DCS800 Hardware Manual

DCS800 Hardware Manual

DCS800

Hardware Manual

DCS800 Drives (20 to 5200 A)

DCS800 Drive Manuals

DCS800 Quick Guide

DCS800 Tools & Documentation CD

DCS800 Converter module

Language

Public. ES

3ADW000191 x x x x x

3ADW000211 x

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Firmware Manual DCS800

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Service Manual DCS800

Flyer Hard - Parallel

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DriveOPC 2.x - User's Manual

Optical Link

DDCS Branching Units - User´s Manual

DCS800 Applications

PLC Programming with CoDeSys

61131 DCS800 target +tool description - Application Program

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DCS800 Crane Drive Manual suppl.

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DCS500/DCS600 Size A5...A7, C2b, C3 and C4 Upgrade Kits

Extension Modules

RDIO-01 Digital IO Extension

AIMA extension

Serial Communication

Fieldbus Adapter with DC Drives RPBA- (PROFIBUS)

Fieldbus Adapter with DC Drives RCAN-02 (CANopen)

Fieldbus Adapter with DC Drives RCNA-01 (ControlNet)

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

Status 10.2008

DCS800 Drive Manuals-List_h.doc

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3AFE64506005

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3AFE64498851

3AFE64539736 x x x x

DCS800 Drives

20 to 5200 A

Hardware Manual

© 2008 ABB Automation Products GmbH. All rights reserved.

3ADW000194R0601 DCS800 Hardware Manual f e

3ADW000194R0601 Rev F

EFFECTIVE: 15.09.2008

3ADW000194R0601 DCS800 Hardware Manual f e

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

3ADW000194R0601 DCS800 Hardware Manual f e

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

3ADW000194R0601 DCS800 Hardware Manual f e

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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.

3ADW000194R0601 DCS800 Hardware Manual f e

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

3ADW000194R0601 DCS800 Hardware Manual f e

9

Operation

These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death or damage the equipment.

Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed.

Do not activate automatic fault reset functions of the Standard Application

Program if dangerous situations can occur. When activated, these functions will reset the drive and resume operation after a fault.

Do not control the motor with the disconnecting device (disconnecting switch); instead, use the control panel keys and , or commands via the I/O board of the drive.

Mains connection

You can use a switch disconnector (with fuses) in the power supply of the thyristor power converter to disconnect the electrical components of the unit from the power supply for installation and maintenance work. The type of disconnector used must be a switch disconnector as per EN 60947-3, Class B, so as to comply with EU regulations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main contacts to open. The mains disconnector must be locked in its "OPEN" position during any installation and maintenance work.

EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the thyristor power converter will neither cause an emergency motor stop, nor will the drive be disconnected from any dangerous potential.

To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals "RUN", "drive OFF" or

"Emergency Stop" respectively "control panel" or "PC tool".

Intended use the operating instructions cannot take into consideration every possible system configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in industrial installations.

If in special cases the electrical machines and devices are intended for use in non-industrial installations - which may require stricter safety regulations (e.g. protection against contact by children or similar). These additional safety measures for the installation must be provided by the customer during assembly.

Safety instructions

3ADW000194R0601 DCS800 Hardware Manual f e

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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

3ADW000194R0601 DCS800 Hardware Manual f e

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Table of contents

DCS800 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-S0x D1...D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Armature circuit converter DCS800-S0x D5...D7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Rebuild system DCS800-R0x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Mechanical installation

Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Delivery check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Before installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Terminal options converter size D1...D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Connection of DC terminals of D4 converter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Terminal cover according to VBG 4 regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Mounting the converter module D6 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Mounting the converter module D7 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Planning the electrical installation

Table of contents

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What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Options for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Line reactors LL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Aspects of fusing for the armature-circuit and field supplies of DC drives . . . . . . . . . . . . . . . . 30

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Conclusion for the armature supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Conclusion for the field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Semiconductor type F1 fuses and fuse holders for AC and DC power lines . . . . . . . . . . . . . . 32

Fuses F3.x and fuse holders for field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Single-phase Transformer T3 for field supply to match voltage levels. . . . . . . . . . . . . . . . . . . 33

Single-phase Commutating reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Auxiliary transformer T2 for electronic system / fan supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Residual current detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Three-phase filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Converters D1...D4 drive configuration using ’on board’ field exciter . . . . . . . . . . . . . . . . . . . . . . . . 39

Converters D5 drive configuration using ’FEX-425-Int’ field exciter . . . . . . . . . . . . . . . . . . . . . . . . . 40

Converters D5...D7 drive configuration using ’external’ field exciter DCF803, DCF804 . . . . . . . . . . 41

Converters D1...D3 3-phase field exciter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

START, STOP and E-STOP control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Drive configuration with reduced components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Fan cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Mains cable (AC line cable) short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Cross-sectional areas - Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

DCS800 panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Location R-Extension and Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

I/O Board Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Pulse encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Pulse encoder receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Connecting the signal and control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Routing the cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

DCS Link Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Installation checklist

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Table of contents

3ADW000194R0601 DCS800 Hardware Manual f e

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Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fan replacement (D6, D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Current ratings - IEC non regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Current ratings - IEC regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Control Board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Layout of the control board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Memory circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Watchdog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Seven segment display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Terminal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Digital and analogue I/O connection of the SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Interface Board SDCS-COM-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Ch2 SDCS-COM-8 Master-Follower connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Ch0 Drive Bus connection to Advant Controller (star) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Ch0 Connection to overriding control (Nxxx fieldbus adapter) . . . . . . . . . . . . . . . . . . . . . . . . 77

Ch3 Ring connection to PC tool DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Ch3 Star connection to PC tool DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

DDCS Branching unit NDBU-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

SDCS-DSL Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Digital I/O board SDCS-IOB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Analogue and encoder I/O board SDCS-IOB-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Power Supply Board SDCS-POW-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Interface Board SDCS-PIN-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Armature circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Field circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Interface Board SDCS-SUB-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Galvanic isolation - T90, A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

DC-DC transducer A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Transformer T90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Dimensional drawings

Table of contents

3ADW000194R0601 DCS800 Hardware Manual f e

14

Module D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Module D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Module D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Module D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Module D5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Module D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Module D7 left-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Module D7 right-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fuses installed inside the converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Accessories

DCF803-0035 and FEX 425 internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Power section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

DCS LINK communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

RS232-Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

FEX425 INTERNAL (Fex-425-Int) Hardware configuration (size D5) . . . . . . . . . . . . . . . . . . . . . . . 113

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

DCF505 / DCF506 Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fuses and fuse holders IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Line reactors IEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Line reactors type ND 01...ND 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Line reactors type ND 07...ND 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Line reactors type ND 401...ND 413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Autotransformer T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Line reactor L3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Supply transformer T2 for electronics and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Optical cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Other cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Table of contents

3ADW000194R0601 DCS800 Hardware Manual f e

The DCS800

What this chapter contains

This chapter describes briefly the operating principle and construction of the converter modules in short.

The DCS800

The DCS800-S size D1...D7 are intended for controlling DC motors.

15

Size D1...D4

20...1000 A

Size D5

900...2000 A

Size D6

1900...3000 A

3ADW000194R0601 DCS800 Hardware Manual f e

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

X

Y

ZZ

B

Product series

Type

Bridge type

Rated current

Rated voltage

(nominal rating in bold)

Power connection

Internal field exciter configuration

Fan voltage

Current measurement

Voltage measurement

SDCS-DSL board

Plus code

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 = 800 V

10 = 990 V

12 = 1200 V

+S164

+0S163

- = Standard D1...D6

L = Left side D7

R = Right side D7 with internal field exciter, external supplied (only D5: 25 A, Rebuild kit: 25 A / 16 A) without internal field exciter (only D1...D4)

+S171

+S172

Size D4

Standard fan voltage: 230 V / 1-ph fan voltage: 115 V / 1-ph

Size D6

Standard 400 V / 500 V / 800 V

Standard 600 V / 690 V

600 V / 690 V fan voltage: 400-500 V / 3-ph fan voltage: 525-690 V / 3-ph fan voltage: 400-500 V / 3-ph

+S175

+S186

+S180

+S181

+S182

+S183

+S189

+S199

+0S199

CMA; D6 and D7 converter

120 V SDCS-SUB-4 for D1...D4 converter modules

600 V for D6 and D7 converter modules

690 V for D6 and D7 converter modules

800 V for D6 and D7 converter modules

990 V for D6 and D7 converter modules galvanic isolation for D6 and D7 converter modules

SDCS-DSL board no SDCS-DSL board

+ plug-in options

Control panel

Fieldbus

I/O and DDCS

0J404

J409

K454

K451

K466

K458

L500

L501

L508

L509 no DCS800 control panel

Door mounting Kit (3 m cable length)

Profibus RPBA

DeviceNet RDNA

Ethernet IP + Modbus TCP RETA

Modbus RMBA

Analogue Extension RAIO

Digital Extension RDIO

DDCS Adapter (10 Mbaud CH0) SDCS-COM-81

DDCS Adapter (5 Mbaud CH0) SDCS-COM-82

The DCS800

3ADW000194R0601 DCS800 Hardware Manual f e

Main circuit and control

Armature circuit converter DCS800-S0x D1...D4

400 V and 500 V units with Onboard field exciter

600 V units are always without Onboard field exciter

Three-phase field supply

DCF 803 / 804

DCF503B0050

DCF504B0050 also possible

On Board FEX PIN 4

17

Memory Card

X20

Slot 4

optical fibre optical fibre

AIMA

3ADW000194R0601 DCS800 Hardware Manual f e

The DCS800

18

Armature circuit converter DCS800-S0x D5...D7

Three-phase field supply

DCF 803 / 804

DCF503B0050

DCF504B0050 also possible

FEX 425 internal **

Memory Card

X20

Slot 4

optical fibre optical fibre

AIMA

The DCS800

3ADW000194R0601 DCS800 Hardware Manual f e

19

Rebuild system DCS800-R0x

Three-phase field supply

DCF 803 / 804

DCF503B0050

DCF504B0050 also possible

SDCS-FEX 4 internal

MM

SDCS-CCB4

Memory Card

X20

Slot 4

optical fibre optical fibre

AIMA

3ADW000194R0601 DCS800 Hardware Manual f e

The DCS800

20

The DCS800

3ADW000194R0601 DCS800 Hardware Manual f e

21

Mechanical installation

Unpacking the unit

• open box

• take out shock dampers

• separate manual and accessories

• do not lift the drive by cover.

5

4

3

2

1

Delivery check

Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the unit is of the correct type. The label includes an IEC rating,

C

UL

US

and CE markings, a type code and a serial number, which allow individual identification of each unit. The remaining digits complete the serial number so that there are no two units with the same serial number.

Example labels are shown below.

Type designation label

Rated input voltage

Rated input current

Rated internal field exciter current

Rated output current

Rated fan voltage

Plus code

Mechanical installation

3ADW000194R0601 DCS800 Hardware Manual f e

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

3ADW000194R0601 DCS800 Hardware Manual f e

23

Terminal options converter size D1...D4

There are different options for protection and connection the terminals for converter sizes D1...D4

Connection of DC terminals of D4 converter module

In special cases it is beneficial to use the lug bar for easier connection of the DC cables.

DC terminals of

D4 module

Id No.

Remark

3ADV280706P0001 right

3ADV280706P0002 left

∅ 7.35

71

∅ 14

60

Bottom view of lug bar mounted on a D4 module

Terminal cover according to VBG 4 regulations

For converter modules D1...D4 we provide shrouds for protection against contact

Id No.

3ADT631137P0001

3ADV400208P0001

3ADV400207P0001

Remark

D1...D2

D3

D4

3ADW000194R0601 DCS800 Hardware Manual f e

Mechanical installation

24

Mounting the D1/D2 cover by using the excisting lateral pins and than swing downward to snap-in at the terminal row. D3 and D4 mounting is accordingly, without the snap-in mechanism.

Examples for covering the DC main terminals on D3 (left) and D4 (right) converter modules.

Mechanical installation

3ADW000194R0601 DCS800 Hardware Manual f e

25

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 converter module

optimum compromise

50

TMR

~ 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 enclosure it is recommended to make sure the exhaust air leaves the enclosure.

A6_li_air_inlet.dsf

Cable entries the module must be fixed at the upper side with

TMR (Top Mounting Rail)

C

D

Power cable connection

The power cable connection is performed via Terminal

option 01 for D6. 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.

U

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 left side. Because of that the length of the remaining threads is limited to 35 mm (see drawing below).

max.

35mm

A6_li_air_inlet_c.dsf

468.2

3ADW000194R0601 DCS800 Hardware Manual f e

Example right side connection

Mechanical installation

26

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-4).

