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DCS800 Hardware Manual

1. SDCS CON 4 A Firmware e N a 90 270 V no X ATACH2 X31 P ky Ele i ar 30 90 V RB gt scm 2 lm E 8 7 ATACH 8 30 V 2 pi 3 s S TO E d 4 d 7 ATACH1 st Oo 5 be S234 4 555 HA Al 6 fB as te 3 3 ms o 10V 35 4 55 gt Ale 8 3 3 ms 9 prim 10 5 ms X4 1 fi gt Al4 2 5 ms 3 GND 4 10V 5 10V 6 GND AOx 1004 475 H 7 TERT L AO1 5ms 8 A lt AO 5ms 9 4 a 10 GND is l act hA X5 1 m y i gt 2 foi tone ipp ChA J 3 TO ChB 4 ET ap e ChB J 5 A Tor ChZ 5 Tot tone 7 pp ChZ J m 7 fa GND 8 Sense 0 V 9 Sense 5 V a PIN 4 9m c POW 4 15 Power 111 15V 24V EA Met ap at X6 H 4kz5 47nF F Z15 I DI1 I 2 Ht 10ms A gt Da 3 Ht 10ms A gt DIS ko 4 om A DIA 5 Hrt 10ms A gt DIS L 6 Homs A DI6 7 H1 33ms A gt DI7 8 Ht 3 3ms A gt DB 9 24 V lt 125 mA 10 x X7 1 Relay driver lt DO1 2 Relay driver lt DO2 3 Relay driver lt DOS 4 Relay driver lt DO4 5 Relay driver lt DO5 6 Relay driver lt DO6 7 Relay driver lt DO7 8 IGND Con4 I O b ds
2. Line reactors type ND 07 ND 12 H 2 E AAN O CH io yi Q 9 V oi o S es E so li re fa escitas a Y Ei A A Sle 5 o 1 Els o s aq F HE H ul Sz o o 98 cic ein e pe a n e EJS Fi el A WEM E e t Ja n ND7 to 12 c dsf F 30 3 B 1 Type A B C C1 E F G H K L busbar 5 5 7 5 x 5 x ND 09 327 250 99 100 292 224 63 100 9x18 423 280 30x5 5 7 X 5 X ND 12 458 250 112 113 424 224 63 100 13x18 554 280 40x6 Line reactors type ND 15 16 all busbars 60x10 140 2 15122 90 45 45 45 1 E38 bi 3 e ne A EN EL 32 4 ge a 123 2 ae 3 El que HA Blow i 3 z5 a 313 a Sag 15 gi e Dl ELE JTF Bat dok lap Vu a a Lol EIE MC 15 2 P B wis A ji 15022 A Noi masas Lal 30 140 1 147 Last A 18122 A ND15 16 c dsf Le 390 1 3ADWOOO194R0601 DCS800 Hardware Manual fe 121 Line reactors type ND 17 40 20 gt O ioe Al 80 x 15 1U1 1V1 1W1 8 g pri als gt Al 80 x 15 c1U2 1V2 1W2 gt 1U1 1v1 1W1 tin plated ND17 dsf 1U2 1v2 1W2 Accessories
3. i 8 X22 X122 X23 X24 X25 vi4 vii V16 V13 V12 V15 i G G G G G G i e gt l l l l i e C 1 Cr je Gt 1 Cr jt Lr i Oo a0 lie gt o 0 5 i No r A B C D E F Foe B Xxx 2 i x HO x x zu a BD E 2 ENE Spee PIN ul K SDCS PIN 46 PIN 48 S o eg 9 me m e 2q c34 b dsf v e L ee N st e ME A xx x x x x 4 Quadrant application no parallel thyristors Construction type D5 D6 D7 SDCS PIN 46 PIN 48 V25 V12 v23 vi6 V21 V14 an an AD ar zx Pl i 3 X22 X122 X23 X24 X25 v24 v11 V26 V13 V22 V15 ER 8 os E a ej e ej ep a 5 C Ci Ci Cr Cr Cr a F j 9 gt OO 5 9 i NO r r A B C D E F F a x xX XL 9 o o o i n F Soca EI E x SDCS PIN 46 PIN 48 Se e co a 4q c3a b dsf Xx B kk Pulse transformer board SDCS PIN 46 PIN 48 Layout of the SDCS PIN 46 PIN 48 pulse transformer board 270 gt Ia UG Gate The board consists of six C C Cathode pulse transformers with amplifiers e eo SDCS PIN 4x Y Pin4x dsf Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e Measuring board SDCS PIN 51 91 This board is always used together with SDCS PIN 4x board On this The vol
