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DCS800
Hardware Manual
DCS800 Drives (20 to 5200 A)
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Hardware Manual DCS800 00S
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Technical Guide
Service Manual DCS800
Planning and Start-up for12-Pulse converters
CMA-2 Board
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DDCS Branching unit User´s manual
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DCS800 Application
1131Programming Tool +Libary
1131 DCS800 target +tool description
Winding with the DCS 800XXXXX
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DCS800 00A Enclosed
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System description DCS800 00A
Installation of DCS800 00A
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DCR Manual
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3 ADT 645 0 ??
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3 ADW 000 163
3 ADW 000 195
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3ADW000199
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RAIO-01 Analogue IO Extension
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Serial interfaces
Drive specific serial communication
Installation and Start-up GuideRPBA-12 (PROFIBUS)
Fieldbus Adapter with DC Drives RPBA- (PROFIBUS)
3AFE 644 84567
3AFE 644 85733
3AFE64661442
3 AFE 645 04215
Fieldbus Adapter with DC Drives RCAN-02 (CANopen)
Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3 AFE 645 06005
Fieldbus Adapter with DC Drives RDNA- (DeviceNet)
Fieldbus Adapter with DC Drives RMBA (MODBUS)
Fieldbus Adapter with DC Drives RETA (Ethernet) x -> existing p -> planned
3 AFE 645 504223
3 AFE 644 98851 x x x x x x x x p p p p
E x p p x p p x x x x x x x x x x x p p p x p p p
D p
Language
I ES p p p p p p p p
F p p p p
CN RES
NN p JF
JF p JF p TW p TV
TW
TW
NN
NN
TW
UW x vdB vdB vdB vdB vdB vdB
UW
UW
UW
UW
UW vdB
UW
UW
UW
TW
TW
TW vdB vdB vdB vdB vdB
TV
TV
TV vdB vdB vdB vdB
DCS800 Drives
20 to 5200 Amps
Hardware Manual
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2005 ABB Automation Products GmbH. All rights reserved.
served.
3ADW000194R0201 DCS800 Hardware Manual e b
3ADW000194R0201 Rev B
EFFECTIVE: 05.10.2005
3ADW000194R0201 DCS800 Hardware Manual e b
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.
5
3ADW000194R0201 DCS800 Hardware Manual e b
Safety instructions
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
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.
7
3ADW000194R0201 DCS800 Hardware Manual e b
Safety instructions
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
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.
9
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table of contents
The DCS800
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The DCS800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Armature circuit converter DCS800 D1...D4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Armature circuit converter DCS800 D5...D7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rebuild system DCR800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mechanical installation
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mounting the converter module D6 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting the converter module D7 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Options for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Aspects of fusing for the armature-circuit and field supplies of DC drives . . . . . . . . . . . . . . . 28
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
12
Semiconductor type F1 fuses and fuse holders for AC and DC power lines . . . . . . . . . . . . . 30
Fuses F3.x and fuse holders for field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single-phase Transformer T3 for field supply to match voltage levels . . . . . . . . . . . . . . . . . 31
Single-phase Commutating reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Auxiliary transformer T2 for electronic system / fan supply . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Residual current detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Three-phase filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Converters D1...D4 drive configuration using ’on board’ field exciter . . . . . . . . . . . . . . . . . . . . . . . 38
Converters D5 drive configuration using ’FEX-425-Int’ field exciter . . . . . . . . . . . . . . . . . . . . . . . . 39
Converters D5...D7 drive configuration using ’external’ field exciter DCF803, DCF804 . . . . . . . . . 40
START, STOP and E-STOP control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Drive configuration with reduced components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power section cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mains cable (AC line cable) short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cross-sectional areas - Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DCS800 panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Location R-Extension and Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
I/O Board Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pulse encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pulse encoder receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connecting the signal and control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DSL Link Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fan replacement (D6, D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
13
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Current ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Control Board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Layout of the control board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Memory circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Watchdog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Seven segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Terminal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Digital and analogue I/O connection of the SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Interface Board SDCS-COM-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
DDCS Branching unit NDBU-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DSL Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Digital I/O board SDCS-IOB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Analogue and encoder I/O board SDCS-IOB-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Power Supply Board SDCS-POW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Interface Board SDCS-PIN-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Armature circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Field circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Galvanic isolation - T90, A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
DC-DC transducer A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Transformer T90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DCS LINK communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
3ADW000194R0201 DCS800 Hardware Manual e b
Size D7
2050...5200
The DCS800
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-S01-
2005). 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
Position A X Y Z B
Position
A
Product series
Type
X
Y
ZZ
B
Bridge type
Rated current
Rated voltage
(nominal rating in bold)
Power connection
Internal field exciter configuration
Fan voltage
SDCS-DSL board
+ plug-in options
Control panel
Fieldbus
I/O and DDCS
+S171
+S172
+S173
+S199
+0S199
0J400
K...
L...
Plus code
+S163
+0S163
DCS800
S0 = Converter module IP00
R0 = Rebuild system
E0 = Panel solution
A0 = Enclosed converter
1 = Single bridge 2-Q
2 = Double bridge 4-Q
YYYY = Rated current (e.g. 0025 = 25 amps)
04 = 400 V
05 = 500 V
06 = 600 V
07 = 690 V
08 = 790 V
10 = 990 V
12 = 1200 V
- = Standard D1...D6
L = Left side D7
R = Right side D7
0 = with internal field exciter (only D5)
A = without internal field exciter (only D1...D4)
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
SDCS-DSL board no SDCS-DSL board no control panel
The DCS800
3ADW000194R0201 DCS800 Hardware Manual e b
Main circuit and control
Armature circuit converter DCS800 D1...D4
Three-phase field supply
DCF 803 / 804
On Board FEX PIN 4
17
Slot 1
X9
Fieldbus interface R...
Memory Card
X20
Slot 4
Slot 2
X10
RDIO
RAIO
Slot 3
X11
COM-8
NDBU95
optical fibre optical fibre
Master/
Follower
NAMIA
NDBU95
3ADW000194R0201 DCS800 Hardware Manual e b
The DCS800
18
Armature circuit converter DCS800 D5...D7
Three-phase field supply
DCF 803 / 804
FEX 425 internal **
The DCS800
Slot 1
X9
Fieldbus interface R...
Memory Card
X20
Slot 4
Slot 2
X10
RDIO
RAIO
Slot 3
X11
COM-8
NDBU95
optical fibre optical fibre
Master/
Follower
NAMIA
NDBU95
3ADW000194R0201 DCS800 Hardware Manual e b
Rebuild system DCR800
Three-phase field supply
DCF 803 / 804
FEX 425 internal
19
Slot 1
X9
Fieldbus interface R...
Memory Card
X20
Slot 4
Slot 2
X10
RDIO
RAIO
Slot 3
X11
COM-8
NDBU95
optical fibre optical fibre
Master/
Follower
NAMIA
NDBU95
3ADW000194R0201 DCS800 Hardware Manual e b
The DCS800
20
The DCS800
3ADW000194R0201 DCS800 Hardware Manual e b
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.
21
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
Floor
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.
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
Mechanical installation
Cooling w baffle.dsf
Airflow
Lead the exhaust cooling air away from the unit above.
Distances see chapter
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
23
Mounting the converter module D6 inside an enclosure
Cooling air entry
The cooling fan takes the air from the backside, both sides and from the area underneath the converter module.
View from: the right side the back the left side
Free space around the conerter module
optimum compromise
50 ~ 100
50 50
Top view
Top view air flow air flow air flow air flow air flow air flow
Cooling air outlet
To avoid circulating air inside the enclosore it is recommended to make sure the exhaust air leaves the enclosure.
A6_li_air_inlet.dsf
Cable entries
C
D
U
Power cable connection
The power cable connection is performed via T
erminal option 01 for A6
. This option consists of one right angle copper busbar. The mechanical details are shown by the figure below.
100
72.2
75
Ø14
21.8
0
250
25
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.
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.
V
W
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).
A6_li_air_inlet_a.dsf
max.
35mm
468.2
3ADW000194R0201 DCS800 Hardware Manual e b
Example right side connection
Mechanical installation
24
Mounting the converter module D7 inside an enclosure
Cooling air entry
The cooling fan takes the air from the backside, both sides and from the area underneath the converter module.
View from front left side / (right side)
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).
ai r flo w
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.
>20
50
A7_re_air_inlet.dsf
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
(P cc
)
u k
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% u k
(relative impedance voltage). It should not exceed 10% u k
, due to considerable voltage drops at converter output.
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
26
Line
L
Line
PCC
L
(P
LR cc
)
Line
PCC
(P cc
)
Configuration B
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.
The combined impedance of Z
Line and Z
LR 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 U k Line
=1%;
U k LR
=4%;
Voltage Dip = Z
Line
/(Z
Line
+Z
R
see
Technical Guide
.
)=20%
. Detailed calculation
Configuration C
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 u k is >1 %.
Line
PCC
(P cc
)
L
LR
L
LR
Configuration C1
L
LR
....
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
Line reactors L1
DCS Type
400V-690V
50/60 Hz
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-S01-0290-06
DCS800-S01-0315-04/05
DCS800-S01-0405-04/05
DCS800-S01-0590-06
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-S02-0320-06
DCS800-S02-0350-04/05
DCS800-S02-0450-04/05
DCS800-S02-0650-06
DCS800-S02-0550-04/05
DCS800-S02-0680-04/05
DCS800-S02-0820-04/05
DCS800-S02-1000-04/05
DCS800-S01-0900-06/07
DCS800-S01-1200-04/05
DCS800-S01-1500-04/05/06/07 DCS800-S02-1500-04/05/06/07
DCS800-S01-2000-04/05 DCS800-S02-2000-04/05
DCS800-S01-2000-06/07
DCS800-S02-0900-06/07
DCS800-S02-1200-04/05
Line choke Design Line choke Design type for Fig.
type for Fig.
configur.
A
configur.
B
ND01
ND02
ND04
ND06
ND06
ND07
ND07
ND08
ND09
ND10
ND13
ND10
ND12
ND13
ND13
ND13
ND14
ND15
ND16
ND16 *
1
1
1
1
1
2
2
2
2
2
3
2
2
3
3
3
3
3
3
3
ND401
ND402
ND403
ND404
ND405
ND406
ND407 on request
ND408
ND409 on request
ND410
ND411
ND412
ND413 on request on request on request on request on request
5
-
5
5
-
5
5
5
-
-
-
-
5
-
5
5
5
5
4
4
* with forced cooling (1m/s)
27
Fig. 1 Fig. 2
Fig. 3
Fig. 4 Fig. 5
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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
3
2
M
The figure shows the arrangement of the switch-off elements in the armature-circuit converter
.
.
.
.
.
For field supply see Fig. 2.6/2
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
2-Q non-regen.
M
Semiconductor
fuses
DCS converter
4-Q resp.