TMR

Screened cable for hardware interface connection IOB2/IOB3 board is strongly recommended

Provide sufficient grounding of card holder ai r flo w

View from bottom

Free space around the converter 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 none of the remaining entries can be blocked.

>20

50

A7_re_air_inlet_b.dsf

IOB2/IOB3

PE screened cables

A7_re_air_inlet_b.dsf

Internal cable ducts are used for snubber circuit wiring. Don’t use these cable ducts for other cables or process signals.

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 enclosure it is recommended to make sure the exhaust air leaves the enclosure.

Do not have loose cables. The air flow from fan will destroy the cables!

Use cable straps for fan cable

Mechanical installation

3ADW000194R0601 DCS800 Hardware Manual f e

27

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-S 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 L1

> 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.

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

28

Line

L

Line

PCC

L

(P cc

L1

)

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

L1

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 L1

=4%; Voltage Dip = Z

Line

/(Z

see Technical Guide.

Line

+Z

L1

)=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

L1

L

L1

Configuration C1

L

L1

....

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, D3, D4, 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_g.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

3ADW000194R0601 DCS800 Hardware Manual f e

Line reactors L

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

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-S01-0590-06

DCS800-S01-0470-04/05

DCS800-S01-0610-04/05

DCS800-S01-0740-04/05

DCS800-S02-0650-06

DCS800-S02-0520-04/05

DCS800-S02-0680-04/05

DCS800-S02-0820-04/05

DCS800-S01-0900-04/05

DCS800-S01-0900-06/07

DCS800-S01-2000-04/05

DCS800-S01-2000-06/07

DCS800-S02-1000-04/05

DCS800-S02-0900-06/07

DCS800-S01-1200-04/05 DCS800-S02-1200-04/05

DCS800-S01-1500-04/05/06/07 DCS800-S02-1500-04/05/06/07

DCS800-S02-2000-04/05

Line choke Design Line choke Design type for Fig.

type for Fig.

configur. A configur. B

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

3

3

3

3

3

3

2

3

3

2

2

2

1

2

2

2

1

1

1

1

ND13

ND10

ND12

ND13

ND13

ND13

ND14

ND15

ND16

ND16 *

ND01

ND02

ND04

ND06

ND06

ND07

ND07

ND08

ND09

ND10

-

-

5

-

-

-

5

5

-

5

5

-

5

5

5

5

5

5

4

4

* with forced cooling (1m/s)

29

Fig. 1 Fig. 2

Fig. 3

Fig. 4 Fig. 5

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

30

Aspects of fusing for the armature-circuit and field supplies of DC drives

General

Unit configuration

Protection elements such as fuses or overcurrent trip circuits are required in all cases to protect against further damage. In some configurations, this will entail the following questions: first, 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 no case standard fusing should be used instead of semi-conductor fusing in order to save money on installation.

In the event of a fault condition, the small amount of money saved can cause the semiconductors ot other devices explode 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

3ADW000194R0601 DCS800 Hardware Manual f e

31

Conclusion for the field supply

Basically, similar conditions apply for both field supply and armature-circuit supply.

Depending on the power converter used (half-controlled bridge, fully controlled 4quadrant 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 (4-Q operation) 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

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

32

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).

Type of converter

2-Q Converter

DCS800-S01-0020-04/05

DCS800-S01-0045-04/05

DCS800-S01-0065-04/05

DCS800-S01-0090-04/05

DCS800-S01-0125-04/05

DCS800-S01-0180-04/05

DCS800-S01-0230-04/05

DCS800-S01-0315-04/05

DCS800-S01-0405-04/05

DCS800-S01-0470-04/05

DCS800-S01-0610-04/05

DCS800-S01-0740-04/05

DCS800-S01-0900-04/05

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).

Size Fuse type Fuse holder

4-Q Converter

DCS800-S02-0025-04/05

DCS800-S02-0050-04/05

DCS800-S02-0075-04/05

DCS800-S02-0100-04/05

DCS800-S02-0140-04/05

DCS800-S02-0200-04/05

DCS800-S02-0260-04/05

DCS800-S02-0350-04/05

DCS800-S02-0450-04/05

DCS800-S02-0520-04/05

DCS800-S02-0680-04/05

DCS800-S02-0820-04/05

DCS800-S02-1000-04/05

D1

D2

D3

D4

170M 1564

170M 1565

170M 1568

170M 1568

170M 3815

170M 3816

170M 3817

170M 5810

170M 6811

170M 6811

170M 6163

170M 6163

170M 6166

OFAX 00 S3L

OFAX 00 S3L

OFAX 00 S3L

OFAX 00 S3L

OFAX 1 S3

OFAX 1 S3

OFAX 1 S3

OFAX 2 S3

OFAX 3 S3

OFAX 3 S3

3x 170H 3006

3x 170H 3006

3x 170H 3006

Type Fuse Holder

North America

FWP-50B

FWP-80B

1BS101

1BS101

FWP-125A 1BS103

FWP-125A 1BS103

FWP-200A 1BS103

FWP-250A 1BS103

FWP-300A 1BS103

FWP-500A 1BS103

FWP-700A See Note 1

FWP-700A See Note 1

FWP-900A See Note 1

FWP-900A See Note 1

FWP-1200A See Note 1

DCS800-S01-0290-06

DCS800-S01-0590-06

DCS800-S02-0320-06

DCS800-S02-0650-06

D3

D4

170M 5810

170M 6813

OFAX 2 S3

OFAX 3 S3

Fuses and fuse holders (details see chapter Technical Data)

Note 1: No fuse holder is available. Attach fuses directly to busbar.

FWP-500A See Note 1

FWP-900A See Note 1

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

3ADW000194R0601 DCS800 Hardware Manual f e

33

Field conv.

Field current

F3.1 F3.2

DCF803-0035 I

F

≤ 6 A

FEX-425-Int *

170M 1558 * OFAA 00 H10

I

F

≤ 12 A 170M 1559 * OFAA 00 H16

DCF803

DCF804

DCF803

I

F

≤ 16 A 170M 1561 * OFAA 00 H25

I

F

≤ 25 A 170M 1564 * OFAA 00 H25

I

F

≤ 35 A

170M 1564 OFAA 00 H50

DCF804

DCF803 I

F

≤ 50 A

170M 1565 OFAA 00 H63

DCF804

Type of protection elements

Semiconduct.

type fuse for fuse holder type OFAX 00

LV HRC type for 690 V; fuse hold. OFAX 00

F 3.3

10 A

16 A

25 A

35 A

50 A

63 A circuit breaker for 500 V or

690 V

* F3.1 Fuse KTK25 included in FEX-425-Int inside D5 converter module

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

≤ 6 A

≤ 12 A

≤ 16 A

≤ 30 A

≤ 50 A

≤ 6 A

≤ 12 A

≤ 16 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

T 3.05

U prim

=

≤ 600 V

T 3.11

T 3.12

T 3.13

U prim

=

≤ 690 V

T 3.11

T 3.12

T 3.13

T 3.14

T 3.15

Autotransformer data (details see chapter Technical Data)

Autotransformer.dsf

T3 autotransformer

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

34

Single-phase Commutating reactor

For DCF803-0016, 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 DCF803/804-0050 and

DCF503B/504B-0050 field power converters, it is already installed.

Converter

500 V; 50/60 Hz

for field current

I

F

Reactor

1ph_reactor_a.dsf

ND 30

DCF803-0016

DCF803-0035 (16 A)

FEX-425-Int

16 A

>16A

IEC

ND 30

* ND 402

US

KLR 45 CTB

ND 402

* 3-phase operation or single-phase operation

Commutating reactor (for more information see chapter Accessories)

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.

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

35

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).

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. 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

2-Q Converter

DCS800-S01-0020-0y

DCS800-S01-0045-0y

DCS800-S01-0065-0y

IDC [A]

20A

4-Q Converter

DCS800-S02-0025-0y

45A DCS800-S02-0050-0y

65A DCS800-S02-0075-0y

IDC [A]

25A

Constr. type

D1

50A D1 NF3-440-50

75A D1

Filter type f. y=4

NF3-440-25

NF3-440-64

DCS800-S01-0090-0y 90A DCS800-S02-0100-0y 100A D1 NF3-440-80

DCS800-S01-0125-0y 125A DCS800-S02-0140-0y 140A D1 NF3-440-110

DCS800-S01-0180-0y 180A DCS800-S02-0200-0y 200A D2 NF3-500-320

DCS800-S01-0230-0y 230A DCS800-S02-0260-0y 260A D2 NF3-500-320

Filter type f. y= 5

NF3-500-25

NF3-500-50

NF3-500-64

NF3-500-80

NF3-500-110

NF3-500-320

NF3-500-320

DCS800-S01-0315-0y 315A DCS800-S02-0350-0y 350A D3 NF3-500-320

DCS800-S01-0405-0y 405A DCS800-S02-0450-0y 450A D3 NF3-500-600

NF3-500-320

NF3-500-600

DCS800-S01-0470-0y 470A DCS800-S02-0520-0y 520A D3 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 NF3-500-600

DCS800-S02-0820-0y 820A

DCS800-S01-0900-0y 900A DCS800-S02-1000-0y 1000A

DCS800-S01-0900-0y 900A DCS800-S02-0900-0y 900A

DCS800-S01-1200-0y 1200A DCS800-S02-1200-0y 1200A

DCS800-S01-1500-0y 1500A DCS800-S02-1500-0y 1500A

DCS800-S01-2000-0y 2000A DCS800-S02-2000-0y 2000A

≤ 3000A ≤ 3000A

D6 NF3-690-2500

➀ NF3-690-2500 ➀

Filter only available on request

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

36

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

DCF803-0016 *

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

3ADW000194R0601 DCS800 Hardware Manual f e

37

EMC filters

You will find further information in publication:

Technical Guide chapter:

EMC Compliant Installation and Configuration for a

Power Drive System

The paragraphs below describe selection of the electrical components in conformity with the EMC Guideline.

The aim of the EMC Guideline is, as the name implies, to achieve electromagnetic compatibility with other products and systems. The guideline ensures that the emissions from the product concerned are so low that

•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.

they do not impair another product's interference immu-

Note on EMC conformity

nity.

In the context of the EMC Guideline, two aspects must

The conformity procedure is the responsibility of both the power converter's supplier and the manufacturer of be borne in mind:

•the product's interference immunity the machine or system concerned, in proportion to their share in expanding the electrical equipment involved.

First environment (residential area with light industry) with PDS category C2

Not applied, since category C1 (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

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

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.

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

38

For compliance with the protection objectives of the

German EMC Act (EMVG) in systems and machines, the following EMC standards must be satisfied:

Product Standard EN 61800-3

EMC standard for drive systems (PowerDriveSystem), interference immunity and emissions in residential areas, enterprise zones with light industry and in industrial facilities.

This standard must be complied with in the EU for satisfying the EMC requirements for systems and machines!

For emitted interference, the following apply:

EN 61000-6-3

Specialised basic standard for emissions in light industry can be satisfied with special features (mains filters, screened power cables) in the lower rating range *(EN 50081-1).

EN 61000-6-4

Specialised basic standard for emissions in industry *(EN

50081-2)

For interference immunity, the following apply:

EN 61000-6-1

Specialised basic standard for interference immunity in residen-

tial 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 old generic standards are given in brackets

PDS category C3

Medium-voltage network

Industrial zone

Earthed neutral

Line reactor +

Y-capacitor

Mains filter

Second environment (industry) with PDS categories C3, C4

satisfied

Supply transformer for a residential area (rating normally

≤ 1.2 MVA)

Earthed 400-V network with neutral conductor;

3~

≤ 400 A

Line reactor Line reactor

Not applicable

on customer's request satisfied

Industrial zone

Converter transformer

PDS category C4

Medium-voltage network

Converter transformer with earthed

iron core

(and earthed screen where appropriate)

satisfied

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 DCS800 series, the limit values for emitted interference are complied with, provided the measure indicated is carried out. PDS of category C2 (formerly restricted distribution in first environment) is intended to be installed and commissioned only by a professional (person or organization with necessary skills in installing and/or commissioning PDS including their EMC aspects).

For power converters without additional components, the following warning applies:

This is a product of category C2 under IEC 61800-

3:2004. In a domestic/residential environment this product may cause radio interference in which case supplementary mitigation measures my be required.

Converter 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 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 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

3ADW000194R0601 DCS800 Hardware Manual f e

Converters D1...D4 drive configuration using ’on board’ field exciter

Wiring the drive according to this diagram offers the highest degree of monitoring functions done by the drive.

39

M 3~

M ~

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

40

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 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. FEX-425-Int can be supplied separate max. 500 V (3-phase), or 2phase.

M 3~

M ~

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

41

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 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 with 3-phase aux. supply.