4. PTC 4 see diagram Conductive Ws line potential power part supports R123 OS a SE X23n2 X24 2 4 X25 2 07 ws w ws we w m X22 X122 tex uem le e Pu iet c dee S3 3 4 TwoPTC RI 2 R21 a 11 12 OnePTC AI Vi wit wo w w w6 LO I ao CE GAL on Wi0 wzo W71 W72 Ree o a up ssp Lo EE pi LT o W1 wie wis wi4 W1i3 wi i ral W80 WS81 w82 PI Rog SE c e AE ule ME X18S X313S Ci wai w20 wig wis wi7 1 I Cat GL GG GG z s2 si I e e 2 o el z ka en mg 2 en 2 Isolating D Ne A5 d WA MEE zl 24 xU gU US L oi d SDCS PIN 51 e 305 Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 92 Settings of the SDCS PIN 51 board if a DCS converter is equipped with it by ABB Current coding RS gt Re 189 Rye R8 189 Ino 189 R10 1892 RI pue R12 182 R13 1892 Ria S gt R15 189 RIG 1892 R18 682 IRi9 1200 0109109 0 TOR Ko 9ooi o ooo Rated current scaling elo lolo ojojoj o i ji Ye Qo Oo oO Q qd qd oo oo ojo ojo J Zero current detection code_tab_PIN1_PIN20_PIN51_e dsf Construction type DS D6 D7 D7 D7 Conv nom voltage V
5. UT T M e O M E lt X510 e 5V or 24V mi YE a 5V E 2511 TKO 4k7 E 3 5 3 T 10k o TR 2 Hi s4 a i 100 nF A o n Lo go 1k0 4k7 g TX5 2 4 5V ul ov X57 SDCS CON 4 ENCODER INPUT A lt S X5 10 e 32 amp 5V or 24V E r e al 5V E LOX93 1KO ak7 ki cox S 3 8 10k zi o I R 2 Hi mi ak S4 on AA 100nF e N f Lt 1k0 4k7 zZ X52 E e 5 V X5 7 SDCS CON 4 ENCODER INPUT A 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 single ended open collector lt X57 5V or 12V or 24V E e a LI X5 1 z tera F S10 E 1k0 AKT O l 3 LI TA t pE ui 2 5 424N li a Lo ot 1k0 4k7 ii x52 OV GND i P X510 SDCS IOB 3 ENCODER INPUT A push pull X57 5V or 12V or 24V r a m l X5 1 0 wig 1009F S10 A 1k0 4k7 Z v 3 a HH He va 10k R 2 5 d a o N L To do 4k7 5 V ul L 52 0V GND S X5 10 SDCS IOB 3 ENCODER INPUT A terminal X5 2 X5 4 X5 6 must be connected via a resistor R to GND differential 4 5V X5 7 a LI X5 1 Z n li 4k7
6. f eo f t i i 0 i i e D i i ke en li a H 5 i E a d kaj 5 D 5 i amp 2 PE S4 E ENE 38 81 8 z N 5 8 E 82 8 E S E 2i o 3 5 i 87 E i d y 3 o i a 5 0 i 8 o o o 84 gt 8i a g c a SF 2 2 a Bi Ez a E E 8 g m 3 i 8 S ae o E zi t zd FE a i 34 x a i ei o co i 8d v l mo SS ae Sa i 57 TE l i ei 3 i 8d i 2d a a 1 i oF H xd Sh at 2 ga EJ 1 sd a l S T gre Bd T i x E z i ro ay Z l 8 i e en E riu Tu e 385 as i y ec aze E 818 i 5i e x xX 3 LT 458 on 8 si E 38 g zd E 27 S i z 5 i E Bi lt 4 X gt i a i x q AS a i Fi SE i l E i i 5 SE i i idi g jet as hg Sz id 3 20 E 5 32 m El E Ez H H ES i li o 88 Eel i 2 H 6 i Sd 3 i 1 Ni i ai E gt 2i laj v b E ie 3 El h Hi St H mm 10 aa 89 w 0 MM MMMMM MMMM L 4 6 4 Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 41 external field exciter lon using 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 Wiring the drive according to this diagram gives the most flexibility and offers the independent net DCF803 0035 can be supplied with 3 phase aux supply Converters D5 D7 drive configurat
7. Fan D2E 160 GR31M GR31M GR35C 380 500 V 525 690 V 400 690 V Rated voltage V 230 1 400 450A 400 500 AA 500 690 A 500 690 A 400 460 A 450 500 A 500 A 600 690 A Tolerance 10 10 10 5 10 10 Frequency Hz 50 60 50 60 50 60 50 60 Power consumption W 653 860 800 A 1340 A 800 A 1200 A 29004 3600 A 700 A 2200 A 3300 A Current consumpt A 2 50 3 4 1 45 A 2 0A 0 9 A 12 A 6 5 A 49A 0 91 A 2 3A 3 0 A Blocking current A 3 75 45 at450VA at500VA at690 VA at500 V A Jat 400 V Alat 