05
≤6 A
≤12 A
≤16 A
≤30 A
≤50 A
T 3.11
T 3.12
T 3.13
T 3.14
T 3.15
≤6 A
≤12 A
≤16 A
≤30 A
≤50 A
Transformer's
secondary current
Isec
Uprim = 500 V; 50/60Hz
≤7 A
≤13 A
≤17 A
≤33 A
≤57 A
Uprim = 690 V; 50/60Hz
≤7 A ➀
≤13 A ➀
≤17 A ➀
≤33 A
≤57 A
Weight Power loss Fuse F3
[kg]
PV [W]
[A]
15
20
20
36
60
65
100
120
180
250
10
16
25
50
63
15
20
30
60
60
80
125
150
230
320
10
16
20
50
63
➀ 690 V transformer input cannot be used for the field converters SDCS-FEX-1 and SDCS-FEX-2 (isolation only 600
V max.)
A
F3
F3
T3
h
T3
Type
T 3.01 / T 3.11
T 3.02 / T 3.12
T 3.03
T 3.13
T 3.04
T 3.14
T 3.05 / T 3.15
G
C
D
e
A B C D
h
e
G
210 110 112 75 240 10x18 95
210 135 112 101 240 10x18 95
230 150 124 118 270 10x18 95
260 150 144 123 330 10x18 95
295 175 176 141 380 12x18 95
B
Line choke L3 for SDCS-FEX-2
1
3
4
1000
2
line choke data L3
Weight Pow
er
loss
L
Irms Ipeak
[µH]
[A]
[A]
[kg]
[W] [mm²]
ND30 2x >500 16
16
1.1
8
2
2
3
4
max70
Type
1
4.5 Ø
55
37
max 80
52
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
116
Supply transformer T2 for electronics and fan
The supply transformer T2 has been re-designed. The new power and current rating allows to supply
then 2-phase fans and the electronics by one transformer only in case A5 converters are used in a 12pulse configuration.
They differ in their electrical data and therefore can be identified by their name plate.
Input voltage:
230/380...690 V/1~; ±10%
Frequency:
50...60 Hz
F2
Output voltage:
115/230 V/1~
T2
Type Power Weight Fuse F2
[VA]
[kg]
[A]
T2
1400
15
16
230 V
115 V
T2_a.dsf
0V
Isec
Power loss
[A]
[W]
6 (0...230 V)
100
12 (0...115 V)
35
0
115
230
0
380
400
415
450
500
525
575
600
660
690
150
6.3 mm Faston
106
128
125
148
T2_dim.dsf
100 +-5
Application hint:
The transformer is designed to work as a 230 V / 230 V transformer to open/
avoid ground loops. This is done via the 380 V and 600 V taping according to
the left picture.
230 V
F2
T2
230 V
115 V
T2_a.dsf
0V
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
117
Optical cables
For the bus communication of the DCS converters there are different optical cables available.
Kind of cable
Connector cable length
plastic fibre optic single cable
plug
0.5...20 m
plastic fibre optic double cable
plug
0.5...20 m
HCS silica (double) without plastic jacket
plug
30...50 m
HCS silica (double) with plastic jacket
plug
50...200 m
Ident. no.
3ADT 693324
3ADT 693318
3ADT 693355
3ADT 693356
Fig.
1
2
3
4
Figure 1
L
Figure 2
L
blue
black
black
blue
Figure 3
L
orange
orange
5 mm
black
black
Figure 4
L
blue
red
blue
8 mm
red
for DCS 400
DCS 500
DCS 600
black
for DCS 600 selected channels.
see manual NDBU 3ADW 000 100 R0201
blue
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
118
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
3ADW000194R0201_Rev B
10_2005
ABB Automation Products GmbH
Postfach 1180
68619 Lampertheim • GERMANY
Telefon: +49 (0) 62 06 5 03-0
Telefax: +49 (0) 62 06 5 03-6 09
www.abb.com/dc
*194R0201A5400000*
*194R0201A5400000*

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project