2-Q regenerative
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
Configurations for field supplies
F3.3
F3.1
ND30 / built-in
2
FF_ASP_b.dsf
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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 Type Fuse holder
2-Q Converter 4-Q Converter
DCS800-S01-0020-04/05 DCS800-S02-0025-04/05 170M 1564 OFAX 00 S3L
DCS800-S01-0045-04/05 DCS800-S02-0050-04/05 170M 1566 OFAX 00 S3L
DCS800-S01-0065-04/05 DCS800-S02-0075-04/05 170M 1568 OFAX 00 S3L
DCS800-S01-0090-04/05 DCS800-S02-0100-04/05 170M 1568 OFAX 00 S3L
DCS800-S01-0125-04/05 DCS800-S02-0140-04/05 170M 3815 OFAX 1 S3
DCS800-S01-0180-04/05 DCS800-S02-0200-04/05 170M 3816 OFAX 1 S3
DCS800-S01-0230-04/05 DCS800-S02-0260-04/05 170M 3817 OFAX 1 S3
DCS800-S01-0315-04/05 DCS800-S02-0350-04/05 170M 5810 OFAX 2 S3
DCS800-S01-0405-04/05 DCS800-S02-0450-04/05 170M 6811 OFAX 3 S3
DCS800-S01-0500-04/05 DCS800-S02-0550-04/05 170M 6811 OFAX 3 S3
DCS800-S01-0610-04/05 DCS800-S02-0680-04/05 170M 6163 3x 170H 3006
DCS800-S01-0740-04/05 DCS800-S02-0820-04/05 170M 6163 3x 170H 3006
DCS800-S01-0900-04/05 DCS800-S02-1000-04/05 170M 6166 3x 170H 3006
DCS800-S01-0290-06
DCS800-S01-0590-06
DCS800-S02-0320-06
DCS800-S02-0650-06
170M 5810
170M 6813
Fuses and fuse holders (details see chapter
Technical Data
)
OFAX 2 S3
OFAX 3 S3
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.
Type of protection elements
Field current
F3.1
DCF803-0035 I
F
FEX-425-Int
DCF803
I
F
I
F
≤
6 A 170M 1558 * OFAA 00 H10
≤
12 A 170M 1559 * OFAA 00 H16
≤
16 A 170M 1561 * OFAA 00 H25
DCF804
DCF803 I
F
≤
30 A 170M 1564 OFAA 00 H50
DCF804
DCF803 I
F
≤
50 A 170M 1565 OFAA 00 H63
DCF804
Semiconduct.
type fuse for fuse holder type OFAX 00
F3.2
LV HRC type for 690 V; fuse hold. OFAX 00
F 3.3
10 A
16 A
25 A
50 A
63 A circuit breaker for 500 V or
690 V
* 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
≤
500 V; 50/60 Hz for field current
I
F external supply
Transformer type 50/60 Hz
DCF803-0035
FEX-425-Int
DCF803/4-0050
DCF803/4-0050
DCF803-0035
FEX-425-Int
DCF803/4-0050
DCF803/4-0050
≤
≤
≤
≤
≤
≤
≤
≤
≤
12 A
16 A
30 A
50 A
≤
6 A
6 A
12 A
16 A
30 A
50 A
U prim
=
≤
500 V
T 3.01
T 3.02
T 3.03
T 3.04
U
T 3.05
prim
=
≤
600 V
T 3.11
T 3.12
U
T 3.13
prim
=
≤
690 V
T 3.14
T 3.15
Autotransformer data (details see chapter
Technical Data
)
Autotransformer.dsf
T3 autotransformer
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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.
Reactor Converter
≤
500 V; 50/60 Hz for field current
I
F
DCF803-0035 (16 A) 16 A
FEX-425-Int >16A
ND 30
*
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:
I
Filter
= 0.8 • I
MOT 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.
type
Filter type f. y=4 Filter type f. y= 5
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 230A DCS800-S02-0260-0y 260A
DCS800-S01-0315-0y 315A DCS800-S02-0350-0y 350A
DCS800-S01-0405-0y
DCS800-S01-0500-0y
IDC [A]
20A
45A
65A
90A
125A
180A
405A
500A
4-Q Converter
DCS800-S02-0025-0y
DCS800-S02-0050-0y
DCS800-S02-0075-0y 75A
DCS800-S02-0100-0y 100A
DCS800-S02-0140-0y
DCS800-S02-0200-0y
DCS800-S02-0450-0y
DCS800-S02-0550-0y
IDC [A]
25A
50A
140A
200A
450A
550A
D1
D1
D1
D1
D1
D2
D2
D3
D3
D3
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
NF3-500-25
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
DCS800-S01-0610-0y 610A DCS800-S02-0680-0y 680A D4 NF3-500-600 NF3-500-600
DCS800-S01-0740-0y 740A D4 NF3-500-600 NF3-500-600
DCS800-S01-0900-0y
DCS800-S01-0900-0y
DCS800-S01-1200-0y
900A
900A
1200A
DCS800-S02-0820-0y
DCS800-S02-1000-0y
DCS800-S02-0900-0y
DCS800-S02-1200-0y
820A
1000A
900A
1200A
D4 NF3-690-1000
➀
NF3-690-1000
➀
D4 NF3-690-1000
➀
NF3-690-1000
➀
D5 NF3-690-1000
➀
NF3-690-1000
➀
D5 NF3-690-1000
➀
NF3-690-1000
➀
DCS800-S01-1500-0y
DCS800-S01-2000-0y
≤
1500A
2000A
3000A
DCS800-S02-1500-0y
DCS800-S02-2000-0y
1500A
2000A
D5 NF3-690-1600
➀
NF3-690-1600
➀
D5 NF3-690-1600
➀
NF3-690-1600
➀
≤
3000A D6 NF3-690-2500
➀
NF3-690-2500
➀
➀
Filter only available on request
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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
DCF803-0035 *
FEX-425-Int *
DCF803-0050
DCF804-0050 further filters for dc current
[A]
8
16
50
50
12
30
Filter type
➀
U max
= 250 V
NF1-250-8
NF1-250-20
NF1-250-55
NF1-250-55
NF1-250-12
NF1-250-30
➀
The filters can be optimized for the real field currents: I
Filter
= I
Field
* single-phase operation
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
35
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
36
EMC filters
You will find further information in publication:
Technical Guide
chapter:
EMC Compliant Installa-
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
tion and Configuration for a
products and systems. The guideline ensures that the
Power Drive System
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
Residential area
Supply transformer for a residential area (rating normally 1,2 MVA)
Earthed neutral
Earthed public 400-V network with neutral conductor
Light industry
Medium-voltage network
Supply transformer for a residential area (rating normally 1.2 MVA)
Earthed neutral
Earthed public 400-V network with neutral conductor
Residential area
Earthed public 400-V network with neutral conductor
Mains filter
Line reactor
Converter 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.
Mains filter Mains filter
Line reactor +
Y-capacitor
Line reactor
Converter Converter
M M M
Operation at public low-voltage network together with other loads of all kinds.
M
Line reactor
Converter 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.
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
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 (
P
ower
D
rive
S
ystem), 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
Industrial zone
Earthed neutral
Line reactor +
Y-capacitor
Second environment
(industry) with restricted distribution
satisfied
Medium-voltage network
Supply transformer for a residential area (rating normally 1.2 MVA)
Earthed 400-V network with neutral conductor ;
3~ 400 A
Mains filter
Line reactor
Not applicable on customer's request satisfied
Industrial zone
Converter transformer
Medium-voltage network
Converter transformer with earthed
satisfied
iron core
(and earthed screen where appropriate)
I > 400 A and/or
U > 500 V
Line reactor
Standards
EN 61800-3
EN 61000-6-3
EN 61000-6-4
EN 61000-6-2
EN 61000-6-1
Classification
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).
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 Converter Converter 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.
M M M M
Operation at low-voltage network together with other loads of all kinds, apart from some kinds of sensitive communication equipment.
M M 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
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.
M 3~
M ~
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
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).
M 3~
M ~
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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.
M 3~
M ~
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
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
HW I/O
ON
RUN
RESET command location (10.01)
PC tool or panel
ON
RUN
RESET local / remote
USED MCW
7.04
used
Main Control Word 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.
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
42
K16
ELEC.
DISCONN.
EMER.
STOP
K15
1
S1
2
K15
K16
CON-2
DIx X6:9
K15
E-STOP
E-Stop ramp
speed
Timer K15
Timer K16
Block current control
K1 main contactor
Coast
Stop-Mode.dsf
E-Stop reaction
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
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.
43
M 3~
M ~
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
44
Power section cooling
Fan assignment for DCS800
Converter type
DCS800-S0x-0045-y1 ...
DCS800-S0x-00140-y1
DCS800-S0x-0180-y1 ...
DCS800-S0x-0260-y1
DCS800-S0x-0315-y1 ...
DCS800-S0x-0350-y1
DCS800-S0x-0405-y1 ...
DCS800-S0x-0550-y1
DCS800-S0x-0610-y1 ...
DCS800-S0x-0820-y1
DCS800-S0x-0610-y1 ...
DCS800-S0x-0820-y1
DCS800-S0x-0900-y1 ...
DCS800-S0x-1000-y1
DCS800-S0x-0900-y1 ...
DCS800-S0x-1000-y1
DCS800-S0x-0900-y1 ...
DCS800-S0x-2000-y1
DCS800-S0x-1900-y4/5/8 ...
DCS800-S0x-3000-y4/5/8
DCS800-S0x-1900-y6/7 ...
DCS800-S0x-3000-y6/7
DCS800-S0x-3300-y1...
DCS800-S0x-5200-y1
Model
D1
D2
D3
D3
D4
D4
Pluscode E171
D4
D4
Pluscode E171
D5
D6
D6
D7
Configuration
1
1
1
3
3
2
3
5
5
3
4
5
Fan Data for DCS800
Fan CN2B2 W2E200 W2E 200 W2E 250 W2E 250
Rated voltage [V]
Tolerance [%]
Frequency [Hz]
Power consumption [W]
Current consumpt. [A]
Blocking current [A]
Air flow [m3/h] freely blowing
Air flow [m3/h] at working point
115; 1~
±10
50
16
60
13
230; 1~
+6/-10
50
64
60
80
50
64
115; 1~
+6/-10
0.2
0.17
0.29 0.35
0.6
< 0.3 < 0.26 < 0.7 < 0,8 < 1.5
156 180 925 1030 925
-
60
80
0.7
< 1.8
1030
115; 1~
50
±10
60
230; 1~
+6/-10
50 60
120 165 135 185
1.06 1.44 0.59 0.82
< 1.8 < 1.8 < 0.9 < 0.9
1835 1940 1860 1975
-
Max. ambient temperature [° C]
Useful lifetime of grease
< 60 < 75 < 75 60 appr. appr.
40000 h/60° 45000 h/60° appr. 45000h/60° appr.
40000 h
60 appr.
40000 h
Protection Impedance
➀
Temperatur detector: internal connected
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.