M 3~

M ~

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

42

Converters D1...D3 3-phase field exciter configuration

Wiring the drive according to this diagram offers the highest degree of monitoring functions done by the drive.

M ~

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

43

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 communication. Even a mixed solution can be realized by selecting different possibilities for the one or the other signal (see parameter group 11).

PC tool or panel

MCW (7.01)

ON

RUN

RESET

HW I/O

ON

RUN

RESET command location (10.01)

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 opening main contactor or drop down 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 DI 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.

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

44

E-STOP

K16

ELEC.

DISCONN.

EMER.

STOP

K15

1

S1

2

K15

K16

CON-4

DI4 X6:9

K15

Block current command

Anschl_special_a.dsf

E-Stop ramp

E-Stop reaction speed

Timer K15

Timer K16

Block current control

K1 main contactor

Coast

Stop-Mode.dsf

d: DC contactor US:

DC contactor US K1.1 is a special designed contactor with 2x NO contacts for C1 and D1 connection and 1x NC contact for connection of Dynamic Brake resistor R

B

.

The contactor should be controlled by signal 6.03 Bit 10.

The acknowledge can be connected to parameter:

10.21 MainContAck

10.23 DCBreakAck

L1

U1 V1 W1 PE

DCS800

Converter module

K1.1

+

C 1 D 1

_

'on board' field exciter

R

B

X10: 2

F+ F-

1

Main contactor 6.03 b 7

Dyn Brake 6.03 b 8

DC Contact US 6.03 b 10

M

DC cont us.dsf

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

45

Drive configuration with reduced components

Converters D1...D4 (400...500 V) using ’on board’ field exciters

Converters D5 using FEX-425-Int field exciter, but externally supplied

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.

M 3~

M ~

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

46

Fan cooling

Fan assignment for DCS800

Converter type

DCS800-S0x-0045-04/05 ...

DCS800-S0x-00140-05/05

DCS800-S0x-0180-04/05 ...

DCS800-S0x-0260-04/05

DCS800-S0x-0315-04/05 ...

DCS800-S0x-0350-04/05

DCS800-S0x-0405-04/05 ...

DCS800-S0x-0520-04/05

DCS800-S0x-0610-04/05 ...

DCS800-S0x-0820-04/05

DCS800-S0x-0610-04/05 ...

DCS800-S0x-0820-04/05

DCS800-S0x-0900-04/05 ...

DCS800-S0x-1000-04/05

DCS800-S0x-0900-04/05 ...

DCS800-S0x-1000-04/05

DCS800-S0x-0900-0y ...

DCS800-S0x-2000-0y

DCS800-S0x-1900-04/05/08 ...

DCS800-S0x-3000-04/05/08

DCS800-S0x-1900-06/07 ...

DCS800-S0x-3000-06/07

DCS800-S0x-3300-yy...

DCS800-S0x-5200-yy

Model

D1

D2

D3

D3

D4

D4

Pluscode E171

D4

D4

Pluscode E171

D5

D6

D6

D7

Configuration

1

1

1

2

3

3

3

3

4

5

5

5

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) y = voltage class

Fan Data for DCS800

Fan

Rated voltage [V]

Tolerance [%]

Frequency [Hz]

Power consumption [W]

CN2B2

115; 1~

50

±10

60

16 13

W2E200

230; 1~

+6/-10

50 60

64 80

Current consumpt. [A]

Blocking current [A]

0.2

0.17

0.29 0.35

0.6

< 0.3 < 0.26 < 0.7 < 0,8 < 1.5

Air flow [m3/h] freely blowing 156 180 925 1030 925

Air flow [m3/h] at working point

-

W2E 200

115; 1~

50

+6/-10

60

64 80

-

0.7

< 1.8

1030

W2E 250

115; 1~

±10

W2E 250

230; 1~

+6/-10

50 60 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 appr.

40000 h/60° appr.

45000 h/60° appr. 45000h/60°

60 appr.

40000 h

60 appr.

40000 h

Protection Impedance Temperature detector: internal connected

➀ Increased losses due to increased current with a blocked rotor will not result in a winding temperature, higher than permissible for the insulation class being involved.

D2E 160

GR31M

400...500 V

GR31M

500...690 V

GR35C

400 V / 690 V

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

47

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]

Useful lifetime of grease

Protection

D2E 160 GR31M GR31M

230; 1~ 400...450

Δ

450...500

380... 500 V

400...500

525... 690 V

Δ 500...690 500...690

500

Δ

653

±10

50 60

2.50

3.75

860

3.4

4.5

50

800

Δ

700

1.45

Δ

0.91

at 450 V

Δ

8.5

±10

60

1340

Δ

2.0 at 500 V

8.5

Δ

Δ

50

800

0.9 at 690 V

4.4

±10

60

1200

1.2 at 500 V

8.5

Δ

50

6.5

2.3

Δ

GR35C

400 / 690 V

400...460

Δ ∗

600...690

+5/-10

2900

Δ

2200

±10

60

3600

Δ

3300

4.9

3.0

Δ at 400 V

Δ

>25 at 400 V

Δ

>30

-

800

2.5 A

750

3.2 A

1500

1.26 A

(450V

Δ)

1600

1.6 A

(500V

Δ)

1500

0.7 A

(690V )

1600

1.65 A

(500V

Δ)

< 55 appr. 30000 h/40°

Temperatur detector: U

N

≤ 230 V~; I

N

≤ 2.5 A~

4200

3.6 A

(400V

Δ)

4250

4.1 A

(400V

Δ)

* 460 V < Supply < 600 V autotransformer strongly recommended, energy saving 20000 kWh/a

Fan connection for DCS800

|-------------------------------------- Terminals on top of converter housing --------------------------------------|

Converter housing

230 Vac 230 Vac

X2: 1 2 3 4 5 X2: 1 2 3 4 5

115 Vac

115 Vac either 230 Vac or 115 Vac

X2: 1 2 3 4 5

X2: 1 2 3 4 5

X2: 1 2 3 4 5

X2: 1 2 3 4 5

X2: 1

L

2

N

3 4 5

M

~

M55

M

~

M56

M55 M56

ϑ

M

M55

L N TW TW

X2: 1 2 3 4 5 6

~

ϑ

U1 V1 W1

ϑ

M

~

U2 V2 W2 PE TK TK

Fan_con_d.dsf

at Connection

U1-W2

V1-U2

W1-V2

U2-V2-W2

M57 M58

Configuration 1

D1...D3

Configuration 2

D3

Configuration 3

D4

Configuration 4

D5

Configuration 5

D6, D7

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

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

48

changes in the cooling air temperature and volume. Since the cooling air volume can 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

3ADW000194R0601 DCS800 Hardware Manual f e

49

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. The necessary wire torque at

60°C wire temperature is the same as recommended in the following tables.

Armature:

C1, D1 (AM1, KM1)

1 (2.)

U1, V1, W1(AK1, AK3, AK5)

1 (2.)

PE

IDC

[A-]

DCS800-S0x-0025-xx

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-0320-xx

DCS800-S0x-0350-xx

DCS800-S0x-0450-xx

DCS800-S0x-0520-xx

DCS800-S0x-0650-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

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

25

50

75

100

140

200

260

320

350

450

520

650

680

820

900

1000 2 x 185

4 x 120

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 6

1 x 10

1 x 25

1 x 25

1 x 35

2 x 35

2 x 35

2 x 70

2 x 70

2 x 95

2 x 95

2 x 120

2 x 120

2 x 150

4 x 95

[mm²]

-

-

-

-

-

1 x 95

1 x 95

1 x 95

-

-

-

-

-

-

3 x 150

-

-

-

Iv

[A~]

41

41

61

82

114

163

204

220

286

367

424

555

555

669

734

816

979

1224

[mm²]

1 x 4

1 x 6

1 x 25

1 x 25

1 x 35

2 x 25

2 x 25

2 x 50

2 x 50

2 x 95

2 x 95

2 x 120

2 x 120

2 x 120

4 x 70

2 x 150

[mm²]

-

-

-

-

-

1 x 95

1 x 95

-

-

-

-

-

3 x 95

4 x 95 3 x 120

4 x 150

6 x 185 1632 4 x 240

1 x 95

-

-

-

6 x 185 1550

6 x 185 1673

-

-

-

-

-

-

-

2040

2122

2448

2693

3264

3876

4202

4 x 240

6 x 120

8 x 120

8 x 120

7 x 185

7 x 185

8 x 240

6 x 300

6 x 300

5 x 150

6 x 185

6 x 185

-

-

-

-

-

1x150

1x185

2x150

2x240

3x120

3x120

4x120

4x120

4x150

4x150

4x240

3x300

3x300

1x 50

1x 50

1x 50

1x 50

1x120

1x120

1x120

1x150

[mm²]

1x 4

1x 6

1x 16

1x 16

1x 16

1x 25

1x 25

➀Reduced ambient temperature 40°C

➁Option for more flexible cable connection available

You will find instructions on how to calculate the PE conductor’s cross-sectional area in VDE 0100 or in equivalent national standards. We would remind you that power converters may have a current-limiting effect.

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

25

25

25

25

6

6

25

25

[Nm]

6

6

6

2 x M12

2 x M12

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

1 x M6

1 x M6

1 x M6

1 x M6

1 x M6

1 x M10

1 x M10

1 x M10

1 x M10

1 x M10

1 x M10

1 x M12

1 x M12

1 x M12

2 x M12

1 x M12

Excitation:

Size

DC output current

D1

6 A

D2

15 A

D3

20 A max. cross sectional area 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10 min. cross sectional area 1 mm²/ AWG 16 2.5 mm²/ AWG 13 4 mm²/ AWG 11 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10

Tightening torque 1.5...1.7 Nm

D4

25 A

D5

25 A

DCF803-0035

35 A

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

50

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

3ADW000194R0601 DCS800 Hardware Manual f e

51

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.

3ADW000194R0601 DCS800 Hardware Manual f e

Planning the electrical installation

52

Planning the electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

53

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

3ADW000194R0601 DCS800 Hardware Manual f e

54

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. contactor, air-circuit-breaker) use overvoltage protection.

The voltage shift of the isolated supply must not be larger than the voltage shift in case on an earth fault.

Voltage shift in case of earth fault

V

U1

V1

W1

Earth fault earth fault volt shift.dsf

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 screening of power cables see manual Technical Guide, see

Reference

Cross sectional areas and tightening torques of power cable see chapter Planning

the electrical installation

Electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

Location R-Extension and Interface Modules

Connect the signal cables as described below. Tighten the screws to secure the extension modules.

55

DCS800

Panel connector

X33:

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

X34:

PCTool

DriveWindow Light

AP Tool

Commissioning assistant

3ADW000194R0601 DCS800 Hardware Manual f e

Electrical installation

56

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: digital I/O´s:

Standard + one channel for residual current measurement all isolated by means of optocoupler/relay, the signal status is indicated by LED

current source for: PT100/PTC element

3ADW000194R0601 DCS800 Hardware Manual f e

57

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

SINGLE-ENDED

A

B

Z

A

B

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

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

.

Note:

If the drive’s measured direction of rotation is wrong or does not correspond to measured EMF speed, the SPEEDFB fault may appear during start-up. If necessary correct by exchanging the field connection

If with a positive reference the position signal 3.07 or 3.08 signal does not look like the illustration below, then tracks A & must be exchanged with inverted signals. For single-ended encoders Tracks A and

B must be exchanged.

65535

IOB3x3_g.dsf

Forward

0

Electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

58

Pulse encoder receiver

Two different incremental encoder connections are available.

-differential connection; pulse encoders generating either voltage or current signals can be used

-single-ended (push pull) connection; voltage signals

Restrictions using jumper S4 (CON-4): or S10 (IOB-3): depending on the board

Line termination via S4/S10 should not be used at 12 V or 24 V encoders, because of the power consumption taken from the encoder. If a pulse encoder with a build in current source is used a burden resistor of 120

Ω is activated via jumper S10: 1-2 on

SDCS-IOB-3 a.s.o.