400 VA 8 5 8 5 4 4 8 5 25 30 Air flow m3 h freely blowing Air flow m3 h 800 750 1500 1600 1500 1600 4200 4250 at working point 2 5 A 3 2 A 1 26 A 1 6 A O 7 A 1 65 A 3 6 A 41A 450V A 500V A 690V A 500V A 400V A 400V A Max ambient temperature C 55 Useful lifetime of grease appr 30000 h 40 Protection Temperatur detector Uy 230 V ly 2 5 A 460 V lt Supply lt 600 V autotransformer strongly recommended energy saving 20000 kWh a Fan connection for DCS800 115 Vac Je E si Configuration 2 D3 either 230 Vac or 115 Vac Configuration 3 Configuration 4 Configuration 5 D4 D5 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
8. Jojoeo NE 3sp ey T sue eso sl SS pu 7 mum 91S0 epoo snjd pajoajas jou 10 jejeurejed Aq pejqesip E bi Z IS l ZIX ux L Z 01X E einpou i 404 900 SOA vod 00 ZOA 100 Ave ela ZIG 910 SIA Id ela zia LIG lovi zov IOV Jeyoxe pray preoq uo JeyeAuo i f 008S9q 7 RE p NOO p1eoq jouuog uonoejoud i f ebeyonano i i lt 909490 J i ne p 2 9 amp ino a i X8 WOD peog on em uongolunwwon I L JeueAuoo eunjeuue I Woy JOu09 peuinbei si uonoejoud eDejjoneAo jeuoppe j 4euu0JsueJ efeyon uDiu wos perddns 109 SIM A LI 89 4o18 uo9 pue y yum peddinbe jou si uongee o l JOLOAUOD einjeuue WOU pejjo4uoo eq ose ueo LA y i IS dois gx Aerop eun e116 u0 O i 4 Yana Wouy jueuno pay PAQWA gt l l 0 puooes euo ue eJoui 0 dn aye ued 1 LSVOO 0 pajoajas 1 eq pinous epou dO19 3 GL indui se 4919Au00 eJnjeuue I jo puewwoo 1SvOO esn T l Even GLy je10xe pay 0 puewwoo T 1 dOLS 3 pouuoo 1uop pounba si a e pea MN dwe dO1S 3 L uofejeo dois yi pe SDIN z z z ASLL 84 G4 ld nU ni ni la A069 m eL uonduosepees 9 A H an Sjo o abeyon 3ADWOOO194R0601 DCS800 Hardware Manual fe Planning the electrical installation 43 START STOP a
9. Technical data 3ADWOOO194R0601 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 Unit type Ipci lbc ui lbc m Ipc iv Size T field curr continu 100 150 Yo 100 6 150 Yo 100 200 Yo 2 Q converters ous 15 min 60s 15 min 120s 15 min 10s 400 V 525 V A A A A DCS800 S01 0020 04 05 20 18 27 18 27 18 36 DCS800 S01 0045 04 05 45 40 60 37 56 38 76 DCS800 S01 0065 04 05 65 54 81 52 78 55 110 D1 6A DCS800 S01 0090 04 05 90 78 117 72 108 66 132 DCS800 S01 0125 04 05 125 104 156 100 150 94 188 DCS800 S01 0180 04 05 180 148 222 144 216 124 248 D2 15A DCS800 S01 0230 04 05 230 200 300 188 282 178 356 DCS800 S01 0315 04 05 315 264 396 250 375 230 460 DCS800 S01 0405 04 05 405 320 480 310 465 308 616 D3 20A DCS800 S01 0470 04 05 470 359 539 347 521 321 642 DCS800 S01 0610 04 05 610 490 735 482 723 454 908 DCS800 S01 0740 04 05 740 596 894 578 867 538 1076 D4 25A DCS800 S01 0900 04 05 900 700 1050 670 1005 620 1240 DCS800 S01 1200 04 05 1200 888 1