Fan type
2x CN2B2
2x CN2B2
2x CN2B2
4x CN2B2
1x W2E200 (230 V)
1x W2E200 (115 V)
1x W2E250 (230 V)
1x W2E250 (115 V)
D2E 160
GR31M
400...500 V
GR31M
500...690 V
GR35C
400 V / 690 V
Planning the electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
45
Fan
Rated voltage [V]
Tolerance [%]
Frequency [Hz]
Power consumption [W]
Current consumpt. [A]
Blocking current [A]
Air flow [m3/h] freely blowing
Air flow [m3/h] at working point
Max. ambient temperature [° C]
D2E 160 GR31M GR31M
230; 1~
380... 500 V
400...450
450...500
∆
525... 690 V
400...500
∆
500...690 500...690
500
∆
653
±10
50 60
2.50
3.75
860
3.4
4.5
50
800
∆
700
1.45
∆
0.91
at 450 V
∆
8.5
±10
60
1340
∆
2.0 at 500 V
8.5
∆
∆
50
800
0.9 at 690 V
4.4
±10
60
1200
1.2 at 500 V
8.5
∆
50
GR35C
400 / 690 V
400...500
∆
600...690
+5/-10
2900
∆
2200
6.5
∆
2.3 at 400 V
∆
>25
±10
60
3600
∆
3300
4.9
3.0
∆ at 400 V
>30
∆
-
800
2.5 A
750
3.2 A
1500
1.26 A
(450V
∆
)
1600
1.6 A
(500V
∆
)
1500
0.7 A
(690V
< 55
)
1600
1.65 A
(500V
∆
)
4200
3.6 A
(400V
∆
)
4250
4.1 A
(400V
∆
)
Useful lifetime of grease
Protection appr. 30000 h/40°
Temperatur detector: U
N
≤
230 V~; I
N
≤
2.5 A~
Fan connection for DCS800
|-------------------------------------- Terminals on top of converter housing --------------------------------------|
Converter housing
230 Vac
230 Vac
X99: 1 2 3 4 5 X99: 1 2 3 4 5
115 Vac 115 Vac either 230 Vac or 115 Vac
X99: 1 2 3 4 5
X99: 1 2 3 4 5
X99: 1 2 3 4 5
X99: 1 2 3 4 5 X99: 1
L
2
N
3 4 5
M
~
M55
M
~
M56
M55 M56
M55
L N TW TW
X2: 1 2 3 4 5 6
~
Fan_con_c.dsf
U1 V1 W1 U2 V2 W2 PE TK TK
at Connection
U1-W2
V1-U2
W1-V2
U2-V2-W2
M57 M58
Configuration 1 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
Converter type
Recommended
cross-sectional area to
DINVDE 0276-1000
and
DINVDE 0100-540
(PE)
trefoil arrangement, up to 50°C ambient temperature.
C1, D1 (AM1, KM1)
1 (2.)
U1, V1, W1(AK1, AK3, AK5)
1 (2.)
PE
IDC
[A-]
DCS800-S0x-0050-xx
DCS800-S0x-0075-xx
DCS800-S0x-0100-xx
DCS800-S0x-0140-xx
DCS800-S0x-0200-xx
DCS800-S0x-0260-xx
DCS800-S0x-0???-xx
DCS800-S0x-0350-xx
DCS800-S0x-0450-xx
DCS800-S0x-0550-xx
DCS800-S0x-0680-xx
DCS800-S0x-0820-xx
DCS800-S0x-0900-6/7
DCS800-S0x-1000-xx
DCS800-S0x-1200-xx
DCS800-S0x-1500-xx
450
550
680
820
900
1000
1200
1500
DCS800-S0x-2000-xx
DCS800-S0x-1900-xx
➁
DCS800-S0x-2050-xx
➁
DCS800-S0x-2500-xx
➁
DCS800-S0x-2600-xx
DCS800-S0x-3000-xx
➁
DCS800-S0x-3300-xx
2000
1900
2050
2500
2600
3000
3300
DCS800-S0x-4000-xx 4000
DCS800-S0x-4800-xx
➀
4800
DCS800-S0x-5200-xx
➀
5200
50
75
100
140
200
260
270
350
4 x 185
8 x 120
8 x 120
8 x 120
7 x 185
7 x 185
8 x 185
8 x 185
7 x 300
8 x 300
8 x 300
[mm²]
1 x 10
1 x 25
1 x 25
1 x 35
2 x 35
2 x 35
2 x 35
2 x 70
2 x 95
2 x 95
2 x 120
2 x 150
4 x 95
2 x 185
4 x 120
[mm²]
-
-
-
-
1 x 95
1 x 95
1 x 95
-
-
-
-
-
3 x 150
-
-
-
Iv
[A~]
41
61
82
114
163
204
220
286
367
424
555
669
734
816
979
1224
6 x 185 1632
6 x 185 1550
6 x 185 1673
-
-
-
-
2040
2122
2448
2693
-
-
-
3264
3876
4202
[mm²]
1 x 6
1 x 25
1 x 25
1 x 35
2 x 25
2 x 25
2 x 25
2 x 50
2 x 95
2 x 95
2 x 120
2 x 120
4 x 70
2 x 150
-
-
-
-
3 x 95
-
4 x 95 3 x 120
4 x 150
4 x 240
-
-
4 x 240
6 x 120
8 x 120
8 x 120
5 x 150
6 x 185
6 x 185
7 x 185
7 x 185
8 x 240
6 x 300
6 x 300
-
-
-
-
[mm²]
-
-
-
-
1 x 95
1 x 95
1 x 95
2x150
2x240
3x120
3x120
4x120
4x120
4x150
4x150
4x240
3x300
3x300
1x 50
1x 50
1x 50
1x120
1x120
1x150
1x150
1x185
[mm²]
1x 6
1x 16
1x 16
1x 16
1x 25
1x 25
1x 25
1 x M10
1 x M10
1 x M12
1 x M12
2 x M12
1 x M12
2 x M12
2 x M12
1 x M6
1 x M6
1 x M6
1 x M6
1 x M8
1 x M8
1 x M8
1 x M8
2 x M12
4 x M12
4 x M12
4 x M12
4 x M12
4 x M12
4 x M12
4 x M12
4 x M12
4 x M12
➀
Reduced ambient temperature 40°C
➁
Option 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.
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
13
25
25
50
6
13
13
13
[Nm]
6
6
6
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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.
3ADW000194R0201 DCS800 Hardware Manual e b
Planning the electrical installation
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
PE
F+, Fohm
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
Fan
AC voltage for field circuit
AC voltage for armature circuit
X99
Terminals
U1, V1, W1 (if used)
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
DCS800
Panel connector
X33:
Connect the signal cables as described below. Tighten the screws to secure the connection.
53
SLOT 1
R IO Extension module or
R-Fieldbus module
Interface connector
X2: SDCS-IOB-3
X1: SDCS-IOB-2
SLOT 2
R IO Extension module
SLOT 3
R IO Extension module or
R DDCS interface board
3ADW000194R0201 DCS800 Hardware Manual e b
Electrical installation
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
X3:
X2:
X1:
X4: X5: X6: X7:
I/O´s via SDCS-CON-4
Analogue I/O´s:
Digital I/O´s:
Encoder input:
standard not isolated not isolated
SDCS-CON-4
X3:
X2:
X1:
X4: X5:
X3: X1:
SDCS-IOB-2
I/O´s via SDCS-CON-4 and SDCS-IOB-2
Analogue I/O´s
:
digital I/O´s:
standard all isolated by means of optocoupler/relay, the signal status is indicated by LED
SDCS-CON-4
Electrical installation
X2:
X1:
X6: X7:
X1: X2:
SDCS-IOB-3
I/O´s via SDCS-CON-4 and SDCS-IOB-3
Analogue I/O´s:
Standard + one channel for residual current measurement
digital I/O´s: encoder input:
not isolated isolated
current source for:
PT100/PTC element
X2:
X1:
X1: X2:
SDCS-IOB-3
X3: X1:
SDCS-IOB-2
I/O´s via SDCS-IOB-2 and SDCS-IOB-3
Analogue I/O´s:
Standard + one channel for residual
digital I/O´s:
current measurement all isolated by means of optocoupler/relay, the signal status is indicated by LED
current source for:
PT100/PTC element
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.
Encoder supply
5 V
12 V
24 V
SDCS-CON-4 supplied by PIN-4 sense controlled
no sense
Hardware configuration
SDCS-CON-4 supplied by POW-1/POW-4 sense controlled no sense no sense
SDCS-IOB-3 sense controlled sense controlled 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 IOB-3
X5:1
X5:2
X5:3
X5:4
X5:5
X5:6
X5:7
X5:8
X5:9
X5:10
ChA+
ChA-
ChB+
ChB-
ChZ+
ChZ-
Power source
Sense power
Sense GND
GND
CON-4
X5:1
X5:2
X5:3
X5:4
X5:5
X5:6
X5:10
X5:9
X5:8
X5:7
Note
:
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.
SINGLE-ENDED
A
B
Z
A
B
Z
+U
0V
IOB-3
X5:1
X5:2
X5:3
X5:4
X5:5
X5:6
X5:7
X5:8
X5:9
X5:10
CON-4
ChA+
ChA-
ChB+
ChB-
ChZ+
ChZ-
Power source
GND
X5:1
X5:2
X5:3
X5:4
X5:5
X5:6
X5:10
X5:9
X5:8
X5:7
IOB3x3_f.dsf
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.
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.
X5:1
SDCS-
IOB-3
e.g. CH A
120
S10
3
2
1
6
+24V
5
10k
4
+
+
X5:2 n.c.
X5:1
X5:2
SDCS-
CON-4
e.g. CH A
120
1 2 3
S4
10k
+24 V
+
+
single ended
push pull
+U
X5:1
-U
X5:2
SDCS-
IOB-3
e.g. CH A
120
S10
3
2
1
6
+24V
5
4
10k
R
GND
+
+
+U
-U
X5:1
X5:2
R
GND
SDCS-
CON-4
e.g. CH A
120
1 2 3
S4
10k
+24 V
+
+
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
U thresh
1 k
Ω
1.2 V
1.5
Ω
1.8 V
2.2 k
2.3 V
Ω
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
3
2
1
6
+24V
5
10k
4
X5:2
CH-
+
+ iob14_e.dsf
differential
voltage source
S4
5 V
CON-4
12/24 V
1-2
4-5
7-8
S4
3=park
6=park
9=park
differential
current source
-
5 V
IOB-3
12/24 V
S10
2-3
S10
4-5
8-9
14-15
S10
1-2
10-11
16-17
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 Cable used
0 ... 50 m
50 ... 100 m
100 ... 150 m
parallel wires for
power source & GND
1x 0.25 mm²
2x 0.25 mm²
3x 0.25 mm²
12x 0.25 mm²
12x 0.25 mm²
14x 0.25 mm²
3ADW000194R0201 DCS800 Hardware Manual e b
Electrical installation
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
Drive
Motor cable
Power cable min 300 mm (12 in.)
Input power cable min 200 mm (8 in.)
90 °
Control cables
Motor cable min 500 mm (20 in.)
Not allowed unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V.
Lead 24 V and 230 V control cables in separate ducts inside the cabinet.
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
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 DCS800 D5 Converter
FEX-425-Int
X3
Set bus termination ON
SDCS-DSL
SDCS-DSL
FEX-425-Int
X51 X52 X51 X52
Termination OFF Termination OFF
X3
Set bus termination ON
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
60
Electrical installation
3ADW000194R0201 DCS800 Hardware Manual e b
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.
61
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
Heatsink temperature check and cleaning
Cooling fan change
Interval
Depends on the dustiness of the environment (every 6 to 12 months)
Every six years See
Fan
.
Instruction
See
Heatsink
.