Pulse encoder connection principles

single ended

open collector

X5:7

X5:1

121

Ω

100 nF

3

S10

6

1k0

2

5

10k

+24V

+5V or +12V or +24V

+5V

4k7

X5:2

0V / GND

X5:10

1 4

1k0 4k7

SDCS-IOB-3 ENCODER INPUT A

+5V

+5V or +24V

X5:10

X5:1

+5V

1k0 4k7

3

10k

R

2

S4

100 nF

1

1k0 4k7

+5V

X5:2

0V

X5:7

SDCS-CON-4 ENCODER INPUT A

single ended

push pull

+5V or +12V or +24V

X5:7

X5:1

+5V

121

Ω

100 nF

3

S10

6

1k0

2 5

10k

+24V

4k7

R

X5:2

0V / GND

X5:10

1

4

1k0 4k7

SDCS-IOB-3 ENCODER INPUT A

+5V

+5V or +24V

X5:10

X5:1

+5V

1k0 4k7

3

10k

R

2

S4

100 nF

1

1k0 4k7

+5V

X5:2

0V

X5:7

SDCS-CON-4 ENCODER INPUT A encoder input_a.dsf

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.

differential

+5V

X5:7

X5:1

+5V

121

Ω

100 nF

3

S10

6

1k0

2 5

10k

+24V

4k7

X5:2

0V / GND

X5:10

1

4

1k0 4k7

SDCS-IOB-3 ENCODER INPUT A

+5V

differential voltage source

5 V

CON-4

12/24 V

S4

1-2

S4

3=park

4-5

7-8

6=park

9=park

differential current source

-

5 V

IOB-3

12/24 V

S10

2-3

8-9

14-15

S10

4-5

10-11

16-17

S10

1-2

7-8

13-14

-

In any case, if SDCS-IOB-3 is used, see required settings of SDCS-CON-4 board

Electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

59

The maximum 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

Use twisted pair cable with pair shielding plus overall shielding.

Cable length

0 to 164 ft

164 to 328 ft

328 to 492 ft

parallel wires for

power source & GND

1 x 24 AWG

2 x 24 AWG

3 x 24 AWG

Cable used

12 x 24 AWG

12 x 24 AWG

14 x 24 AWG

3ADW000194R0601 DCS800 Hardware Manual f e

Electrical installation

60

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

Size D6, D7

Screen connection

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.

24 V 115/230 V

Control cable duct

Motor cable

Drive min 300 mm (12 in.)

Power cable

24 V 115/230 V

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 115/230 V.

Lead 24 V and 115/230 V control cables in separate ducts inside the cabinet.

Electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

DCS Link Wiring

DCS Link is a 500 KBaud serial communication 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 communication.

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 for 12-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. It must be located in both ends and activated by jumper or switch.

Preferred cable type: DEVICENET

Supplier: Helu Kabel, Germany; type 81910PUR

Belden, USA; type 3084A

61

120 ohm

1%, 1/4 W

Node 1

• • •

CAN_H

CAN_L

CAN_Bus_termination.dsf

120 ohm

1%, 1/4 W

3ADW000194R0601 DCS800 Hardware Manual f e

Electrical installation

62

The bus ground (GNDB) is isolated. It can be ground terminated at one point only.

Example of two DCS800 D5 converters with FEX-425-Int internal field supply.

DCS800 D5 Converter

SDCS-DSL

CAN_Bus_termination_c.dsf

SDCS-DSL

DCS800 D5 Converter

FEX-425-Int FEX-425-Int

GNDB

S1100:2

S1100:1

X3: 3

S1100:3

2 1 X52: 1 2 3

GNDB

S2

3 2 1

X53:

X52: 1 2 3

GNDB

S2

3 2 1 X53: X3:

S1100:1

2

GNDB

S1100:2

S1100:3

3 1

(next drive)

(next converter)

Bus termination

Set bus termination ON

(S1100:1 closed)

Termination OFF Termination OFF

Set bus termination ON at the end

The connection of isolated GNDB between two or more serial communication interfaces is optional. It is recommended to connect GNDB if the supply voltage is above 690 V and the cabling is made from cubicle to cubicle.

Example of one DCS800 D5 converter plus external field supply.

DCS800 D5 Converter

SDCS-DSL

DCF803-0035

FEX-4

X51:1

X51:2

+24 V

0 V

+24 V

0 V

GNDB

S1100:2

X52: 1 2 3

GNDB

1

2

S1

S2

3 2 1 X53:

X3:

S1100:1

2

S1100:3

3 1

X1:1

X1:2

Bus termination

Set bus termination ON

(S1:1-2 closed)

Set bus termination ON

(S1100:1 closed)

Cable length

The cable length influences the maximum baudrate.

Baudrate

50 k

125 k

250 k

500 k

800 k

888 k

1000 k max. cable length

500 m

500 m

250 m

100 m

50 m

35 m

25 m default and recommended setting

The bus is designed for cable length up to 50 meters. Larger distances on request.

Electrical installation

3ADW000194R0601 DCS800 Hardware Manual f e

63

Installation checklist

Checklist

Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the

Safety

instructions

on the first pages of this manual before you work on the unit.

Check

MECHANICAL INSTALLATION

The ambient operating conditions are allowed. (See

Mechanical installation, current ratings

Ambient conditions

.)

The unit is fixed properly on a vertical non-flammable wall. (See

Mechanical installation.

)

The cooling air will flow freely.

The motor and the driven equipment are ready for start. (See

Planning the electrical installation

)

All screen terminals are checked for tightness.

All cable connections are seated properly.

ELECTRICAL INSTALLATION (See

Planning the electrical installation, Electrical installation.

)

The drive is grounded properly.

The mains (input power) voltage matches the drive nominal input voltage.

The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.

Appropriate mains (input power) fuses and disconnector are installed.

The motor connections at C1, D1 and F+, F- and their tightening torques are OK.

Proper function of E_Stop circuit and relay..

Fan power wiring connected.

The external control connections inside the drive are OK.

There are no tools, foreign objects or dust from drilling inside the drive.

Drive, motor connection box and other covers are in place.

Installation checklist

3ADW000194R0601 DCS800 Hardware Manual f e

64

Installation checklist

3ADW000194R0601 DCS800 Hardware Manual f e

65

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 Instruction

Depends on the dustiness of the environment (every 6 to 12 months)

Every six years

See

Heatsink

.

See

Fan

.

3ADW000194R0601 DCS800 Hardware Manual f e

Maintenance

66

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. Assemble back 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)

see Service Manual

Maintenance

3ADW000194R0601 DCS800 Hardware Manual f e

67

Technical data

What this chapter contains

This chapter contains the technical specifications of the drive, e.g. the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings and warranty policy.

Reference:

Hardware extension RAIO Analog I/O Extension

Hardware extension RDIO Digital I/O Extension

publ.no.:3AFE64484567 publ.no.:3AFE64485733

DCS800 1131 Programming target

publ.no.:3ADW000199

Branching units NDBU-95 publ.no.:3ADW000100

Environmental Conditions

System connection

Voltage, 3-phase:

Environmental limit values

230 to

≤ 1000 V acc. to IEC 60038

Permissible cooling air temp.

±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 / NEMA TYPE OPEN

IP 20/21/31/41 light grey RAL 9002 light grey RAL 7035

Vibration class

(IEC-60721-3-3)

Site elevation

<1000 m above M.S.L.:

>1000 m above M.S.L.:

2

3M3 - D1...D4

3M1 - D5...D7

100%, without current reduction with curr. reduct., see Fig. below

Size

D1

D2

D3

D4

D5

D6

D7

Sound pressure level L as module

55 dBA

55 dBA

60 dBA tance)

66...70 dBA, depending on fan

73 dBA

75 dBA

82 dBA

P

(1 m disenclosed conv.

54 dBA

55 dBA

73 dBA

77 dBA

78 dBA

73 dBA

80 dBA

Vibration Shock

1.5 mm, 2...9 Hz

0.5 g, 9...200 Hz

7 g / 22 ms

Transport in original Package

Short circuit withstand rating

The DCS800 is suitable for use in a circuit capable of delivering not more than: as module

1.2 m 65 kA rms symmetrical amps at maximum

600 VAC

1.0 m

0.3 mm, 2...9 Hz

0.1 g, 9...200 Hz

4 g / 22 ms

0.25 m

Shock monitor

100 kA rms symmetrical amps at maximum 600 VAC

Effect of the ambient temperature on the converter module load capacity

110

Effect of the site elevation above sea level on the converter’s load capacity

100

90

80

70

60

50

1000 5000 m 2000 3000 4000

Current reduction to (%)

100

90

80

70

30 35 40 45 50 55°C

Current reduction to (%) for converter modules

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

68

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 61800-1

[IEC 61800-1]

EN 60204-1

[IEC 60204-1]

EN 60204-1

[IEC 60204-1]

EN 61800-1

[IEC 61800-1]

EN 60204-1

[IEC 60204-1]

EMC Directive

89/336/EEC

93/68/EEC

Declaration of Conformity EN 61800-3

[IEC 61800-3]

EN 61800-3

[IEC 61800-3]

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

➀ in accordance with

3ADW 000 032

➀ in accordance with

3ADW 000 032/3ADW 000

091

North American Standards

In North America the system components fulfil the requirements of the table below.

Rated supply voltage

Converter module

Standards

Enclosed converter to 600 V UL types: on request • see UL Listingwww.ul.com / certificate no.

E196914

Approval: c

UL us

The spacings in the modules were evaluated to table 36.1 of UL 508 C.

Spacings also comply with table 6 and table 40 of

C22.2 No. 14-05.

>600 V to 990 V

• or on request

EN / IEC xxxxx see table above.

Available for converter modules including field exciter units.

EN / IEC types: on request

(for details see table above)

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

69

Current ratings - IEC non regenerative

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 / 525 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-S01-0470-04/05

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

800 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

I

DC I

continuous

[A]

405

470

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

Note

AC current I

AC

= 0.82*I

DC

240

470

684

1200

1479

1520

1940

2530

2416

3036

3734

100 %

15 min

I

DC II

150 %

60 s

[A]

320

359

490

596

700

888

1200

1479

104

148

200

264

18

40

54

78

1550

1980

2350

2416

2977

3800

480

539

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

347

482

578

670

872

1156

1421

100

144

188

250

18

37

52

72

1480

1880

2220

2300

2855

3669

465

521

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

100 %

15 min

I

DC IV

200 %

10 s

[A]

308

321

454

538

620

764

1104

1361

94

124

178

230

18

38

55

66

1450

1920

2280

2277

2795

3733

616

642

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 *

+S164

-

-

25 A *

+S164

-

-

-

-

-

-

-

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

70

Current ratings - IEC regenerative

Unit type

4-Q converters

400 V / 525 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-S02-0520-04/05

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

800 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

I

DC I

continuous

[A]

450

520

680

820

1000

1200

1500

2000

25

50

75

100

140

200

260

350

2050

2500

3000

3300

4000

5200

1900

2500

3000

3300

4000

4800

2050

2600

3300

4000

320

650

900

1500

2050

2500

3000

3300

4000

4800

256

514

684

1200

1520

1940

2270

2416

3036

3734

I

DC II

100 %

15 min

[A]

360

398

544

664

766

888

1200

1479

110

152

214

286

23

45

66

78

1550

2000

2330

2416

2977

3800

150 %

60 s

540

597

816

996

1149

1332

1800

2219

35

68

99

117

165

228

321

429

2325

3000

3495

3624

4466

5700

1500

1910

2250

2655

3036

3734

1577

2000

2551

2975

384

771

1026

1800

2280

2910

3405

3624

4554

5601

2250

2865

3375

3983

4554

5601

2366

3000

3827

4463

246

508

670

1104

1450

1870

2190

2300

2900

3608

100 %

15 min

I

DC III

[A]

150 %

120 s

346

385

538

648

736

872

1156

1421

105

148

206

276

22

43

64

75

1480

1930

2250

2300

2855

3669

519

578

807

972

1104

1308

1734

2132

33

65

96

113

158

222

309

414

2220

2895

3375

3450

4283

5504

1430

1850

2160

2540

2889

3608

369

762

1005

1656

2175

2805

3285

3450

4350

5412

2145

2775

3240

3810

4334

5412

1500

1900

2428

2250

2850

3642

2878 4317

Data on request

235

462

594

1104

1430

1740

2030

2277

2950

3700

100 %

15 min

I

DC IV

[A]

200 %

10 s

315

356

492

598

675

764

1104

1361

99

126

184

265

21

38

57

67

1450

1790

2080

2277

2795

3733

630

712

984

1196

1350

1528

2208

2722

42

76

114

134

198

252

368

530

2900

3580

4160

4554

5590

7466

1400

1710

2000

2485

2933

3673

1471

1922

2458

2918

470

924

1188

2208

2860

3480

4060

4554

5900

7400

2800

3420

4000

4970

5866

7346

2942

3844

4916

5836

Size

D1

D2

D3

D4

D5

D6

D7

D3

D4

D5

D6

D7

D6

D7

D7

internal field curr.

6 A

15 A

20 A

25 A

25 A *

+S164

-

-

25 A *

+S164

-

-

-

-

-

-

-

* as option

Note

AC current I

AC

= 0.82*I

DC

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 DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 °C

(104 °F) or the drive is loaded cyclically.

