ABB DCS800 Hardware Manual

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ABB DCS800 Hardware Manual | Manualzz

DCS800

Hardware Manual

DCS800 Drives (20 to 5200 A)

DCS800 Single Drive Manuals

DCS 800 Quick Guide (191 + CD)

DCS 800 converter module

Flyer DCS800

Flyer DCS800 E Panel solution

Catalogue DCS800

Hardware Manual DCS800 00S

Firmware Manual

Installation according to EMC

Technical Guide

Service Manual DCS800

Planning and Start-up for12-Pulse converters

CMA-2 Board

Flyer Hard - Parallel

Tools + optical link

DriveWindow 2.x

DriveOPC

Optical DDCS Communication Link

DDCS Branching unit User´s manual

NETA Remote diagnostic interface

DCS800 Application

1131Programming Tool +Libary

1131 DCS800 target +tool description

Winding with the DCS 800XXXXX

Winder application description

Flyer magnetic application

Magnetic application description

DCS800 00A Enclosed

Flyer DCA 800

System description DCS800 00A

Installation of DCS800 00A

DCR 500 rebuild system

Flyer DCR

DCR Manual

DCS500/DCS600 upgrade manual

Public. number

3 ADT 645 0 ??

3 ADW 000 190

3 ADW 000 0??

3 ADW 000 192

3 ADW 000 194

3 ADW 000 193

3 ADW 000 032

3 ADW 000 163

3 ADW 000 195

3 ADW 000 196

3 ADW 000 136

3 ADW 000 153

3 BFE 645 60981

3 BFE 000 73846

3 AFE 639 88235

3 BFE 642 85513

3 AFE 546 05062

CoDeSys2.3

3ADW000199

3 ADW 000 058

3 ADW 000 198

3 ADW 000 091

3 ADW 000 007

3 ADW 000 197

Hardware Extension

RAIO-01 Analogue IO Extension

RDIO-01 Digital IO Extension

AIMA R-slot extension

Serial interfaces

Drive specific serial communication

Installation and Start-up GuideRPBA-12 (PROFIBUS)

Fieldbus Adapter with DC Drives RPBA- (PROFIBUS)

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

¤

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

NF3-690-1000

D4 NF3-690-1000

NF3-690-1000

D5 NF3-690-1000

NF3-690-1000

D5 NF3-690-1000

NF3-690-1000

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

NF3-690-1600

D5 NF3-690-1600

NF3-690-1600

3000A D6 NF3-690-2500

NF3-690-2500

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

U max

= 250 V

NF1-250-8

NF1-250-20

NF1-250-55

NF1-250-55

NF1-250-12

NF1-250-30

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

Temperatur detector: internal connected

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

DCS800-S0x-2050-xx

DCS800-S0x-2500-xx

DCS800-S0x-2600-xx

DCS800-S0x-3000-xx

DCS800-S0x-3300-xx

2000

1900

2050

2500

2600

3000

3300

DCS800-S0x-4000-xx 4000

DCS800-S0x-4800-xx

4800

DCS800-S0x-5200-xx

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

Reduced ambient temperature 40°C

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

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

1.2 V

1.5

1.8 V

2.2 k

2.3 V

Make sure the threshold is half of the supply voltage and the minimum voltage of the encoder output (saturation voltage UCE of a transistor).

differential

CH+

X5:1

SDCS-IOB-3 e.g. CH A

120

S10

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

[IEC 61800-3]

Declaration of Conformity EN 61800-3

[IEC 61800-3]

(Provided that all installation instructions concerning cable selection, cabling and EMC filters or dedicated transformer are followed.)

in accordance with

3ADW 000 032

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

, 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

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

-> "0 signal"

-> "1 signal"

(115V~)

R1...R8 = 22 k

-> "0 signal"

-> "1 signal"

(230 V~)

R1...R8 = 47 k

-> "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

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

, 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

-20...0...+20 mA by setting S1

4...20 mA by

+ Software function

-1...0...-1 V by setting S2/S3 (CMR ±10 V)

-2...0...-2 mA by setting S2/S3 + S1 (CMR ±10 V)

designated for PT100 evaluation per firmware and hardware

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

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

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]

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

Galvanic isolation

Resistors Rx on PIN51

DC-DC transducer

A92

Switch position R

G

*

27.4 k

27.4 k

27.4 k

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

1500A 660V UR

1250A 660V UR

2500A 660V UR

3000A 660V UR

3500A 660V UR

630A 1250V UR

1100A 1250V UR

1400A 1100V UR

700A 1250V UR

1000A 1250V UR

1100A 1250V UR

1000A 1250V UR

2500A 1000V UR

3000A 1000V UR

3000A 1000V UR

700A 1250V UR

700A 1250V UR

1000A 1250V UR

1100A 1250V UR

1000A 1250V UR

2500A 1000V UR

3000A 1000V UR

3000A 1000V UR

1800A 1250V UR

1800A 1250V UR

2500A 1250V UR

2500A 1250V UR

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

]

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

13 A

17 A

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

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

*194R0201A5400000*

*194R0201A5400000*

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