3ADW000194R0201 DCS800 Hardware Manual e b
Maintenance
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
publ.no.:3AFE64484567
Hardware extension RDIO Digital I/O Extension
DCS800 1131 Programming target
publ.no.:3AFE64485733 publ.no.:3ADW000199
Branching units NDBU-95
publ.no.:3ADW000100
Environmental Conditions
System connection
Voltage, 3-phase: 230 to 1000 V acc. to IEC 60038
Environmental limit values
Permissible cooling air temperat.
±10% continuous; ±15% short-time * - at converter module air inlet: Voltage deviation:
Rated frequency: 50 Hz or 60 Hz
Static frequency deviation: 50 Hz ±2 %; 60 Hz ±2 %
with rated DC current:
w. different DC curr. acc. Fig.
Dynamic: frequency range: df/dt:
50 Hz: ±5 Hz; 60 Hz: ± 5 Hz
17 % / s
0 to +55°C
0 to +40°C
+30 to +55°C
below:
- Options: 0 to +40°C
Relative humidity (at 5...+40°C): 5 to 95%, no condensation
* = 0.5 to 30 cycles.
Please note
: Special consideration must be taken for voltage deviation in regenerative mode.
Degree of protection
Relative humidity (at 0...+5°C): 5 to 50%, no condensation
Change of the ambient temp.: < 0.5°C / minute
-40 to +55°C
-40 to +70°C Converter Module and options (line chokes, fuse holder,
Storage temperature:
Transport temperature:
Pollution degree (IEC 60664-1,
IEC 60439-1): field supply unit, etc.):
Enclosed converters:
Paint finish
Converter module:
Enclosed converter:
IP 00
IP 20/21/31/41
NCS 170 4 Y015R light grey RAL 7035
Vibration class D1...D4
D5...D7
Site elevation
<1000 m above M.S.L.:
>1000 m above M.S.L.:
2
3M3
3M1
100%, without current reduction with curr. reduct., see Fig. below
Size
D1
D2
D3
D4
D5
D6
D7
Sound pressure level L
P
(1 m distance) as module enclosed conv.
55 dBA ?? dBA
55 dBA
60 dBA
?? dBA
?? dBA
77 dBA 66...70 dBA, depending on fan
73 dBA
75 dBA
82 dBA
78 dBA
73 dBA
80 dBA
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
60
80
50
1000 2000 3000 4000
Current reduction to (%)
5000 m
70
30 35 40 45 50
Current reduction to (%) for converter modules
55°C
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
93/68/EEC
Low Voltage Directive
73/23/EEC
93/68/EEC
Declaration of Incorporation
Declaration of Conformity
EN 60204-1
[IEC 60204-1]
EN 60146-1-1
[IEC 60146-1-1]
EN 50178 [IEC --]
see additional
EN 60204-1
[IEC 60204-1]
EN 60204-1
[IEC 60204-1]
EN 60439-1
[IEC 60439-1]
IEC 60664
EMC Directive
89/336/EEC
93/68/EEC
EN 61800-3
➀
[IEC 61800-3]
Declaration of Conformity EN 61800-3
➀
[IEC 61800-3]
(Provided that all installation instructions concerning cable selection, cabling and EMC filters or dedicated transformer are followed.)
➀
in accordance with
3ADW 000 032
➀
in accordance with
3ADW 000 032/3ADW 000
091
North American Standards
In North America the system components fulfil the requirements of the table below.
Rated supply voltage
Converter module
Standards
Enclosed converter to 600 V UL/CSA types: on request 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.
>600 V to 1000 V
E196914
• or on request
EN / IEC xxxxx see table above.
Available for converter modulesincluding field exciter units.
EN / IEC types: on request(for details see table above
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
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.
Size internal field curr.
Unit type
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
continuous
[A]
405
500
610
740
900
1200
1500
2000
125
180
230
315
20
45
65
90
2050
2500
3000
3300
4000
5200
1900
2500
3000
3300
4000
4800
2050
2600
3300
4000
290
590
900
1500
2000
2050
2500
3000
3300
4000
4800
* as option
IDC I
240
470
684
1200
1479
1520
1940
2530
2416
3036
3734
IDC II
100 %
15 min
[A]
320
436
490
596
700
888
1200
1479
104
148
200
264
18
40
54
78
1550
1980
2350
2416
2977
3800
150 %
60 s
480
654
735
894
1050
1332
1800
2219
27
60
81
117
156
222
300
396
2325
2970
3525
3624
4466
5700
1500
1920
2500
2655
3036
3734
1577
2000
2551
2975
360
705
1026
1800
2219
2280
2910
3795
3624
4554
5601
2250
2880
3750
3983
4554
5601
2366
3000
3827
4463
225
472
670
1104
1421
1450
1840
2410
2300
2900
3608
100 %
15 min
I
DC III
150 %
120 s
[A]
310
418
482
578
670
872
1156
1421
100
144
188
250
18
37
52
72
1480
1880
2220
2300
2855
3669
465
627
723
867
1005
1308
1734
2132
27
56
78
108
150
216
282
375
2220
2820
3330
3450
4283
5504
1430
1820
2400
2540
2889
3608
337
708
1005
1656
2132
2175
2760
3615
3450
4350
5412
2145
2730
3600
3810
4334
5412
1500
1900
2428
2878
2250
2850
3642
4317
Data on request
205
434
594
1104
1361
1430
1880
2430
2277
2950
3700
IDC IV
100 %
15 min
[A]
308
380
454
538
620
764
1104
1361
94
124
178
230
18
38
55
66
1450
1920
2280
2277
2795
3733
200 %
10 s
616
760
908
1076
1240
1528
2208
2722
36
76
110
132
188
248
356
460
2900
3840
4560
4554
5590
7466
1400
1860
2400
2485
2933
3673
1471
1922
2458
2918
410
868
1188
2208
2722
2860
3760
4860
4554
5900
7400
2800
3720
4800
4970
5866
7346
2942
3844
4916
5836
D1
D2
D3
D4
D5
D6
D7
D3
D4
D5
D6
D7
D6
D7
D7
6 A
15 A
20 A
25 A
25 A *
-
-
-
-
-
-
-
-
-
25 A *
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
68
Unit type
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
550
680
820
1000
1200
1500
2000
2050
2500
3000
3300
4000
5200 continuous
[A]
25
50
75
100
140
200
260
350
450
2050
2600
3300
4000
320
650
900
1500
2050
2500
3000
3300
4000
4800
1900
2500
3000
3300
4000
4800
* as option
IDC I
256
514
684
1200
1520
1940
2270
2416
3036
3734
1500
1910
2250
2655
3036
3734
1577
2000
2551
2975
IDC II
100 %
15 min
[A]
286
360
436
544
664
766
888
1200
23
45
66
78
110
152
214
1479
1550
2000
2330
2416
2977
3800
150 %
60 s
429
540
654
816
996
1149
1332
1800
35
68
99
117
165
228
321
2219
2325
3000
3495
3624
4466
5700
2250
2865
3375
3983
4554
5601
384
771
1026
1800
2280
2910
3405
3624
4554
5601
2366
3000
3827
4463
235
462
594
1104
1430
1740
2030
2277
2950
3700
1400
1710
2000
2485
2933
3673
1471
1922
2458
2918
IDC IV
100 %
15 min
[A]
265
315
380
492
598
675
764
1104
21
38
57
67
99
126
184
1361
1450
1790
2080
2277
2795
3733
200 %
10 s
530
630
760
984
1196
1350
1528
2208
42
76
114
134
198
252
368
2722
2900
3580
4160
4554
5590
7466
2800
3420
4000
4970
5866
7346
470
924
1188
2208
2860
3480
4060
4554
5900
7400
2942
3844
4916
5836
1430
1850
2160
2540
2889
3608
246
508
670
1104
1450
1870
2190
2300
2900
3608
1500
1900
2428
2878
2250
2850
3642
4317
Data on request
369
762
1005
1656
2175
2805
3285
3450
4350
5412
2145
2775
3240
3810
4334
5412
100 %
15 min
I
DC III
[A]
150 %
120 s
276
346
418
538
648
736
872
1156
22
43
64
75
105
148
206
1421
1480
1930
2250
2300
2855
3669
414
519
627
807
972
1104
1308
1734
33
65
96
113
158
222
309
2132
2220
2895
3375
3450
4283
5504
Size internal field curr.
D1
D2
D3
D4
D5
D6
D7
D3
D4
D5
D6
D7
D6
D7
D7
6 A
15 A
20 A
25 A
25 A *
-
-
25 A *
-
-
-
-
-
-
-
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
I
max
).
Note 2:
Use the Drive
Size
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
S1
3
2
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
*
Jumper parking position
No filter; Normal DC Tacho
Filter for AC Tacho with rectifier
Tacho input X3:4 connected with 0 V / GND
Jumper parking position; no grounding of Tacho input
Tacho input 1 at X3:4 and X3:1/2/3 at
SDCS-CON-4
Tacho input 2 at X2:23 and X2:24 at
SDCS-IOB-3 / PS5311
2
1
X33
X300
H2500
D2001
1
2
X9
1
D1000
30
S2
S3
2
1
2
1
2
1
2
1
2
1
2
1
4
3
4
3
*
8
7
8
7
8
7
*
8
7
*
AI1 - X3:5-6: R
IN
= 200 kOhm
Range -10V...0V...+10V
AI1 - X3:5-6: R
Range I
IN
IN
= 250 Ohm
= -20mA...+20mA
AI2 - X3:7-8: R
IN
= 200 kOhm
Range -10V...0V...+10V
AI2 - X3:7-8: R
IN
= 250 Ohm
Range I
IN
= -20mA...+20mA
Jumper parking position 5-6
Pull-up resistor 4.74 kOhm activated at X3:7 for PTC temperature sensor
S4
3
2
1
3
2
1
3
2
1
3
2
1
S5
2
1
2
1
4
3
4
3
*
12
11
10
*
Encoder mode:
differential
; RC load with
R = 121 Ohm and C = 100 nF activated
12
11
10
Encoder mode:
single ended
; Pull-up resistors
4.75 kOhm activated
12
11
10
*
Encoder supply 5 V, sense X5:8-9 are active
12
11
10
Encoder supply 24 V, uncontrolled
Step 1: Preparation for download operation
Step 2: download + normal program execution
*
default value
1
X17
1
2
25
26
25
26
3
S1
2
1
X3
X2
1
2
Jumpers shown in default position
X1
9
8
7
2
S2
4
1 3
1
2
1
1
2
S3
8
7
3
2
1
X4
12
11
10
S4
1
1
2
X11
5
6
X34
1
9
X5
2
S5
4
1 3
1
X6
1
2
1
2
X8
X10
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
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 internal FlashPROM error (check sum)
E02 external FlashPROM error (check sum) error
E04 RAM
E05 no error
Firmware
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:
Data format:
Message format:
Transmission method:
Baudrate:
Number of Data bits:
Number of Stop bits:
Parity-Bit:
RS232 (+12V / -12V)
UART
Modbus-Protocol half-duplex
DriveWindow Light: variable
CodeSys download: 38.4 kBaud
FDT firmware download: self-adapting
8
1 odd
2
3
X34:
1
4
5
6...9
Description not connected
TxD
RxD not connected
SGND Signal ground not connected
5
9 6
1
X34:
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:
RDIO / RAIO
R... Fieldbus adapter
SDCS-COM-8
Second fieldbus RMBA
Memory Card
Slot 1
X9: x x
Slot 2
X10: x x x x
Slot 3
X11: x
Slot 4
X20: x
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
72
Digital and analogue I/O connection of the SDCS-CON-4
X7: 1
2
3
4
5
6
7
8
SDCS-CON-4
±90...±270 V
X3:1
±30...±90 V
2
3
4
5
6
7
8
9
10
±8...±30 V
S1
3
1
39k2
12k8
5k 1k66
S1
6
GND
4
S2
3
S3
6
8
S3
3
4 250
5
7
4 250
4k75
+10V
-
+
-
+
-
+
-
+
Firmware
-
+
ATACH2
9
8
7
S1
ATACH1
ATACH
AI1
(3.3 ms)
AI2
(3.3 ms)
AI3
(10 ms)
X4:1
2
3
4
5
6
7
8
9
10
9
10
6
7
8
X5:1
2
3
4
5
-
+
GND
+10V
-10V
GND (AOx)
100
47.5
100n
AI4
(10 ms)
AO1
AO2
X6:1
2
3
4
5
6
7
8
9
10
GND
121 100nF
10k
121 100nF
10k
121 100nF
10k
ChA
1 2 3
S4
ChA
ChB
4 5
6
S4
ChB
ChZ
7 8 9
S4
ChZ
GND
2k21 221k
-
+
-
+
-
+
Z15
Sense 0 V
Sense 5 V
Power
5 V
-
+
4k75 47nF
= 10 ms
= 10 ms
= 10 ms
= 10 ms
= 10 ms
= 3
.