Duty cycle

I

DCI

I

DCII

I

DCIII

I

DCIV

100% t

150%

15 min

100% t

15 min

150%

100% t

15 min

200% 100% t

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

71

Control Board SDCS-CON-4

Layout of the control board SDCS-CON-4

S1

3

2

1

3

2

1

3

2

1

3

2

1

3

2

1

3

2

1

S2

2

1

2

1

S3

2

1

2

1

2

1

2

1

Jumper coding

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 reserved: Tacho input 2 at X2:23 and X2:24 at

SDCS-IOB-3 / PS5311

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

IN

= 250 Ohm

; ∗∗

Range I

IN

= -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

12

11

10

*

Encoder mode: differential; RC load with

R = 121 Ohm

and C = 100 nF activated

12

11

10

Encoder mode: single ended, or if IOB-3 connected; Pull-up resistors 10 kOhm activated

12

11

10

Encoder supply 5 V, sense X5:8-9 are active

*

or SDCS-POW-4 see section

Power supply board SDCS-POW-4

12

11

10

Encoder supply 24 V, uncontrolled supplied from CON-4

12

11

10

Park position

When connecting an encoder to IOB-3 set jumper S4 on CON-4 board to park position

3

2

1

S5

2

1

2

1

4

3

4

3

*

Step 1: Preparation for Firmware download operation

Step 2: Text download + normal program execution

*

**

default value

250 Ohm x 20 mA = 5 V = 100%

1

X17

25

26

S1

1

3

2

X3

X2

2

1

X33

1

2

X300

H2500

Jumpers shown in default position

9

8

7

X1

2

1

S2

4

3

1

2

1

1

2

S3

8

7

3

2

1

X4

12

11

10

S4

1

1

2

247

X11

5

6

X34

1

9

X5

2

1

S5

4

3

1

D2001

X6

1

2

1

2

2

1

X8

X9

1

D1000

30

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

SDCS-PIN-4

SDCS-CON-4

SDCS-POW-4

SDCS-CON-4

10 11 12 24V 10 11 12

5V

S4

5V

12V

15V

24V

S4

24V

X5:10 encoder supply

X5:10 encoder supply

The 24 V encoder supply can be selected either directly from

CON-4 board (S4=11-12) or from POW-4 board (S4=10-11);

S4 is located on the CON-4 board

Con4_layout_c.dsf

1

2

25

26

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 and pointers group

51) 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

3ADW000194R0601 DCS800 Hardware Manual f e

72

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-4).

X12: and X13: connector are used for measurement voltage, current and temperature and firing thyristors by SDCS-PIN-4/PIN-41/PIN-46/PIN-41/PIN-51.

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 for DWL and IEC61131 programming connection.

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

The RS232 interface is normally used for setting parameter in the drive via the DWL 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 needed 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 61131 Programming target

see chapter SDCS-COM-8 board

X20 (Slot 4) is used for Memory Card, see description IEC61131 programming.

Prepared function of:

RDIO / RAIO

R... Fieldbus adapter

SDCS-COM-8

Second fieldbus RMBA

Memory Card x x

Slot 1

X9:

Slot 2

X10: x x x x

Slot 3

X11: x

Slot 4

X20: x

73

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

74

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

±8...±30 V

S1

3

1

5

6

7

8

9

10

39k2

12k8

5k

S1

6

GND

4

S2

3 4 250

S3

6

8

5

7

S3

3 4 250

4k75

1k66

+10V

-

+

-

+

-

+

-

+

Firmware

-

+

ATACH2

9

8 ATACH

7

S1

ATACH1

AI1

(3.3 ms)

AI2

(3.3 ms)

AI3

(5 ms)

9

10

6

7

8

X5:1

2

3

4

5

X4:1

2

3

4

5

6

9

10

7

8

-

+

GND

+10V

-10V

GND (AOx)

100

μ

47.5

100n

AI4

(5 ms)

AO1 (5ms)

AO2 (5ms)

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

10

S4

11

12

5 V

-

+

4k75 47nF

τ = 10 ms

τ = 10 ms

τ = 10 ms

τ = 10 ms

τ = 10 ms

τ = 3.3 ms

τ = 3.3 ms

+/- I-act

PIN-4 = 5 V

POW-4 = 5V/

15V/24V

CON-4 = 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-b.dsf

Resolution

[bit]

15 + sign

Input/output values

Scaling by

Common

Hardware 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

+ Hardw.

≤ 5 mA

8 V -> min. of 325% of [99.03] or

230% of [4.05]

Encoder supply

5 V

24 V

Input value Signal definition by

Firmware

0...7.3 V

7.5...50 V

-> “0“ status

-> “1“ status

Remarks

Output value

≤ 250 mA

≤ 200 mA

Signal definition by

Remarks

Inputs not isolated

Impedance = 120

Ω, if selected max. frequence

≤ 300 kHz

Sense lines for GND and supply to correct voltage drops on cable (only if

5 V encoder is in use).

Remarks

50 * mA

22 V at no load

Firmware Current limit for all 7 outputs = 160 mA

Do not apply any reverse voltages!

* short circuit protected

➀ gain can be varied in 15 steps between 1 and 4 by software parameter

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

75

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, AC800M, Nxxx-xx

(adapter modules for fieldbus), AC80) or via adapter modules from other controllers) to the

DCS800-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 a d e b

COM_8_layout_b.dsf

conductive support

Type

Explanation of LEDs on SDCS-COM-8

LED

V6

V1 color Meaning green 5 V supply ok red blinking: boot procedure permanent: SDCS-COM-8 fault

Revision optical components Channel 0 used for max. driver current Cunductive support

Ch 0

PLC

Ch 1

I/O

Ch 2

M/F

Ch 3

DW

SDCS-COM-81 from D...F

10 Mb 5 Mb 10 Mb 10 Mb other interfaces

SDCS-COM-82 from D...F

5 Mb 5 Mb 10 Mb 10 Mb Fieldbus adapter modules Nxxx-xx

SDCS-COM-81 from G...

10 Mb 5 Mb 10 Mb 10 Mb other interfaces

SDCS-COM-82 from G...

5 Mb 5 Mb 10 Mb 10 Mb Fieldbus adapter modules Nxxx-xx

Ch 0, 2, 3 50 mA

Ch 2, 3 50 mA

Ch 0, 2, 3 50 mA

Ch 2, 3 50 mA x x

Color of optical components:

5 Mb -> blue driver current maximum 30 mA

Remark: Only channels with the same components (e.g. 10 Mb component) may be connected to each other.

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

76

X19

V6

D200

Ch2 SDCS-COM-8 Master-Follower connections

SDCS-COM-8x

SDCS-COM-8x

D100

D100

D200

D400

V6

D400

V6

V1

V1

X19

X19 plastic optic fibre

D200

SDCS-COM-8x

V1

30 m - SDCS-COM-8 Rev D and higher

Ch0 Drive Bus connection to Advant Controller (star)

D200

SDCS-COM-81

D200

SDCS-COM-81

D200

SDCS-COM-81

D400

D100 com8_bus conn_a.dsf

. . .

. . .

0, 1, 2 ...

NDBU-95

...8

plastic optic fibre

20 m - SDCS-COM-8 up to Rev C

30 m - SDCS-COM-8 Rev D and higher

30 m plastic optic fibre

AC80 Ch0 Drive Bus

AC 800M CI 858 Drive Bus Module

PEC800 CI 858 Drive Bus Module

FCI (CI 810 Adapter module) com8_bus conn_a.dsf

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

Ch0 Connection to overriding control (Nxxx fieldbus adapter)

D200

SDCS-COM-82

D200

SDCS-COM-82

D200

SDCS-COM-82

. . .

plastic optic fibre

10 m

77

Nxxx-xx Nxxx-xx

Fieldbus

Ch3 Ring connection to PC tool DriveWindow

D200

SDCS-COM-8x

D200

SDCS-COM-8x

. . .

plastic optic fibre

. . .

Nxxx-xx

com8_bus conn_a.dsf

D200

SDCS-COM-8x

30 m - SDCS-COM-8 Rev D and higher max. 20 m instead of

DriveWindow

NETA internet module can be connected, see

Manual

3AFE64605062

Internet/Ethernet

NETA

PCI/PCMCIA adapter (PC)

NDPC-12

NDPA-02

(Laptop) com8_bus conn_a.dsf

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

78

Ch3 Star connection to PC tool DriveWindow

D200

SDCS-COM-8x

D200

SDCS-COM-8x

D200

SDCS-COM-8x

. . .

Plastic opt. fibre

30 m - SDCS-COM-8

Rev D and higher

. . .

0, 1, 2 ...

NDBU-95 ...8

Branching unit max. 20 m instead of

DriveWindow

NETA internet module can be connected, see Manual

3AFE64605062

Internet/Ethernet

NETA

. . .

Plastic opt. fibre max. 30 m or 200 m

HCS

. . .

0, 1, 2 ...

NDBU-95 ...8

Branching unit

. . .

0, 1, 2 ...

NDBU-95 ...8

Branching unit

Plastic opt. fibre max. 30 m

HCS

Silicat max. 200 m

Technical data

PCI/PCMCIA adapter (PC)

NDPC-12

NDPA-02

(Laptop)

3ADW000194R0601 DCS800 Hardware Manual f e com8_bus conn_a.dsf

79

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 documentation.

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

V108

TXD

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

3ADW000194R0601 DCS800 Hardware Manual f e

80

SDCS-DSL Board

The SDCS-DSL board provides a drive to drive communication. The communication hardware and protocol is based on CAN bus.

This communication will be used for 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 section DCS Link Wiring

SDCS-DSL-4

77

X51

1 2

X52

1 2 3

X53

1 2 3

X54

1 2 3

S2

DSL-4_drw_b.dsf

Jumper coding

S1

Bus termination

3

2

1

120 Ohm

3

2

1

*

no termination, park position

S2

Ground termination

2

1

2

1

4

3

4

3

0 Ohm (direct) ground termination

200 kOhm R-C ground termination

2

1

3

4

*

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

S2

3 4

1 2

GNDB

Termination 200 kOhm

X54:1

2

3

TxD

RxD

DSL-4_dia_a.dsf

.

Supply

24 V

≤ 200 mA

DSL communication

Bus termination

S1 1-2

2-3

Ground termination

S2 2-4

1-3

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

3ADW000194R0601 DCS800 Hardware Manual f e

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.

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

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.

I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4

SDCS-CON-4 SDCS-CON-4

X2: X1:

X1: X2:

SDCS-IOB-3

X3: X1:

SDCS-IOB-2

X3:

X2:

X4: X5:

X1:

X3: X1:

SDCS-IOB-2

The cable length between X1:/X1: and X2:/X2: is max. 1.7 m (D1...D4 converters) is max. 4 m screened (required for D7 converters) between X1:/X3: is max. 0.5 m because of EMC reasons.

See chapter Other cables.

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 3

4

*

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_d.dsf

There is a card holder available as option for fastening the SDCS-IOB-2 board. For more information see chapter Dimensional drawings.

81

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

82

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

R3

W5 W6

4

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

Technical data

Note:

When the SDCS-CON-4 control board with the SDCS-IOB-

2 I/O board is installed, terminals X6: and X7: on the

SDCS-CON-4 must not be used.

Output value Signal definition by Remarks

K1...K5, K8

Firmware potential-isolated by relays

(NO contact element)

Contact ratings:

AC:

≤ 250 V~/ ≤ 3 A~

DC:

≤ 24 V-/ ≤ 3 A-

or

≤ 115/230 V-/ ≤ 0.3 A-)

MOV-protected (275 V)

K6, K7

Firmware potential-isolated by optocoupler

Switching capacity:

≤ 50 mA external voltage:

≤ 24 V-

X4:, X5: are screw-clamp terminal types for leads up to 4 mm² crosssectional area.

Default values are shown within the software diagrams.

The ground potential of the digital outputs may vary within ±100 V to each other.

Input value Signal definition by

Channel

Firmware

1...8

IOB-21

0...8 V

18...60 V

IOB-22

0...20 V

60...130 V

IOB-23

0...40 V

90...250 V

Firmware

Remarks

potential-isolated by optocoupler

(24...48V-) R1...R8 = 4.7 k

Ω

-> "0 signal"

-> "1 signal"

(115V~)

R1...R8 = 22 k

Ω

-> "0 signal"

-> "1 signal"

(230 V~)

R1...R8 = 47 k

Ω

-> "0 signal"

-> "1 sig." including tolerance; absolute max. values

X6: / X7: are screw-clamp terminal types for leads up to 4 mm² crosssectional area

Input resistance: see diagram.

Input smoothing time constant: see diagram.

Smoothing time constant of channel 7 and 8 can be changed; see fig. before.

Power supply for digital inputs X7:3,4:

• 48V /

≤ 50mA

• not galv. isolated from the DCS electronics!

• only available at SDCS-IOB-21

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 DCS800 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.

3ADW000194R0601 DCS800 Hardware Manual f e

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.