10. DCF803 DCF804 ep eBed je Buiweipees uoneuuojur Jequnj Jsp oe T sue gsoa asn gt i i ainpow i ZA 908 youms enssaig be e E vossod i a toa Av2 810 IQ 910 sia vid ela Zid iid LOVI ZOV LOW A0l A0L 08Sod einpou qun 19joxe pjet4 JeuoAuo M ue i i K ddns samod b NOD paeoq jouuog X8 NOD peog sa UuonBOoIUNWWOJ I L l l s y E E By 27 37 z 9 v 0c z gt de A rh zl a 1 UM dOLs UU EN 9 a AT A l BIN god sp gi eri i La es X vi f IAN ta a D vex kl 1HVlS NO AOE zak 09 T Rose ene cs cotta cse o Dn ory E AS9Z mer dois 4 330 NOSE AS9E vi AO EL ASI lle SD NC el S gy ADS m 3 z A r eL 83 793 L L ni L la A082 bi 12 H MON yondyosepees 9 a n an siena abeyon Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e ing ep ebed ye Buiweip ees uomeuuojur jeun ffers the highest degree of monitor iagram o is d ing to th ive accord the dr functions done by the drive iring Converters D1 D3 3 phase field exciter configuration 42
11. Y 4 400V Y 6 600V Y 7 690V v 4 400V Y 6 600V Y 7 690v Y 8 800v Y 9 Y 1 o U1 V AC Y 5 500V Y 5 500V 990v gt 1000v Voltage measurement scaled by type code 500V 600 V 690 V 500V 600 V 690 V 800 V 1000 V parameter selection PIN 51 PIN 51 PIN 51 PIN 51 PIN 51 see ox apen o e oo isolation 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 dontear S3 40 Os wo To 2fa ol Board used as a spare part indicates a removed jumper e default all jumpers Wxx Rxx are in o o condition exo ensure the correct converter type related settings Technical data 3ADWOOO194R0601 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 JSP LW TS IHd 8irNid SOas MRR 909 999 9 89 89 vo 8i Nid S0oas I V v OM OVS 38 TE I de 9 yaza l y yaza z Zaza T TdZH pas odo 1900 Xp go Yao vo PA ces AA pey AS ee AR
12. a1 oz zz v2 QNO te ASE 189 ASIE a Aver iv A Spt PZ Aver i uex ioe laN9 Toe nas 1 Ob LA 8r sjeuueyo asind uny E zv eus i1 edza 6 Sdza PZ vaza is dza zaza L taza zou t ans soas tou 94 94 qa Q4 on Ws synouto Buunseeui eDeyoA OG OV 14 S0d0NH S Q0OOMH 4 OLNV HOOSb VOOcL VLOS ZS Typical armature circuit thyristor converter diagram with SDCS PIN 4 and SDCS SUB 4 board ISL dd L 8 QNO Seouejsise Buunseeui jueuno eynpeuuv tore od li preoq jouuog eoepeojul non einjeuuv Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 96 Galvanic isolation T90 A92 The Galvanic isolation is an option for converters in the current range 2050 5200 A DC and rated voltages lt 1000 V For converters with a rated AC voltage of 1190 V and 12 pulse serial gt 2x 500 V the galvanic isolation is
13. half duplex Baudrate DriveWindow Light variable CodeSys download 38 4 kBaud FDT firmware download self adapting Number of Data bits 8 Number of Stop bits 1 Parity Bit odd X34 Description 1 not connected 2 TxD 3 RxD 4 not connected 5 SGND Signal ground 6 9 not connected 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 see chapter SDCS COM 8 board X20 Slot 4 is used for Memory Card see description IEC61131 programming Prepared function of Hardware extension RDIO Digital I O Extension DCS800 61131 Programming target Slot 1 Slot 2 Slot 3 Slot 4 X9 X10 X11 X20 RDIO RAIO x x x R Fieldbus adapter x SDCS COM 8 x Second fieldbus RMBA x x Memory Card x 3ADW000194R0601 DCS800 Hardware Manual f e Technical data 74 Digital and analogue I O connection of the SDCS CON 4