3 ms
= 3
.
3 ms
+/- I-act
S4
10
11
12
5 V
24 V
+24 V; 125 mA
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
X
Relay driver
Relay driver
Relay driver
Relay driver
Relay driver
Relay driver
Relay driver
GND
DO1
DO2
DO3
DO4
DO5
DO6
DO7
Con4_I_O.dsf
Resolution
[bit]
15 + sign
Input/output values
Hardware
Scaling by
Common mode range
±90...270 V ¿
±30...90 V Firmware ±15 V
±8...30 V
15 + sign
15 + sign
15 + sign
-10...0...+10 V
-10...0...+10 V
-10...0...+10 V
Firmware
Firmware
Firmware
±15 V
±15 V
±15 V
15 + sign
11 + sign
11 + sign
Remarks
-10...0...+10 V Firmware ±15V
+10 V
-10 V
Power
≤
5 mA for ext. use
≤
5 mA e.g. refer. pot.
-10...0...+10 V Firmware
≤
5 mA
-10...0...+10 V Firmware
≤
5 mA
-10...0...+10 V Firmware
≤
5 mA 3 V -> nom.
??
+ Hardw.
motor curr.
Encoder supply
5 V
24 V
Input value Signal definition by
Firmware
0...7.3 V
7.5...50 V
-> “0“ status
-> “1“ status
Remarks
Output value
≤
250 mA
≤
200 mA
Signal definition by
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
5 V encoder is in use).
Remarks
50 * mA
22 V at no load
Firmware 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
D400
V1
X19
y g a d e b
COM_8_layout.dsf
Type
Ch 0
SDCS-COM-81 10 Mb
SDCS-COM-82 5 Mb optical components
Ch 1 Ch 2
5 Mb
5 Mb
10 Mb
10 Mb
Ch 3
10 Mb
10 Mb
Channel 0 used for other interfaces
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
3ADW000194R0201 DCS800 Hardware Manual e b
Technical data
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
Layout of the NDBU-95 branching unit
Optical links:
Master channels
Slave channels
Data rate
1 DDCS input and 1 DDCS output
9 DDCS inputs and 9 DDCS outputs
1 - 4 MBd, programmable
DBU
41
Driving current
Monitoring
20 mA, 30 mA, 50 mA + channel disabling, programmable a green LED for each channel, switched on when NDBU is receiving messages
Transmission device 10 Mb component for each channel
Power supply:
Input voltage
Input current
Monitoring
+24 VDC ± 10%
300 mA a green LED switched on when the output voltage is normal
Operating temperature:
+0 ... +50 °C
PCB dimensions:
s. diagram beside
Remark:
Only channels with the same components (e.g.
10 Mb component) may be connected to each other.
For further information see Appendix D in the DriveWindow
User's Manual.
Note
For addressing and automatic node numbering of the drives and branching units see DriveWindow documentaion.
94
V120
TXD
NDBU-95
DDCS
BRANCHING
UNIT, 8+1 CH
CH8
V119
RXD
TXD
V118
CH7
V117
RXD
ADDRESS
8
S1
TXD
V116
CH6
V115
RXD
1 0
1
TXD
V114
CH5
V113
RXD
MBIT/S
+
+
+
+
+
+
1 2 4
+
+
X12
TXD
V112
CH4
V111
RXD
TXD
V110
CH3
V109
RXD
TXD
V108
CH2
V107
RXD
TXD
V106
CH1
V105
RXD
TRANSM
SETTING
+
+
+
+
+
+
+
+
X2-
X11
DIS
LONG
MEDIUM
SHORT
TXD
V104
CH0
V103
RXD
264
TXD
V102
MSTR
RXD
V101
+5V OK
X1
1
2
24 V DC
0 V
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
SDCS-DSL-4
77
X51
1 2
X52
1 2 3
X53
1 2 3
X54
1 2 3
S2
DSL-4_drw.dsf
Jumper coding
S1
Bus termination
3
2 120 Ohm
1
3
2
1
*
no termination, park position
S2
Ground termination
2
1
2
1
4
3
4
3
200 kOhm R-C ground termination
0 Ohm R-C ground termination
2
1
4
3
*
no termination, park position
*
default value
SDCS-DSL-4
X51:1
2
X52:1
2
3
X53:1
2
3
24 V / 200 mA
2
S1
1 3
CANL
CANH
X8:
Software
CON-4
S1
3 4
1 2
GNDB
Termination 200 kOhm
X54:1
2
3
TxD
RxD
DSL-4_dia.dsf
.
Supply
24 V
≤
200 mA
DSL communication
Bus termination
S1
Ground termination
S2
1-2
2-3
1-3
2-4
3-4
RS 485 communication
Remarks
24 V grounded supply for FEX425 internal and DCF803-0035 field exciter units; short circuit protected
250 mA
Remarks
120 ohm no termination; park position
200 kOhm R-C ground termination
0 Ohm ground termination no termination; park position
Remarks
no isolation
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
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.
The board IOB-2x has 8 digital inputs and 8 digital outputs.
I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
SDCS-CON-4 SDCS-CON-4
There are three different types existing, which differ at the input voltage level:
SDCS-IOB-21 24...48V DC
SDCS-IOB-22 115 V AC
SDCS-IOB-23 230 V AC
X2: X1:
X1: X2:
SDCS-IOB-3
X3: X1:
SDCS-IOB-2
X3:
X2:
X4: X5:
X1:
X3: X1:
SDCS-IOB-2
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.
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.
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-2x board
233.5
1
X3
DO1 DO2
DO3
DO4
DO5
X1
DO6 DO7
K1 K2 K3 K4 K5
DO8
K8
1
SDCS-IOB-2x
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8
R1
Line potential !
1
R2 R3 R4 R5 R6 R7 R8
1
4 *
5
X4
4
Jumper coding
S7
S8
input
DI 7
DI 8 time constant
2ms 10ms
2
1
4
3
2
1
4
3
*
2
1
4
3
2
1
3
4
*
*
default value
X5 X6 supports are conductive diameter of all supports: 4.3 mm
* this dimension may vary (4/5 mm)
depending on revision
(
** W100 as printed circuit
) ?
X7
4
5 iob2x1_c.dsf
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
80
SDCS-IOB-2x
DOx
X4:1
K1
2
5
6
3
4
7
8
K2
K3
K4
X5:1
2
3
4
7
8
5
6
66V
66V
K5
K8
X6:1
2
681
R1
W1
W2
100n
R2
W3 W4
+
DIx
681
-
+
3
4
R3
W5 W6
R4
W7 W8
5
R5
W9 W10
6
R6
W11 W12
7
R7
W13 W14
8
R8
W15 W16
X7:1
2
3
4 up to revision D
W100 from revision E on
+48V conductive support iob2x2_b.dsf
Software
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
Note:
When the SDCS-CON-4 control board with the SDCS-IOB-
2 I/O board is installed, terminals X6: and X7: on the
SDCS-CON-4 must not be used
.
Output value Signal definition by Remarks
K1...K5, K8
Firmware potential-isolated by relays
(NO contact element)
Contact ratings:
AC
:
≤
250 V~/
≤
3 A~
DC
:
≤
24 V-/
≤
3 A-
or
≤
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-
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
0...40 V
90...250 V
Firmware
Remarks
potential-isolated by optocoupler
(24...48V-)
R1...R8 = 4.7 k
Ω
-> "0 signal"
-> "1 signal"
(115V~)
R1...R8 = 22 k
Ω
-> "0 signal"
-> "1 signal"
(230 V~)
R1...R8 = 47 k
Ω
-> "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.
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.
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.
I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
SDCS-CON-4
SDCS-CON-4
X2: X1:
X2: X1:
X6: X7:
X1: X2:
SDCS-IOB-3
X3: X1:
SDCS-IOB-2
X1: X2:
SDCS-IOB-3
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.
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
X1
SDCS-IOB-3
2
X2
14
13
S1
*
70
8
7
2
S2
*
1
8 7
1
2
S3
*
1
R110
1
3
S5
*
2
4
V17
3
2
1
S10
*
24
23
22
1
12 1
12
1
X3
X4
5
T1
1
S4
2
11
X5
12
10
4
Jumper coding
S1
S2
S3
Functionallity of analogue inputs
Ch
AITAC
AI1
AI2 activation of
500 between input terminal gain = 1
-10V..+10V
*
YES
S1:1-2
S1:3-4
YES
S1:5-6
S2
8
6
4
2 gain = 10
-1V..+1V
7
5
3
1
S2
8
6
4
2
7
5
3
1
Sum I AC not equal to 0
*
AI3 S1:7-8
AI4 S1:9-10
S3
8
6
4
2
YES
7
5
3
1
S3
8
6
4
2
7
5
3
1
S1:11-12
S1:13-14
S4
Pulse encoder supply
7
9
11
1
3
5
5 V
6
8
2
4
10
12
1
3
5
7
9
11
12 V
6
8
2
4
10
12
7
9
11
1
3
5
24 V
*
6
8
2
4
10
12
S5
Temperature sensor supply
PTC
1.5 mA
PT100
5 mA
*
1
3
2
4
1
3
2
4 iob3_c.dsf
4
5
70
85
S10
Characteristics for pulse encoder inputs single ended:
3
2
1
5 V
*
24
23
22
3
2
1
12/24 V
24
23
22
5 V 12/24 V differential:
3
2
1
24
23
22
3
2
1
*
24
23
22
*
default value
3
2
1
13 mA
24
23
22
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
82
-
TG
+
X1:1
2
3
6
7
8
4
5
81-270V
25-90V
8-33V
R9
PS5311
SDCS-IOB-3
-
S1
X3:1
1 2
+
2
500
-
3
+
3 4
4
-
5
5 6
+
6
-
7
+
7 8
8
-
9
9 10
+
10
~
11
~
12
12
11
S2 x10 x10
S3
S1
100
14
13
X2:3
6
7
8
SDCS-CON-x
100k
100k
100k
1n
1n
100k
Software
AITAC
AI1
3.3 ms
AI2
3.3 ms
AI3
10 ms
AI4
10 ms
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:
Terminals X3:, X4: and X5: on the SDCS-CON-4 must not be used
.