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 (D1...D4 converters) is max. 4 m screened (required for D7 converters) between X1:/X3: is max. 0.5 m because of EMC reasons.

I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4

SDCS-CON-4

SDCS-CON-4

X2: X1:

X1: X2:

SDCS-IOB-3

X3: X1:

SDCS-IOB-2

X2:

X1: X2:

SDCS-IOB-3

X1:

X6: X7:

Layout and jumper settings of the SDCS-IOB-3 board

233.5

V17

70 conductive supports

X1

8

7

2

S2

*

1

2

8 7

1

2

S3

*

1

X2

14

13

S1

*

R110

1 12

1

X3

SDCS-IOB-3

1

3

S5

*

2

4

X4

3

2

1

S10

*

24

23

22

12

1

5

T1

1

S4

2

11

X5

12

10

4

AI3 S1:7-8

S3

4

2

8

6

Jumper coding

S1

S2

S3

Functionallity of analogue inputs

Ch

AITAC

AI1

Paralleling of

500

Ω between input terminal for 0/4...20 mA

S1:1-2

S1:3-4

AI2 S1:5-6 gain = 1

*

-10V..+10V

YES

YES

S2

4

2

8

6 gain = 10

-1V..+1V

3

1

7

5

S2

4

2

8

6

3

1

7

5

Residual current measurement

X3:11

X3:12

3

1

7

5

S3

4

2

8

6

3

1

7

5

AI4 S1:9-10 YES

S1:11-12

S1:13-14

S10

Characteristics for pulse encoder inputs single ended push/pull

3

*

24

(5V/12V/24V)

2 23

1 22

5 V 12/24 V differential:

3

2

1

24

23

22

3

2

1

*

24

23

22

S4

Pulse encoder supply

5

7

1

3

9

11

5 V

2

4

6

8

10

12

5

7

1

3

9

11

12 V

2

4

6

8

10

12

5

7

1

3

9

11

24 V

*

2

4

6

8

10

12

S5

Temperature sensor supply

PTC

1.5 mA

PT100

5 mA

*

1

3

2

4

1

3

2

4

3

2

1 single ended open collector

3

2

1

24

23

22

13 mA

24

23

22 iob3_e.dsf

*

default value

When using SDCS-IOB-3 encoder input, the following S4 jumper setting on SDCS-CON-4 has to be made

S4 on SDCS-CON-4

3

2

1

12

11

10

4

70

85

5

There is a card holder available as option for fastening the SDCS-IOB-3 board. For more information see chapter Dimensional drawings.

83

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

84

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:

X4:1

2

3

4

5

6

9

10

7

8

11

12

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

14

13

100

100

μ

100n

47.5

0V

100

μ

1 2

S5

3 4

SDCS-CON-x

100k

100k

100k

1n

1n

100k

Software

AITAC

100

μ

47.5

100n

0V

AO1 x

R110

0V

+/- I-act

8 V = 325% [99.03] max. 230% [4.05]

+10V

0V

-10V

1.5 mA

5 mA

0V

AO2

AI1

3.3 ms

AI2

3.3 ms

AI3

10 ms

AI4

10 ms

X5:1

2

3

6

7

4

5

8

9

10

S10

4 5 6 +24V

S10

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 iob3x2_g.dsf

Terminals X3: (except for connector 1, 2, 3, 4), X4: and X5: on the

SDCS-CON-4 must not be used

.

Resolution

[bit]

15 + sign

Input/output values

Scaling by

Common mode

Hardware range

-10...0...+10 V Firmware ±20 V

Remarks

➀➁➂➅

15 + sign

15 + sign

-10...0...+10 V Firmware ±20 V

-10...0...+10 V Firmware ±40 V

➀➁➂

➀➁➂➃➄

15 + sign

15 + sign

11 + sign

11 + sign analogue

-10...0...+10 V Firmware

-10...0...+10 V Firmware

±40 V

±40 V

➀➁➂➃➄

➀➁➂

Power

-10...0...+10 V Firmware

≤ 5 mA*

-10...0...+10 V Firmware

≤ 5 mA*

-10...0...+10 V R110

≤ 5 mA*

R i

= 3

Ω ≤ 5 mA*

≤ 5 mA*

1.5 mA

5 mA gain: 0.5...5

for external use e.g. reference pot.

Curr. source for

PTC or PT100

Encoder supply

5 V

12 V / 24 V

≤ 250 mA *

≤ 200 mA *

Remarks

Inputs not isolated

Impedance = 120

Ω, if selected max. frequence

≤ 300 kHz

Sense lines for GND and supply to correct voltage drops on cable (only if

5V/12V encoder is in use)

➀ total smoothing time ≤ 2 ms

➁ -20...0...+20 mA by setting S1

➂ 4...20 mA by ➁ + Software function

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

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

➄ designated for PT100 evaluation per firmware and hardware

➅ should always be used directly at SDCS-CON-4

X3:1...4

* 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 Ohm 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

Ω 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

3ADW000194R0601 DCS800 Hardware Manual f e

85

Power Supply Board SDCS-POW-4

The SDCS-POW-4 board is designed for DCS800 converter modules and is mounted on the electronic support. This board is used for all types of modules type D5, D6 and D7 (>1000 A and rebuild system

DCS800-R).

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 is automatically detected and set to either 230 V AC or to 115 V AC. The following figure shows the instructions for the selection of the encoder supply voltage.

If SDCS-CON-4 input X5: is used for encoder speed measurement, the incremental encoder supply voltage for 5V, 12 V or 15 V must be selected by jumpers S3, S4 and S5.

SDCS-POW-4

SDCS-CON-4

10 11 12 24V

5V

12V

15V

24V

S4

X5:10 encoder supply

The 24 V encoder supply can be selected either directly from

CON-4 board (S4=11-12) or from POW-4 board (S4=10-11);

S4 is located on the CON-4 board

X3

X4

X5

Jumper coding

Encoder supply selection

X3 X4 X5

Sensefunction

5 V

*

15V

24V

B B

A A yes

Relay output

1 2

X96

DO8 line potential !

N L

AC supply

X99

X95

+

-

12 V

15 V

15V

24V

B B

A A yes

15V

24V

B B

A A no

24 V 15V

24V

B B

A A no

X137 X14

X37 and X137 are connected in parallel

X14 is used for SDCS-PAR-1 hard parallel converters

*

default value

110

Pow4a.dsf

Auxiliary supply voltage X99

Supply voltage 115 V AC 230 V AC

Frequency

Power consumption

Power loss

Inrush current * recommended fusing

Mains buffering

Powerfail

45 Hz ... 65 Hz

120 VA

≤ 60 W

20 A / 20 ms

6 AT min 30 ms

95 V

45 Hz ... 65 Hz

120 VA

≤ 60 W

10 A / 20 ms

6 AT min 300 ms

95 V

* Frequently switching ON and OFF increases inrush current

Input circuit POW-4

NTC

ϑ

X99:

F1

3.15 AT

POW4_in-output_circuit.dsf

Output X96-DO8

Potential isolated by relay (NO contact)

MOV- element (275 V)

Contact rating: AC:

3 A~

DC:

24 V-/

≤ or

≤ ≤

0.3 A-

Backup supply X95

These two terminals 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.

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

86

Interface Board SDCS-PIN-4

General

The SDCS-PIN-4 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 plug-in modules

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 4x

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 = automatic = default

2-3 = 230 V fix

K301

W1

X20

K400

F400

D1

X96

F300

X99

Relay output

DO 8

Input

Aux.

supply

Output field current

Different functional areas on SDCS-PIN-4

Pin4_layout_b.dsf

3ADW000194R0601 DCS800 Hardware Manual f e

87

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 either 230 V or 115 V and switches relays K301.

In case of varying 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

Tolerance -15%/+10%

Frequency

Power consumption

45 Hz ... 65 Hz

120 VA

Power loss

Inrush current recommended fusing

≤ 60 W

20 A / 20 ms

6 AT

Mains buffering

Powerfail min 30 ms

95 V

230 V AC

-15%/+10%

45 Hz ... 65 Hz

120 VA

≤ 60 W

10 A / 20 ms

6 AT min 30 ms

185 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

1-2 -> automatic detection of input voltage range (default)

2-3 -> 230 V operation fix

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-)

X99: Input circuit PIN-4

X96:

PIN4_in-output_circuit_b.dsf

275 V

6

Ω

X99:

6

Ω

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

88

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 setting.

Field circuit interface

The On board field exciter 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 F100, F101, F102 for cable and motor field protection.

• 600 V converter are always without Onboard field exciter

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

6 mm²

AWG 10

1 mm²

AWG 16

D2

15A

D3

20A

6 mm²

AWG 10

2.5 mm²

AWG 13

KTK - 25

6 mm²

AWG 10

4 mm²

AWG 11

D4

25A

6 mm²

AWG 10

6 mm²

AWG 10

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

Typical armature circuit thyristor converter diagram with SDCS-PIN-4 board

89

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

90

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-48.

The following figures show the different connections between the SDCS-PIN-48 and SDCS-PIN-51 board depending on the application 2- or 4-quadrant and the construction type.

The firing board SDCS-PIN-46 is used for converters DCS800-S02-2500, DCS800-S02-3000 double bridge D6 modules.

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

3ADW000194R0601 DCS800 Hardware Manual f e

91

Measuring board SDCS-PIN-51

This board is always used together with SDCS-PIN-4x board. On this board there are the circuits located needed for current, voltage and temperature measuring and for hardware coding.

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.

Voltages (U1, V1, W1 and C1(+) and D1(-)) are measured by using high ohm resistor chains. Scaling of AC and DC voltage is done by activating 1 M

Ω resistors (= cutting out short circuit wires, which are represented by low ohmic resistors).

The voltage measurement uses 5 resistor:

U1:W1 to W5

V1:W6 to W11

W1:W12 to W16

C1(+):W17 to W21

D1(-):W22 to W26

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..

W5

R123

Isolating supports

Layout of the SDCS-PIN-51 board line potential !

U1

W5

C1

W21 W20

W4 W3 W2 W1

V1

W11 W9 W8

W1

W16 W15

W7 W6

W14 W13 W12

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

W10 W70

W71

X23

W72

2

W80 W81 W82

1

X24 2

1

X25 2

R1 . . . . . . . R21

W83

X12S X413S

X13S X313S

S2 S1

R22

R26

305

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

92

Current coding

Construction type

Current transf. ratio

Rated current [A DC]

R1-R4

18

Ω

R5

18

Ω

R6

R7

R8

R9

R10

R11

R12

18

Ω

18

Ω

18

Ω

18

Ω

18

Ω

18

Ω

18

Ω

R13

R14

R15

R16

R17

R18

R19

R20

R21

R22

R23

R24

R25

R26

18

Ω

18

Ω

18

Ω

18

Ω

33

Ω

68

Ω

120

Ω

270

Ω

560

Ω

47

Ω

47

Ω

47

Ω

47

Ω

100

Ω

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_e.dsf

Voltage coding

Construction type

Conv. nom. voltage [V]

U1 [V AC]

Voltage measurement scaled by type code parameter selection

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)

500 V

PIN-51

600 V

PIN-51

Y=7 (690V) Y=4 (400V)

Y=5 (500V)

690 V

PIN-51

500 V

PIN-51

D6 / D7

Y=6 (600V) Y=7 (690V) Y=8 (800V)

600 V

PIN-51

690 V

PIN-51

800 V

PIN-51

D7

Y=9

(990V)

1000 V

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 don't care

W10

indicates a removed jumper

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

93

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

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

3ADW000194R0601 DCS800 Hardware Manual f e

*

Technical data

94

Interface Board SDCS-SUB-4

General

On SDCS-PIN-4 and SDCS-PIN-51 the line voltage and DC voltage measurement is done by high ohmic resistors typical 5 M ohm for 500 V units.

Voltages below 100 V line voltage must be adapted by smaller resistance and rescaled measurement channel. Such rescaling provide improved mains synchronization and DC measurement resolution at small voltage.

SDCS-SUB-4 board provides a different scaling of voltage measurement. The default selection is 1.17

Mohm with maximum mains voltage of 120 V. The maximum measurement voltage scale is 200 V.

Adjust voltage scaling parameter according to table below.