Resolution
[bit]
15 + sign
Input/output values
Scaling by
Common
Remarks
Hardware mode range
-10...0...+10 V Firmware ±20 V
➀➁➂➅
15 + sign -10...0...+10 V Firmware ±20 V
➀➁➂
15 + sign
15 + sign
15 + sign
-10...0...+10 V Firmware ±40 V
➀➁➂➃➄
-10...0...+10 V Firmware ±40 V
➀➁➂➃➄
-10...0...+10 V Firmware ±40 V
➀➁➂
X4:1
2
5
6
3
4
7
8
9
10
11
12
100
100n
0V
47.5
100
100n
47.5
0V
100
1 2
S5
3 4 x
0V
+/- I-act
R110
+10V
0V
-10V
1.5 mA
5 mA
0V
AO1
AO2
11 + sign
11 + sign analogue
R
-10...0...+10 V Firmware
≤
5 mA*
-10...0...+10 V Firmware
≤
5 mA*
-10...0...+10 V R110 i
= 3
Ω
1.5 mA
5 mA
Power
≤
5 mA* gain: 0.5...5
≤
≤
5 mA* for external use
5 mA* e.g. reference pot.
Curr. source for
PTC or PT100
9
10
6
7
8
X5:1
2
3
4
5
S10
4 5 6
S10
+24V 1 2 3
10 11 12 +24V 7 8 9
16 17 18 +24V 131415
Sense Power +
Sense GND
S4
V17
ChA +
ChA -
ChB +
ChB -
ChZ +
ChZ -
Power-
Source
GND
Encoder supply
5 V
12 V / 24 V
≤
≤
250 mA *
200 mA *
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) iob3x2 e.dsf
➀ total smoothing time
≤
2 ms
➁
-20...0...+20 mA by setting S1
➂
4...20 mA by
➁
+ Software function
➃
-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
➆
Residual 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.
3ADW000194R0201 DCS800 Hardware Manual e b
Technical data
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.
Field current measurement Armature firing Power supply
T100
6A 5x
25A 1x
Technical data
X12
X5
X4
X3
X22
SDCS-PIN-4
X1
X2
-
+
X8
X10
X9
+
X24
C1 U1
X21
conducting point
X25
V1
X23
X7
X31
S1
1
2
3
1-2 = 230 V
2-3 = automatic
K301
W1
X20
K400
F400
D1
X96
F300
X99
Pin4_layout.dsf
Different functional areas on SDCS-PIN-4
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
Supply voltage 115 V AC
Tolerence -15%/+10%
Frequency
Power consumption
45 Hz ... 65 Hz
120 VA
Power loss
Inrush current
≤
60 W
20 A / 20 ms
Mains buffering
Powerfail min 30 ms
85 V
230 V AC
-15%/+10%
45 Hz ... 65 Hz
120 VA
≤
60 W
10 A / 20 ms min 30 ms
170 V
Backup supply
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)
Contact rating:AC: 230 V~/ <3 A~
DC: 24 V-/ <3 A- or 115/230 V-/ <0.3 A-)
Input circuit PIN-4
X96:
275 V
PIN4_in-output_circuit.dsf
Filtering
X99:
3ADW000194R0201 DCS800 Hardware Manual e b
Technical data
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
AC insulation voltage
Frequency
AC input current
Minimum Current
110...500 V (525 V)
500 V
50 Hz / 60Hz
< field current
?300 mA
DC output current
Size max. cross sectional area min. cross sectional area
Fuse type
D1
6A
16 mm²
AWG 6
1 mm²
AWG 16
D2
15A
D3
20A
16 mm²
AWG 6
2.5 mm²
AWG 12
KTK - 25
16 mm²
AWG 6
4 mm²
AWG 10
D4
25A
16 mm²
AWG 6
6 mm²
AWG 8
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
Typical armature circuit thyristor converter diagram with SDCS-PIN-4 board
87
3ADW000194R0201 DCS800 Hardware Manual e b
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.
2-Quadrant application, no parallel thyristors - Construction type D5/D6/D7
X22 X122 X23 X24 X25
C
V14
G
C
V11
G
C
V16
G
C
V13
G
C
V12
G
C
V15
G
A B C D E F
SDCS-PIN-5x
SDCS-PIN-46/PIN-48
2q_c34_b.dsf
4-Quadrant application, no parallel thyristors - Construction type D5/D6/D7
X22 X122 X23 X24 X25
SDCS-PIN-46/PIN-48
C
V25
G
V24
C
G
V11
G
V12
G
V26
C
G
V23
C
G
V13
G
V16
C
G
V22
G
V21
C
G
V15
G
C
T4
C
T1
C
T6
C
T3
C
T2
V14
G
C
F
A B C D E F
SDCS-PIN-5x
SDCS-PIN-46/PIN-48
4q_c3a_b.dsf
Pulse transformer board SDCS-PIN-46/PIN-48
Layout of the SDCS-PIN-46/PIN-48 pulse transformer board
270
G
C
G
C
G
C
G
C
G
C
X1
X113
A B C D
SDCS-PIN-4x
E
G
C
Gate
Cathode
F
X213
X2
Pin4x.dsf
The board consists of six pulse transformers with amplifiers.
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
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 activating 1 M
Ω
resistors (= cutting out short circuit wires, which are represented by low ohmic resistors).
If there is a need for voltage adaptation, all 5 chains must be handled in the same way.
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
W5
R123
Isolating supports line potential !
U1
W5 W4 W3 W2 W1
V1
W11 W9 W8
W1
W16 W15
W7 W6
W14 W13 W12
C1
W21 W20 W19 W18 W17
D1 W26 W25 W24 W23 W22
SDCS-PIN-51
PTC see diagram power part
Conductive supports
S3
X22 X122
3
1
4
2
1
Two PTC
One PTC
X23
W10 W70
W71 W72
2
W80 W81 W82
1
X24 2
1
X25 2
R1 . . . . . . . R21
W83
X12S X413S
X13S X313S
S2 S1
R22
R26
305
Layout of the SDCS-PIN-52
U1
V1
W1
C1
D1
SDCS-PIN-52
S3
In the past some converters for line voltages lower/equal 500 V had been equipped with SDCS-
PIN-52 boards. The SDCS-PIN-
51 board serves as a spare part for those converters.
3ADW000194R0201 DCS800 Hardware Manual e b
Technical data
90
Current coding
Construction type
Current transf. ratio
Rated current [A DC]
R1-R4
18
R5
18
R6
R7
18
18
R8
R9
R10
R11
R12
R13
R14
18
18
18
18
18
18
18
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
18
18
33
68
120
270
560
47
47
47
47
100
Settings of the SDCS-PIN-51 board if a DCS converter is equipped with it by ABB
D5
2500:1
D6
2500:1
900 1200 1500 2000 1900 2050 2500 3000 2050 2600 3300 4000
D7
4000:1
4800 5200 code_tab_PIN1_PIN20_PIN51_d.dsf
Voltage coding
Construction type
Conv. nom. voltage [V]
➀
U1 [V AC]
Value f. conv. nom. volt at SET(TINGS) block
Measuring board SDCS
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
Y=4 (400V)
Y=5 (500V)
D5
Y=6 (600V)
0
PIN-51 PIN-51
Y=7 (690V)
= HW type coding
PIN-51
Y=4 (400V)
Y=5 (500V)
D6 / D7
Y=6 (600V) Y=7 (690V) Y=8 (790V)
500
PIN-51
600
PIN-51
690
PIN-51
800
PIN-51
D7
Y=9
(990V)
1000
PIN-51
D7
Y=1
(>1000V) 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
4 3
2 1
Board used as a spare part
:
• default: all jumpers Wxx, Rxx are in condition
• ensure the correct converter type related settings
2 Q - 4 Q coding
W10
indicates a removed jumper
2-Q 4-Q
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
91
Typical armature circuit thyristor converter diagram with SDCS-PIN-48 and SDCS-PIN-51 boards for a
4-Quadrant D7 type converter
R22
47R
R23
47R
R24
47R
R25 47R
R26 100R
R8
18R
R9 18R
R10
18R
R11
18R
R12
18R
R13
18R
R14
18R
R15 18R
R16
18R
R17
33R
R18
68R
R19
120R
R20
270R
R21 560R
R1 18R
R2
18R
R3
18R
R4
18R
R5
18R
R6
18R
R7
18R
3ADW000194R0201 DCS800 Hardware Manual e b
*
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
Construction type
Conv. nom. voltage [V] * Y=4 (400V)
Y=5 (500V)
D5 / D6 / D7
Y=6 (600V) Y=7 (690V) Y=8 (790V) Y=9 (1000V) Y=1 (1190V)
Rated mains voltage [V AC] 220…500 270…600 300…690 350…790 450…1000
Value f. conv. nom. volt at
SET(TINGS) block *
Measuring board
SDCS-
Resistors W1…W26
PIN-51 PIN-51 PIN-51 PIN-51 PIN-51 PIN-51
all resistors are 0
Ω
Galvanic isolation
Resistors Rx on PIN51
DC-DC transducer
A92
Switch position R
G
*
27.4 k
Ω
27.4 k
Ω
27.4 k
Ω
27.4
8680A1
7
(675 V)
6
(810 V)
5
(945 V)
4
(1080 V)
2
(1350 V)
1
(1620 V)
Transformer
T90
3ADT 745047
Secondary Terminals * 2U1
2V1
2W1
2N
2U2
2V2
2W2
2N
2U3
2V3
2W3
2N
2U4
2V4
2W4
2N
2U5
2V5
2W5
2N
2U6
2V6
2W6
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
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
R22 47R
R23 47R
R24
47R
R25 47R
R26 100R
R9 18R
R10
18R
R11
18R
R12 18R
R13
18R
R14
18R
R15 18R
R16
18R
R17
33R
R18 68R
R19
120R
R20
270R
R21 560R
R1
18R
R2
18R
R3
18R
R4
18R
R5 18R
R6
18R
R7
18R
R8 18R
*
3ADW000194R0201 DCS800 Hardware Manual e b
Technical data
94
DC-DC transducer A92
Principle circuit diagram of the DC-DC transducer A92
17
Input voltage
20
6 M appr. 280nF
6 M appr. 3.9
k
230 V AC
1
2
TRANSDUCER
1 : 1
POWER SUPPLY
+15V
0V
-15V
OPAMP
R
G
10nF
9
10
Output voltage
GAIN
7 STEPS
0V
Data
Selectable voltage gains:
Switch position
675
7
810 945
6 5
1080 1215
4 3
1350
2
1620 V DC
1
Output voltage:
Auxiliary power:
Clearance in air:
Insulation voltage:
Insulation test voltage:
Ambient temperature range:
Weight:
9,84 V / 5 mA
230 V ± 15 %; 50/60 Hz; 3 W
Auxiliary power to Output: >13 mm
Input/Output to Auxiliary power: >14 mm
2000 V
5000 V
- 10 …+ 70 °C appr. 0.4 kg
The voltage gain and frequency response is especially designed for
DCS800 converters.
Dimensions in mm
Side view
112.0
10.0
2.0
Buttom view
76.0
70.0
Location of terminals
20 17
5.0
50.0
60.0
1 2
Gain selector
R
G
9 10
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
95
Transformer T90
Principle diagram of the transformer T90
1U 2N 2U6 2U5 2U4 2U3 2U2 2U1
1V
1W
1N
2V6 2V5 2V4 2V3 2V2 2V1
2W6 2W5 2W4 2W3 2W2 2W1
S
Data
Selectable transfer ratios U prim
:
Output voltage:
Insulation voltage:
Isolation test voltage:
Ambient temperature range:
Weight:
502, 601, 701, 800,1000, 1200 V AC rms
7.3 V AC rms
1200 V
3500 V
- 10 …+ 70 °C
- 10 …+ 70 °C
Dimensions in mm max 116
Remark
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.
5.2 x 7.7
118....120
130
3ADW000194R0201 DCS800 Hardware Manual e b
Technical data
96
Technical data
3ADW000194R0201 DCS800 Hardware Manual e b
97
Dimensional drawings
Module D1
DCS800-S01-0020
DCS800-S01-0045
DCS800-S01-0065
DCS800-S01-0090
DCS800-S01-0125
DCS800-S02-0025
DCS800-S02-0050
DCS800-S02-0075
DCS800-S02-0100
DCS800-S02-0140
Dimensional drawings of the DCS800 are shown below. The dimensions are given in milllimeters.
for size D1 for size D2...D3
direction of air flow screw M6 fan terminal
Module D2
DCS800-S01-0180
DCS800-S01-0230
DCS800-S02-0200
DCS800-S02-0260
Module D3
DCS800-S01-0315
DCS800-S01-0405
DCS800-S01-0500
DCS800-S02-0350
DCS800-S02-0450
DCS800-S02-0550
Size earthing point screw
Weight
Signal terminals
Field and power supply terminals
Power connection
D1toD3_dim_a.dsf
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
98
Module D4
DCS800-S01-0610
DCS800-S01-0740
DCS800-S01-0900
DCS800-S02-0680
DCS800-S02-0820
DCS800-S02-1000
Weight appr. 38 kg for size D4
Dimensional drawings
D4_dim_a.dsf
3ADW000194R0201 DCS800 Hardware Manual e b
99
Module D5
DCS800-S0x-0900
DCS800-S0x-1200
DCS800-S0x-1500
DCS800-S0x-2000
Weight appr. 110 kg
127.5
U1
125
510
450
125
V1 W1 for M10
400
85.5
17 26
Ø 14
17
26
34
Support Support
*
> 510 min. 480
C1 earthing M12
276 fan terminals
400
461
483
Busbars in mm:
AC
80 x 10
DC
60 x 5
Ø 14 earthing
M12 cable tray with = 40 mm height =39 mm
D1
17.75
fan terminals
65.5
25 50 50
325.5
50
A5_dim_a.dsf
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
DCS800-S0x-1900
DCS800-S0x-2050
DCS800-S0x-2500
DCS800-S0x-3000
Weight appr. 180 kg
C
D
U
V
W
458.2
425
375
250
10x20
Pressure switch
409
C
D
62
40
M12
50
U
V
W
*
Air outlet
385
445
468.2
15
M10
72 100
355
A6_dim.dsf
Air entry
from the front, right, left and back
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
Module D7 left-hand
DCS800-S0x-2050-xxL
DCS800-S0x-2600-xxL
DCS800-S0x-3300-xxL
DCS800-S0x-4000-xxL
DCS800-S0x-4800-xxL
DCS800-S0x-5200-xxL
Weight appr. 315 kg
230 530
350 for M10
*
Pressure switch
A7_dim_a.dsf
for M10
Busbars in mm:
AC and DC
100 x 10
101
3ADW000194R0201 DCS800 Hardware Manual e b
Dimensional drawings
102
Module D7 right-hand
DCS800-S0x-2050-xxR
DCS800-S0x-2600-xxR
DCS800-S0x-3300-xxR
DCS800-S0x-4000-xxR
DCS800-S0x-4800-xxR
DCS800-S0x-5200-xxR
Weight appr. 315 kg for M10
Busbars in mm:
AC and DC
100 x 10
*
Pressure switch for M10
A7_dim_a.dsf
Dimensional drawings
3ADW000194R0201 DCS800 Hardware Manual e b
Fuses installed inside the converter
Model Fuse F1 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
D5
D5
D5
D6
D6
D6
D6
D7
D7
D7
D5
D5
D5
D6
D6
D6
D6
D7
D7
D7
D6
D6
D6
D6
D6
D7
D7
D7
D7
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
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
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
1800A 1250V UR
1800A 1250V UR
2500A 1250V UR
2500A 1250V UR
➀
12 fuses per bridge (2x per F1x)
Size
9
9
9
9
6
6
6
6
6
8
8
8
5
5
5
5
7
7
7
5
5
5
6
6
6
6
6
6
6
8
8
8
Type
170M 6162
170M 6166
170M 6169
170M 6168
170M 6163
170M 6168
170M 6166
170M 7026
170M 7028
170M 7057
170M 6144
170M 6149
170M 6151
170M 6145
170M 6148
170M 6149
170M 6148
170M 7036
170M 7156
170M 7156
170M 6145
170M 6145
170M 6148
170M 6149
170M 6148
170M 7036
170M 7156
170M 7156
170M 7976
170M 7976
170M 7978
170M 7978
F1x
F1x
F1x
L1 L2 L3
F1x
F1x
F1x
103
3ADW000194R0201 DCS800 Hardware Manual e b
Dimensional drawings
104
Size 5, 6
14
11 b
108
139 a b
17
Size
5
6
a
50
80 b c d
29 30 76
14 30 76
Indicator max d
Size 7...10
15 max 105
4xM10 min 10 deep
Ø
3
3
Ø 11
A
8
25
100
25
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
5 A
35 A
I
Fact
Setting of switchable burden resistors by rated field current
U
V
W
Field
Fex4x1.dsf
Layout of the SDCS-FEX-4 board
X110
P2
T113
P1
X100
240
T110
T112
T111
X101
V110
R106
R107
R108
X7
D800
S800
U730
S801
U731
Fex4_layout.dsf
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
106
Electrical data
Power circuit
AC Field input voltage
AC input current
Frequency
AC isolation voltage
Line reactor
Line fuses
DC output current
Powerloss
Auxiliary supply
DC input voltage
Input current
Buffering
110 V -15%...500 V +10% single or three-phase
< DC output current same as DCS Converter module
600 V external or shared with D5 armature converter
KTK25 for FEX425 internal; external for DCF803-0035
300 mA (min)...25 A= FEX425 internal; ...35 A = DCF803-0035
< 130 W ( at rated current)
24 V DC
< 200 mA supplied from SDC-DSL-4 X51
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 U
DC
voltage depending on operation modes
1
0,75
0,5 single-phase half-controlled
0,25 three-phase half-controlled
0
0,1 0,4 0,7 1 three-phase full-controlled
U dc field
DCS LINK communication
The field converter is controlled from armature converter via DCS link serial communication based on
CAN hardware.
X1:1
2
Fex4_DCSLink.dsf
24 V / 200 mA
.
Supply
24 V
≤
200 mA
Remarks
24 V grounded supply f. SDCS-FEX-4
X3:1
2
3
S1100:3
S1100:1
CANL
CANH
GNDB
S1100:2
Termination 200 kOhm
DSL communication
Bus termination
S1100 :1 = ON
:1 = OFF
Remarks
120 ohm no termination
Ground termination
S1100 :2 = ON
:3 = ON
200 kOhm R-C ground termination
0 Ohm ground termination
:2,:3 = OFF no termination
Node address is set by: S800 digit 0 (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 S1100:4 Baudrate kBaud *
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON OFF
ON
20
50
125
250
ON
ON
ON
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
500
800
888
1000
Selection of armature converter
2
3
0
1
6
7
4
5
* 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
green and yellow continues
green blinking no 24V supply
No firmware
25 A / 35 A output active, waiting for DCSLINK communication
green continues
yellow blinking
yellow continues
green and yellow toggling:
25 A / 35 A output active, DCSLINK communication OK
5A output active (X100:2), waiting for DCSLINK communicat.
5A output active (X100:2), DCSLINK communication OK
X times yellow Y times green
X=1 Y=1 Alarm phase missed
Y=2 Alarm maximum temperature heatsink
X=2 Y=1
Y=2
Y=3
Y=5
Fault DCS link serial communication failed
Fault Synchronization fault
Fault Overcurrent
Fault Field AC supply voltage < 30V
Y=6
Y=9
Fault Field AC supply voltage < 650V
Fault maximum temperature heatsink
Y=12 Fault Auxiliary voltage
Y=14 Fault general hardware
Y=15 Fault general software
No RESET
No RESET
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
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:
Message format:
Transmission method:
Baudrate:
UART
Modbus-Protocol half-duplex
9.600 Baud
Number of Data bits:
Number of Stop bits:
Parity-Bit:
8
1 odd
2
3
X2:
1
4
5
6...9
Description not connectedßtext1
TxD
RxD not connected
SGND Signal ground not connected
5
9 6
1
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).
109
3ADW000194R0201 DCS800 Hardware Manual e b
Accessories
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 [m
Ω
]
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
Dimensions [mm] Size 0...4
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...3
Size
4
4
3
3
1
2
1
1
0
1
0
0
0
0
0
0
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
Indicator
Size
0
1
2
3 a
78,5
135
150
150 b b
50
69
69
68 c
35
45
55
76 d e
21 15
45 20
55 26
76 33 a c
F1
L1 L2 L3
10
6 d e
Fuse1_a.dsf
Size 4
Indicator
14
11
29
108
139
50
29
17
76
Main dimensions of fuse holders
Fuse holder HxWxD [mm] Protection
OFAX 00 S3L 148x112x111
OFAX 1 S3 250x174x123
IP20
IP20
OFAX 2 S3
OFAX 3 S3
250x214x133
265x246x160
IP20
IP20 fuse2_a.dsf
H
OFA X 2 S3
OFAX ...