75

X109

X105

X103

X101

X107

Mains voltage

30...120 V

A92/T90 (600V) chain R

C

...R

D

W

V

U

C

GND

Example: chain R

C

=R109+R110+R111

D

Setting

97.03

Size appr. 1.17 MOhm 117 V D1...D4

27.4 kOhm 0 V D1...D4

Field current measurement sub4 layout.dsf

Armature firing Power supply

SDCS-SUB-4

D

W

V

U

C

GND

X12

X8

X10

X9

X5

X4

X3

X22

SDCS-PIN-4

X1

X2

+

X24

C1 U1

X21

conducting point

X25

V1

X23

-

+

X7

X31

S1

1

2

3

1-2 = automatic

2-3 = 230 V fix

K301

W1

X20

K400

F400

D1

X96

F300

X99

Pin4_SUB4 layout.dsf

Relay output

DO 8

Input

Aux.

supply

Output field current

Layout of SDCS-SUB-4 and location on SDCS-PIN-4

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

Typical armature circuit thyristor converter diagram with SDCS-PIN-4 and SDCS-SUB-4 board

95

B-4 -SU

2 X11

CS SD

X12

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

96

Galvanic isolation - T90, A92

The Galvanic isolation is an option for converters in the current range 2050...5200 A

DC and rated voltages

≤ 1000 V. For converters with a rated AC 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.

8601A1 42000D3

42001D3

3ADT 745047

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 (800V) Y=9 (990V) Y=1 (1200V) voltage AC] 220…500 270…600 300…690 350…800 450…990 530…1200

Value f. conv. nom. volt at

SET(TINGS) block *

500 600 690 800 990 1200

Resistors W1…W26

all resistors are 0

Ω

Galvanic isolation

Resistors Rx on PIN51

DC-DC transducer A92

Switch position R

G

*

DC-DC transducer A92

Switch position R

G

*

DC-DC transducer A92

Switch position R

G

*

27.4 k

Ω 27.4 k

Ω 27.4 k

Ω 27.4

8680A1

7 (675 V) 6 (810 V) 5 (945 V) 4 (1080 V) 2 (1350 V) 1 (1620 V)

42000D3 x

42001D3

C (0.8 kV) D (1 kV) x x x x x x x B (1.6 kV)

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 SConvScaleVolt (97.03) and the scaling of measurement channel. See 12-pulse manual for DCS 800.

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

97

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

R1 18R

R22 47R

R23

47R

R24

47R

R25 47R

R26

100R

R10

18R

R11 18R

R12

18R

R13

18R

R14

18R

R15

18R

R16

18R

R17 33R

R2 18R

R3

18R

R4

18R

R5 18R

R6

18R

R7 18R

R8

18R

R9

18R

R18 68R

R19

120R

R20

270R

R21 560R

*

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

98

DC-DC transducer A92

Principle circuit diagram of the DC-DC transducer A92

17

Input voltage

20

6 M

Ω appr. 280nF

6 M

Ω appr. 3.9

k

Ω

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

Output voltage:

Auxiliary power:

Clearance in air:

Insulation voltage:

Insulation test voltage:

Ambient temperature range:

675

7

810 945

6 5

1080

4

1215

3

1350

2

1620 V DC

1

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

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

3ADW000194R0601 DCS800 Hardware Manual f e

99

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:

Dimensions in mm max 116

502, 601, 701, 800,1000, 1200 V AC rms

7.3 V AC rms

1200 V

3500 V

- 10 …+ 70 °C

- 10 …+ 70 °C

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.

3 mm

5.2 x 7.7

118....120

130

3ADW000194R0601 DCS800 Hardware Manual f e

Technical data

100

Technical data

3ADW000194R0601 DCS800 Hardware Manual f e

101

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.

S

S = 5 mm

S = 10 mm

48.5

270

225

S

Module D2

DCS800-S01-0180

DCS800-S01-0230

DCS800-S02-0200

DCS800-S02-0260

Module D3

DCS800-S01-0315

DCS800-S01-0405

DCS800-S01-0470

DCS800-S02-0350

DCS800-S02-0450

DCS800-S02-0520

C1 U1

86

V1

4x45=180

W1 D1

H

A B C D E F G H

C

D

600 V types

DCS800-S01-0290

DCS800-S02-0320

Signal terminals

Field and power supply terminals

Power connection

E

F

G

D1toD3_dim_b.dsf

Dimensional drawings

3ADW000194R0601 DCS800 Hardware Manual f e

102

Module D4

DCS80 0-S01-0610

DCS80 0-S01-0740

DCS80 0-S01-0900

DCS80 0-S02-0680

DCS80 0-S02-0820

DCS80 0-S02-1000

600 V types

DCS800-S01-0590

DCS800-S02-0650

Weight appr. 38 kg

S

S = 10 mm for size D4

S

48.5

270

225 fan terminal f. M6

U1 C1 V1

D1

W1

107

52

40

80

80

80 f. M12

Power terminal: Busbar 40x5 mm

Weight appr. 38 kg

345

298 fan terminal

Direction of air flow

Dimensional drawings

Earthing

M12

147.5

195.5

240(PIN-4)

287.5(CON-4)

D4_dim_b.dsf

3ADW000194R0601 DCS800 Hardware Manual f e

103

Module D5

DCS800-S0x-0900

DCS800-S0x-1200

DCS800-S0x-1500

DCS800-S0x-2000

Weight appr. 110 kg

127.5

U1

125

510

450

V1

125

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:

DC 80 x 10

AC 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 D5 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

3ADW000194R0601 DCS800 Hardware Manual f e

104

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

3ADW000194R0601 DCS800 Hardware Manual f e

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

105

3ADW000194R0601 DCS800 Hardware Manual f e

Dimensional drawings

106

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

3ADW000194R0601 DCS800 Hardware Manual f e

Fuses installed inside the converter

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

Model

➀ 12 fuses per bridge (2x per F1x)

D7

D7

D7

D7

D6

D6

D6

D7

D5

D5

D5

D6

D7

D7

D6

D7

D7

D7

D6

D6

D6

D6

D5

D5

D5

D6

D6

D6

D6

D7

D7

D7

800A 660V UR

1250A 660V UR

1600A 660V UR

1500A 660V UR

900A 660V UR

1250A 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

1100A 1250V UR

2500A 1000V UR

3000A 1000V UR

3000A 1000V UR

700A 1250V UR

700A 1250V UR

1000A 1250V UR

1100A 1250V UR

1100A 1250V UR

2500A 1000V UR

3000A 1000V UR

3000A 1000V UR

1800A 1250V UR

1800A 1250V UR

2500A 1250V UR

2500A 1250V UR

Size

9

9

9

9

5

7

5

5

7

7

5

5

5

5

8

8

6

8

6

6

6

6

6

6

6

6

6

6

6

8

8

8

Type

170M 6162

170M 6166

170M 6169

170M 6168

170M 6163

170M 6166

170M 6166

170M 7026

170M 7028

170M 7057

170M 6144

170M 6149

170M 6151

170M 6145

170M 6148

170M 6149

170M 6149

170M 7036

170M 7156

170M 7156

170M 6145

170M 6145

170M 6148

170M 6149

170M 6149

170M 7036

170M 7156

170M 7156

170M 7976

170M 7976

170M 7978

170M 7978

F1x

F1x

F1x

L1 L2 L3

F1x

F1x

F1x

107

3ADW000194R0601 DCS800 Hardware Manual f e

Dimensional drawings

108

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

Card holder for SDCS-IOB-2/3

IOB assembly / mounting kit 3ADT783046

• card holder

• finger protection cover

• screen clamp

(IOB-2x / IOB-3 not included)

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.

with universal Phoenix clamp 1202713 it is possible to mount the card holder on standard rail system in horizontally or vertically direction

Dimensional drawings

3ADW000194R0601 DCS800 Hardware Manual f e

109

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 the armature converter.

The field exciter is prepared to operate as three phase as well as single phase converter. Single phase operation is provided with terminals U and W

I

Fact

Setting of switchable burden resistors by rated field current

X101: U1

X101: V1

X101: W1 measurement channel

5 A

35 A

X100: 5A

X100: 35A

Field

Fex4x1_a.dsf

X100: D1

Layout of the SDCS-FEX-4 board

240

X110

P2

T113

P1

Field X100

T110

T112

T111

D800

S800

U730

U731

S801

Mains

X101

X1: 24 V supply

X1:1 24 V DC

X1:2 0 V DC

V110

R106

X3: DSL Link

X3:1 GND B

X3:2 CAN L

X3:3 CAN H

R107

R108

X7

Fex4_layout_a.dsf

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

110

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

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 SDCS-DSL-4 X51

10ms

* 3-phase or single phase operation

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 and 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 reactor 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. The supply must be connected by independant line reactors located outside of the D5 module, see drawing in chapter The DCS800, section Armature circuit converter DCS800-S D5...D7.

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 adaptation is recommended.

Please see comparison of output voltage ripple between single-phase and three phase-supply.

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

111

Voltage ripple of U

DC

voltage depending on operation modes

1

0,75 single-phase half-controlled

0,5

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

X3:1

2

3

Fex4_DCSLink.dsf

24 V / 200 mA

Supply

24 V

S1100:3

S1100:1

CANL

CANH

GNDB

S1100:2

Termination 200 kOhm

200 mA

DSL communication

Bus termination

S1100 :1 = ON

:1 = OFF

Ground termination

S1100 :2 = ON

:3 = ON

:2,:3 = OFF

Remarks

24 V grounded supply f. SDCS-FEX-

4

Remarks

120 ohm no termination

200 kOhm R-C ground termination

0 Ohm ground termination no termination

Node address is set by: S800 digit 0

S801 digit 10

(node address 00 is not possible!)

Same node address must be selected in the corresponding armature converter.

example: node address=13 ==> S800 = 3 and S801 = 1

S800

S801

Switch_0-9.dsf

Selection of communication speed is set by S1100

S1100:6 S1100:5 S1100:4 Baudrate kBaud *

OFF

OFF

OFF

OFF

ON

ON

ON

ON

OFF

OFF ON

ON OFF

ON

OFF

OFF

ON

ON

OFF

ON

OFF

ON

OFF

ON

20

50

125

250

500

800

888

1000

Selection of armature converter, param

5

6

3

4

7

1

2

[94.02]

0

* see Parameter [94.08], [94.09]

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

112

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

green continues

yellow blinking

yellow continues no 24V supply

No firmware

25 A / 35 A output active, waiting for DCSLINK communication

25 A / 35 A output active, DCSLINK communication OK

5A output active (X100:2), waiting for

DCSLINK communication

5A output active (X100:2), DCSLINK communication OK

green and yellow toggling:

X times yellow Y times green

X=1 Y=1 Alarm phase missed

X=2 Y=1

Y=2

Y=3

Fault DCS link serial communication failed

Fault Synchronization fault

Fault Overcurrent

Y=5

Y=6

Fault Field AC supply voltage < 30V

Fault Field AC supply voltage < 650V

Y=9 Fault maximum temperature heatsink

Y=12 Fault Auxiliary voltage

Y=14 Fault general hardware

Y=15 Fault general software

No RESET

No RESET

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

113

RS232-Port

The RS232 interface is used for download the 'Field exciter firmware package'.

The default settings of this interface are as follows:

X2:

1

Description not connected

Signal level:

Data format:

RS232

UART

Message format: Modbus-Protocol

Transmission method: half-duplex

2

3

4

5

6...9

Baudrate:

Number of Data bits:

Number of Stop bits:

9.600 Baud

8

1

TxD

RxD not connected

SGND Signal ground not connected

Parity-Bit: odd

5

9 6

1

The firmware download is activated by setting S2:1-2 during auxiliary voltage is switched ON. Setting for field exciter mode is S2:3-4 (default).

FEX425 INTERNAL (Fex-425-Int) Hardware configuration (size D5)

K3 L3

U

V

W

F301

F302

U1

V1

F303

W1

SDCS-FEX-4

Supply voltage max. 500 V

1- or 3-phase; for supply voltages 500...600 V an autotransormer is mandatory

D1(-)

5A(+)

35A(+)

Plus code +S164

FEX425 INTERNAL

L1

K3

Supply voltage max. 600 V

L3 max. 500 V;

1- phase

L1

U

V

W

F301

F302

U1

V1

F303

W1

SDCS-FEX-4

HW conf FEX4.dsf

D1(-)

5A(+)

35A(+)

Plus code +S164

FEX425 INTERNAL

HW conf FEX4.dsf

Further information about line reactors see sections Line reactor L3 (ND30) and Line reactors type

ND401...413 (ND402) in this chapter.

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

114

Dimensions

6 kg

X1

2 1

X2

X3

3 2 1

DCF803-0035

35A 5A D1 U1 V1 W1 earthing M6

DCF803-0035.dsf

173

100

X1

2 1

X2

X3

S1100

1 3 2 1

3

36.5

67 for mounting on mounting plate provide hole with diameter of min 5 mm for thermal sensor

90

16A 5A D1 U1 V1 W1

DCF803-0016.dsf

Accessories

DCF803-0016

3ADW000194R0601 DCS800 Hardware Manual f e

115

DCF505 / DCF506 Overvoltage Protection

The three-phase converter can be used as motor field supply. This operation needs a separate active

Overvoltage Protection unit DCF 505 or DCF 506 to protect the power part against inadmissibly high voltages.