W D
170H 3006 (IP00)
110
M10
M8
A
A
205
180
Ø
9
M8
A-A
60
85
M10
170H3006_a.dsf
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
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 Choke
L
[
µ
H]
I rms
[A]
I peak
[A] rated
Voltage
[U
N
]
Weight Power loss
Fe Cu
[kg] [W] [W] recommended for armature converter 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
37.5
25.0
33.8
18.8
18.2
9.9
10.9
6.1
512
250
300
168
135
90
50
56.3
18
37
37
55
82
102
184
196
245
367
326
490
367
551
490
734
698
930
1047
1395
1163 1744
1510 2264
27
68
68
82
122
153
275
294
Line chokes type ND 01...ND 06
500
500
600
500
690
500
690
500
500
500
600
500
600
500
500
600
16.0
22.2
22.6
36.0
46.8
46.6
84.0
81.2
2.0
3.0
3.8
5.8
6.4
7.6
12.6
12.8
50
80
80
95
170
100
190
210
5
7
45
45
5
7
9
10
16 DCS...-0025
22 DCS...-0050
20 DCS...-0050
33 DCS...-0075
30 DCS...-0110
41 DCS...-0140
90 DCS...-0250
130 DCS...-0270
140 DCS...-0350
185 DCS...-0520
185 DCS...-0450
290 DCS...-0680
160 DCS...-0820
300 DCS...-1200
680 DCS...-1500
650 DCS...-2000
3
A
B
C
X
Y
Z
X, Y, Z
A, B, C
A
X
B
Y
C
Z
A, B, C
600
100
0
X, Y, Z a a1 d b
ND1_to_6_a.dsf
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
100 130 48 65
100 130 58 65
125 157 63 80
125 157 78 80
125 157 78 80
150 180 72 90
116 4 8
116 4 8
143 5 10
143 5 10
143 5 10
170 5 10 mm²
6
10
10
16
25
35 f
3ADW000194R0201 DCS800 Hardware Manual e b
Accessories
112
Line chokes type ND 07...ND 12
H ±2
C ±1
F ±0.3
A
L
C1
Type
ND 07, 08
ND 09
ND 10, 11
ND 12
3 AST4 78 2 23 D5
3AFE 10014603
0 .0 1 88 mH
4 90 A
I ma x 7 34 A
A
7
A-A
ND7_to_12_c.dsf
F ±0.3
B ±1
A B
285 230
327 250
408 250
458 250
C
86
99
99
C1
100
100
100
112 113
E F G
250 176 65
292 224 63
374 224 63
424 224 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 13, 14
all busbars 40x10
100 100
140 ±2
45 45
Line chokes type ND 15, 16
all busbars 60x10
140 30
151 ±2
90
45
18
290 ±1
A
150 ±2
123 ±2
ø 13
40
A
15
ND13_14_c.dsf
30
390 ±1
140
147
ø 13
15
A
147
181 ±2
15
48
A
ND15_16_c.dsf
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
170
A X B Y C Z
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 U rated supply
= 400 V, DC curr. 1 = 90% of nominal current
- for U rated 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 Choke
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
L
1000
600
450
350
250
160
120
90
70
60
50
40
35
I rms
332
406
502
605
740
I peak
[mH] Line AC [A] [A]
18.5
37
55
74
104
148
192
252
27
68
82
111
156
220
288
387
498
609
753
805 rated
Voltage
[U
N
400
400
400
400
400
400
400
400
400
400
400
400
1105 400
]
Weight
[kg]
3.5
7.5
11
13
19
22
23
29
33
51
56
62
75
Line chokes type ND 401...ND 402
91
104
117
137
170
260
260
280
312
Power loss
Fe
[W]
Cu
[W]
13
13
42
78
35
50
90
105
105
130
130
160
215
225
300
335
410
Load
DC curr. 1
(f. U supply
=400V)
22.6
45
67
90
127
179
234
315
405
495
612
738
900
Load
DC curr.2
(f. U supply
18
=500V)
36
54
72
101
143
187
252
324
396
490
590
720
Type A B C D E F Ø G Ø H
ND 401
160 190 75 80 51 175 7 9
ND 402
200 220 105 115 75 200 7 9
Terminals: WAGO Type 202
UL File E45172
ø H tin-coated
X
Y
Z
D
A
B
C
ø G
F±1
B
ø G+5
E±2
C
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
114
Accessories
Line chokes type ND 403...ND 408
Type A B C D E F Ø G Ø H Ø K
ND 403
220 230 120 135 100 77.5
7
ND 404
220 225 120 140 100 77.5
7
9
9
6.6
6.6
ND 405
235 250 155 170 125 85 10 9 6.6
ND 406
255 275 155 175 125 95 10 9 9
ND 407
255 275 155 175 125 95 10 9 11
ND 408
285 285 180 210 150 95 10 9 11
B
ø H tin-coated
X Y
Z
A B C
ø
G+5
50 45
F ±2
10
E ±2
C
D
Line chokes type ND 409...ND 413
Type A B C D E F Ø G Ø H Ø K
ND 409
320 280 180 210 150 95 10 11 11
ND 410
345 350 180 235 150 115 10 13 14
ND 411
345 350 205 270 175 115 12 13 2x11
ND 412
385 350 205 280 175 115 12 13 2x11
ND 413
445 350 205 280 175 115 12 13 2x11
B
ø H tin-coated
A B C
X Y
Z
øK AL
øK AL
X Y Z
A B C
ø
G+6
F ±2
12
E ±2
C
D
3ADW000194R0201 DCS800 Hardware Manual e b
115
Autotransformer T3
Type for Field curr.
T 3.01
T 3.02
T 3.03
T 3.04
T 3.05
T 3.11
T 3.12
T 3.13
T 3.14
T 3.15
≤
≤
≤
≤
≤
IF
6 A
12 A
16 A
30 A
50 A
≤
6 A
≤
12 A
≤
16 A
≤
30 A
≤
50 A
Transformer's secondary current
I sec
U prim
= 500 V; 50/60Hz
≤
7 A
≤
13 A
≤
17 A
≤
33 A
≤
57 A
U prim
= 690 V; 50/60Hz
≤
7 A
➀
≤
13 A
➀
≤
17 A
➀
≤
33 A
≤
57 A
Weight Power loss Fuse F3
[kg]
15
20
20
36
60
15
20
30
60
60
P
V
[W]
65
100
120
180
250
80
125
150
230
320
[A]
10
16
25
50
63
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
F 3 F 3
T 3 T 3
C D
B
Line choke L3 for SDCS-FEX-2
2 1 3 e
G
Type A B C D h e G
T 3.01 / T 3.11
210 110 112 75 240 10x18 95
T 3.02 / T 3.12
210 135 112 101 240 10x18 95
T 3.03
T 3.13
T 3.04
T 3.14
T 3.05 / T 3.15
230 150 124 118 270 10x18 95
260 150 144 123 330 10x18 95
295 175 176 141 380 12x18 95
4
1
3
2
4
Type line choke data L3 Weight Pow
L
[
µ
H]
I rms
I peak
[A] [A]
ND30 2x >500 16 16 er
loss
[kg] [W] [mm²]
1.1
8 2
4.5 Ø
55 max 80
37
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.
F2
Input voltage:
Frequency:
230/380...690 V/1~; ±10%
50...60 Hz
Output voltage: 115/230 V/1~
T2
230 V 115 V
T2_a.dsf
0 V
[VA]
T2 1400
[kg]
15
[A]
16
I sec
[A]
6 (0...230 V)
12 (0...115 V)
Power loss
[W]
100
6.3 mm Faston
106
125
T2_dim.dsf
128
148
100 +-5
Application hint:
230 V
F2
T2
230 V 115 V T2_a.dsf
0 V
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.
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
Optical cables
For the bus communication of the DCS converters there are different optical cables available.
Kind of cable plastic fibre optic single cable plastic fibre optic double cable
Connector cable length plug plug
HCS silica (double) without plastic jacket plug
HCS silica (double) with plastic jacket plug
0.5...20 m
0.5...20 m 3ADT 693318 2
30...50 m
Ident. no.
3ADT 693324
3ADT 693355
50...200 m 3ADT 693356
Fig.
1
3
4
Figure 1
blue
L black
Figure 2
blue
L black blue black
Figure 3
orange
Figure 4
black blue red
L
L
5 mm
8 mm blue red orange black
117
3ADW000194R0201 DCS800 Hardware Manual e b
Accessories
118
Accessories
3ADW000194R0201 DCS800 Hardware Manual e b
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
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Table of contents
- 2 DCS800 Single Drive Manuals
- 5 Safety instructions
- 11 Table of contents
- 15 The DCS800
- 16 Type code
- 17 Main circuit and control
- 18 Armature circuit converter DCS800 D5...D7
- 17 Armature circuit converter DCS800 D1...D4
- 19 Rebuild system DCR800
- 21 Mechanical installation
- 21 Unpacking the unit
- 21 Delivery check
- 22 Before installation
- 22 Cabinet installation
- 23 Mounting the converter module D6 inside an enclosure
- 24 Mounting the converter module D7 inside an enclosure
- 25 Planning the electrical installation
- 36 EMC conformity
- 38 Converters D1...D4 drive configuration using ’on board’ field exciter
- 39 Converters D5 drive configuration using ’FEX-425-Int’ field exciter
- 40 Converters D5...D7 drive configuration using ’external’ field exciter
- 41 START, STOP and E-STOP control
- 43 Drive configuration with reduced components
- 44 Power section cooling
- 46 Thermal overload and short-circuit protection
- 47 Cross-sectional areas - Tightening torques
- 48 Selecting the control cables
- 49 Connection of a motor temperature sensor to the drive I/O
- 25 Options for the drive
- 25 Line reactors
- 28 Aspects of fusing for the armature-circuit and field supplies of DC drives
- 31 Single-phase Transformer T3 for field supply to match voltage levels
- 30 Fuses F3.x and fuse holders for field supply
- 31 Single-phase Transformer T3 for field supply to match voltage levels
- 32 Single-phase Commutating reactor
- 32 Auxiliary transformer T2 for electronic system / fan supply
- 32 Residual current detection
- 32 EMC filters
- 33 Three-phase filters
- 34 Single-phase filters for field supply
- 51 Electrical installation
- 51 Checking the insulation of the assembly
- 52 IT (ungrounded) systems
- 52 Supply voltage
- 52 Connecting the power cables
- 52 Location R-Extension and Interface Modules
- 54 I/O Board Configuration
- 55 Pulse encoder connection
- 56 Pulse encoder receiver
- 58 Connecting the signal and control cables
- 58 Routing the cables
- 59 DSL Link Wiring
- 61 Installation checklist
- 63 Maintenance
- 64 Heatsink
- 64 Fan
- 65 Technical data
- 65 Environmental Conditions
- 67 Current ratings
- 69 Control Board SDCS-CON-4
- 92 Galvanic isolation - T90, A92
- 73 Interface Board SDCS-COM-8
- 77 DDCS Branching unit NDBU-95
- 78 DSL Board
- 79 Digital I/O board SDCS-IOB-2
- 81 Analogue and encoder I/O board SDCS-IOB-3
- 83 Power Supply Board SDCS-POW-4
- 84 Interface Board SDCS-PIN-4
- 88 Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x
- 97 Dimensional drawings
- 97 Module D1
- 97 Module D2
- 97 Module D3
- 98 Module D4
- 99 Module D5
- 100 Module D6
- 101 Module D7 left-hand
- 102 Module D7 right-hand
- 103 Fuses installed inside the converter
- 105 Accessories
- 105 DCF803-0035 and FEX 425 internal
- 110 Fuses and fuse holders
- 111 Line chokes
- 115 Autotransformer T3
- 115 Line choke L3 for SDCS-FEX-2
- 116 Supply transformer T2 for electronics and fan
- 117 Optical cables