The protection unit activates a free-wheeling circuit between the F+ and F- connectors if an overvoltage occurs. The DCF 505/506 consists of a trigger unit (SDCS-FEP-x) and a free-wheeling thyristor (two in anti-parallel at DCF 506).

The DCF 506 consist of a relay output to indicate a free-wheeling condition to the field supply converter.

When the free-wheeling function is triggered, it will last until the DC current is less than appr. 0.5 A.

During this time the relay contacts are closed.

The overvoltage protection unit DCF 505 is suitable for 2-Q converters DCS800-S01 with simple non-motoric inductive load.

For motor field supply via DCS800-S01 (2-Q) or

DCS800-S02 (4-Q) the overvoltage protection unit DCF

506 is always required.

3-phase Field supply

Converter

Overvoltage protection

DCF 505

C1(+) X11

DCS800-S

D1(-) X12

DCF505bl_e.dsf

Simple load with DCS800-S01 and 2-Q Overvoltage Protection DCF 505

3-phase Field supply

Converter

C1(+)

DCS800-S

X6:2 9

D1(-)

M

X11

Overvoltage protection

DCF 506

X12

X4:1 2

Motor field supply with DCS800-S02 and 4-Q Overvoltage Protection DCF 506

Assignment Field supply converter to Overvoltage protection unit

Field supply converter for motor fields *

2-Q, 500 V

DCS800-S01-0020-05

DCS800-S01-0045-05

DCS800-S01-0065-05

DCS800-S01-0090-05

DCS800-S01-0180-05

DCS800-S01-0315-05

DCS800-S01-0405-05

4-Q, 500V

DCS800-S02-0025-05

DCS800-S02-0050-05

DCS800-S02-0075-05

DCS800-S02-0100-05

DCS800-S02-0200-05

DCS800-S02-0350-05

DCS800-S02-0450-05

Inductive load supply for other applications

4-Q, 500V

DCS800-S02-1200-05

DCS800-S02-1500-05

4-Q, 690V

DCS800-S02-0900-07

DCS800-S02-1500-07

Overvoltage Protection

DCF506-0140-51

DCF506-0520-51

DCF506-0140-51

DCF506-0520-51

Overvoltage Protection

DCF506-1200-51

DCF506-1500-71

* These converter types are released for field supply operation. A derating of 10% is recommended.

See also dimensioning of installation (fuses, reactors, contactors).

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

116

A1

Diagramm

SDCS-FEP-1 (500 V)

SDCS-FEP-2 (690 V)

X2:1

X2:2

X1:3 red grey

X1:1

X1:2

X2:3 red grey

X3:1

X3:2

X11

1

R2

2

V1

A

G2 K2

K

K1 G1

AK

1

R1

2

1

R3

2

X12

1

R4

2

Accessories

parts not built-in at 2-Q unit, R3 jumpered

DCF505di_d.dsf

X4:1

X4:2

Overvoltage Protection DCF 505 / DCF 506

X1 X3

Output X4:1-2

Potential isolated by relay (NO contact)

Contacts no protected

Contact rating: AC:

≤ 60 V~/ ≤ 50 mA~

DC:

≤ 60V-/ ≤ 50 mA- line potential !

X2 X4

Fep1_2.dsf

Layout of SDCS-FEP-1/FEP-2

There are two trigger units in use:

- SDCS-FEP-1 for systems, used at line voltages up to 500 V; this board is equipped with a 1400 V trigger diode.

- SDCS-FEP-2 for systems, used at line voltages up to 690 V; this board is equipped with a 1800 V trigger diode.

3ADW000194R0601 DCS800 Hardware Manual f e

117

Dimensions

Overvoltage Protection

DCF 505-0140/0520-51

DCF 505-1200-51

DCF 506-0140/0520-51

16 75 33.5

Dimensions in mm

Weight appr. 8 kg

342

7

42 145

355

145

2

1

20

135

X4

1

X11 (F+)

M8

X12 (F-)

MB_520_a.dsf

Overvoltage Protection

DCF 506-1200-51

DCF 506-1500-51

DCF 506-1500-71

Dimensions in mm

Weight appr. 20 kg

2

X4

1

X2

SDCS-FEP-1 (500 V)

SDCS-FEP-2 (690 V)

X3 X1

X11

X12

32 40 M8 f. M6

3ADW000194R0601 DCS800 Hardware Manual f e

MB_1500_a.dsf

Accessories

118

Fuses and fuse holders IEC

Type

170M 1558

170M 1559

170M 1561

170M 1564

170M 1565

170M 1566

170M 1568

170M 3815

170M 3816

170M 3817

170M 3819

170M 5810

170M 6811

170M 6813

170M 6163

170M 6166

Resistance [m

Ω]

30

21

15

6

4

3

1.8

0.87

0.59

0.47

0.37

0.30

0.22

0.15

0.15

0.09

Dimensions [mm] Size 0...4

Fuse F1

10A 660V UR

20A 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

3

4

2

3

4

1

1

1

1

Size

0

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

2

3

Size a

0

1 b

78,5 50

135 69

150 69

150 68

b

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 fuse2_a.dsf

Main dimensions of fuse holders

Fuse holder HxWxD [mm] Protection

OFAX 00 S3L 148x112x111 IP20

OFAX 1 S3 250x174x123 IP20

OFAX 2 S3

OFAX 3 S3

250x214x133 IP20

265x246x160 IP20

OFAX ...

H

OFAX 2 S3

W D

170H 3006 (IP00)

110

M10

M8

A

A

205

180

Ø

9

M8

A-A

60

85

M10

170H3006_a.dsf

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

119

Line reactors IEC

Line reactors type ND 01...ND 17

Line reactors (u k

= 1%) for use in industrial environment (minimum requirements), low inductive voltage drop, deep commutation notches.

Line reactors 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 reactor terminals as cable or busbar support!

Type reactor

L

[

μH]

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

ND 17

37.5

25.0

33.8

18.8

18.2

9.9

10.9

6.1

4.0

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

1800 2700

27

68

68

82

122

153

275

294

Frequency 50 / 60 Hz

Line reactors type ND 01...ND 06

500

500

600

500

690

500

690

500

800

500

500

600

500

600

500

500

600

16.0

22.2

22.6

36.0

46.8

46.6

84.0

81.2

86.0

2.0

3.0

3.8

5.8

6.4

7.6

12.6

12.8

50

80

80

95

170

100

190

210

250

5

7

45

45

5

7

9

10

140

185

185

290

160

300

680

650

700

16

22

20

33

30

41

90

130

DCS...-0025

DCS...-0050

DCS...-0050

DCS...-0075

DCS...-0110

DCS...-0140

DCS...-0250

DCS...-0270

DCS...-0350

DCS...-0520

DCS...-0450

DCS...-0680

DCS...-0820

DCS...-1200

DCS...-1500

DCS...-2000

DCS...-2500

3

A

B

C

X

Y

Z

X, Y, Z

A, B, C

A

X

B

Y

C

Z

A, B, C

60

0

100

0

X, Y, Z a a1 d b

ND1_to_6_a.dsf

Type

ND 01

ND 02

ND 03

ND 04

ND 05

ND 06 a1 a b c d e

120 100

120 100

148 125

148 125

148 125

178 150

130 48 65 116

130 58 65 116

157 63 80 143

157 78 80 143

157 78 80 143

180 72 90 170 f g

4 8

4 8 mm²

6

10

5 10 10

5 10 16

5 10 25

5 10 35

f

3ADW000194R0601 DCS800 Hardware Manual f e

Accessories

120

Line reactors 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 AST 4 78 2 23 D5

3AFE 10014603

0 .0 1 88 mH

4 90 A

I ma x 7 34 A

A

7

A

285

327

408

458

F ±0.3

B ±1

B C

230 86

250 99

250 99

250 112

C1 E

100 250

100 292

100 374

113 424

F G H

176 65 80

224 63 100

224 63 100

224 63 100

I

9x18

9x18

11x18

13x18

A-A

ND7_to_12_c.dsf

K

385

423

504

554

L

232

280

280

280

Line reactors type ND 13, 14 all busbars 40x10

100 100

140 ±2

45 45

Line reactors type ND 15, 16 all busbars 60x10

140 30

151 ±2

90

45

busbar

20x4

30x5

60x6

40x6

18

290 ±1

A

150 ±2

123 ±2

ø13

40

A

15

ND13_14_c.dsf

30

390 ±1

140

147

ø13

15

A

147

181 ±2

15

48

A

ND15_16_c.dsf

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

Line reactors type ND 17

ND17.dsf

20

80

40 20

ø14

121

3ADW000194R0601 DCS800 Hardware Manual f e

Accessories

122

Line reactors type ND 401...ND 413

Line reactors (u k

= 4%) for use in light industrial/residential environment, high inductive voltage drop, reduced commutation notches.

These reactors 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. 2 = 72% of nominal current

For easier reading the maximum average DC load current is listed instead of the percentage in the next table.

Line reactors 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 reactor

L I rms

I peak

[

μH]

Line AC [A] [A]

ND 401 1000 18.5

27

ND 402 600 37 68

ND 403

ND 404

ND 405

ND 406

ND 407

ND 408

ND 409

ND 410

ND 411

ND 412

ND 413

450

350

250

160

120

90

70

60

50

40

35

55

74

104

148

192

252

332

406

502

605

740

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

56

62

75

23

29

33

51

11

13

19

22

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 Load

DC curr. 1 DC curr.2

(f. U supply

=400V) (f. U

22.6

supply

=500V)

18

45 36

67

90

127

179

234

315

405

495

612

738

900

54

72

101

143

187

252

324

396

490

590

720

Frequency 50 / 60 Hz

Line reactors type ND 401...ND 402

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

170

A X B Y C Z

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

3ADW000194R0601 DCS800 Hardware Manual f e

123

Line reactors 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 reactors 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

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

124

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

30

60

60

15

20

20

36

60

P

V

[W]

65

100

120

180

250

80

125

150

230

320

[A]

10

16

20

50

63

10

16

25

50

63

690 V transformer input cannot be used for the field converters SDCS-FEX-4 (isolation only 600 V max.)

A

F 3 F 3

T 3 T 3

e

G

C D

B

Line reactor L3

for single phase for DCF503-0035 as well as FEX-425-Int

2 1 3 4

Input voltage: 500 V

Frequency: 50 / 60 Hz

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

1

3

2

4

Type line reactor data L3 Weight Pow er

L

[

μH]

I rms

I peak

[A] [A] [kg]

ND30 2x >500 16 16 1.1

loss

[W] [mm²]

8 2

4.5 Ø

55 max 80

37

52

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

125

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 D5 converters are used in a

12-pulse configuration.

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

Type Power Weight Fuse F2 I sec

[VA] [kg] [A] [A]

T2 1400 15 16

Power loss

[W]

6 (0...230 V) 100

12 (0...115 V)

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

3ADW000194R0601 DCS800 Hardware Manual f e

126

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 Ident. no.

plug plug

HCS silica (double) without plastic jacket plug

HCS silica (double) with plastic jacket plug

0.5...20 m

0.5...20 m

30...50 m

50...200 m

3ADT 693324

3ADT 693318

3ADT 693355

3ADT 693356

Fig.

1

2

3

4

Figure 1

blue

L black

Figure 2

blue

L black blue

Figure 3

black orange

Figure 4

black blue red

L

L

∅ 5 mm

∅ 8 mm blue red orange black

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

127

Other cables

DCSLink cable

dismantling for shield grounding

1

2

3

2

1

30 mm

2

1

1

2

3 red black white blue black screen

10 mm

20 mm

Heat shrink tubing cable screen wire netting tinfoil cable sheath two cable pairs not twisted

40 mm

10 mm red black

1

2

1

2 white blue black screen

3

2

1

20 mm

Heat shrink tubing

140 mm

DCS link cable.dsf

0.54 / 2 / 4 / 10 / 20 m

Unscreened cable for SDCS-CON-4 - SDCS-IOB-2/IOB-3 connection

3

2

1

5

4

3

Pull tab

(for cable marking)

Screened cable for SDCS-CON-4 - SDCS-IOB-2/IOB-3 connection

1.4 / 3.2 / 4 m screen laid open

IOB2-3 unscreened flat cab.dsf

Pull tab

(for cable marking)

SDCS-IOB-x

Pull tab

(for cable marking)

SDCS-CON-x

IOB2-3 screened flat cab.dsf

Accessories

3ADW000194R0601 DCS800 Hardware Manual f e

ABB Automation Products

Wallstadter Straße 59

68526 Ladenburg • GERMANY

Telefon: +49(0)6203-71-0

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

*194R0601A8410000*

*194R0601A8410000*

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