14. 1620 VDC Switch position 7 6 5 4 3 2 1 Output voltage 9 84 V 5 mA Auxiliary power 230 V 15 50 60 Hz 3 W eeecccccco Clearance in air Auxiliary power to Output gt 13 mm Insulation voltage Insulation test voltage Ambient temperature range Weight Input Output to Auxiliary power gt 14 mm 2000 V 5000 V 10 70 C appr 0 4 kg The voltage gain and frequency response is especially designed for DCS800 converters Dimensions in mm E t Location of terminals Buttom view 76 0 70 0 7 0 Snap on mounting on DIN 46277 rail Technical data lt 50 0 3 5 0 60 0 3ADWOOO194R0601 DCS800 Hardware Manual fe Gain selector 7 Re eooooooee Transformer T90 99 Principle diagram of the transformer T90 1U 2N 2U6 2U5 2U4 2U3 2U2 2U1 Oo ko es 1V 2V6 2V5 2V4 2V3 2V2 2V1 o A A 1W 2W6 2W5 2W4 2W3 2W2 2W1 o E 1N pes Data Selectable transfer ratios Uprim 502 601 701 800 1000 1200 V AC rms Output voltage 7 3 V AC rms Insulation voltage 1200 V Isolation test voltage 3500 V Ambient temperature range 10 70 C Weight 10
15. 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 gt 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 4 SDCS CON 4 E ioi Pu 10 1112 o4y Relay output S AC supply gt e 12V 15V S4 YA 24V 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 Jumper coding X3 Encoder supply selection X4 X3 X4 X5 trien Xs sve EE m ev Rogo gt isvl B HB 15V ae pi no Y o a a re a D X37 and X137 are connected in parallel X14 is used for SDCS PAR 1 hard parallel converters av EEE default value Pow4a dsf Auxiliary
16. 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 49 Cross sectional areas Tightening torques Recommended cross sectional area to DINVDE 0276 1000 and DINVDE 0100 540 PE trefoil arrangement up to 50 C ambient temperature The necessary wire torque at 60 C wire temperature is the same as recommended in the following tables Armature Converter type C1 D1 AM1 KM1 UT V1 W1 AK1 AK3 AK5 PE 1 2 1 2 IDC Iv km Wi A mme mm2 A mm mm mm Nm IDCS800 SOx 0025 xx 25 1x6 41 1x 4 1x4 1xM6 6 DCS800 S0x 0050 xx 50 1x 10 41 1x 6 1x 6 1x M6 6 DCS800 S0x 0075 xx 75 1x 25 61 1x 25 1x 16 1x M6 6 DCS800 S0x 0100 xx 100 1x 25 82 1x 25 1x 16 1x M6 6 DCS800 S0x 0140 xx 140 1x 35 114 1x 35 1x 16 1x M6 6 DCS800 SOx 0200 xx 200 2x 35 1x 95 163 2x 25 1x 985 1x25 1xM10 25 DCSs800
17. encoder supply 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 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 e Thyristor firing control is reset and disabled Digital outputs are forced low Programmable analogue outputs are reset to zero OV 3ADWOOO194R0601 DCS800 Hardware Manual f e Technical data 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 internal FlashPROM error check sum external FlashPROM error check sum LI RAM error RAM error no Firmware watchdog error
18. 3876 6x 300 3x300 4xM12 50 DCS800 S0x 5200 xx 5200 8x 300 4202 6x 300 3x300 4xM12 50 Reduced ambient temperature 40 C Option for more flexible cable connection available You will find instructions on how to calculate the PE conductor s cross sectional area in VDE 0100 or in equivalent national standards We would remind you that power converters may have a current limiting effect Excitation Size D1 D2 D3 D4 D5 DCF803 0035 DC output current 6A 15A 20A 25A 25A 35 A max cross sectional area 6 mm AWG 10 6 mm AWG 10 6 mm AWG 10 6 mm AWG 10 6 mm AWG 10 6 mm AWG 10 min cross sectional area 1 mm AWG 16 2 5 mm AWG 13 4 mm AWG 11 6 mm AWG 10 6 mm AWG 10 6 mm AWG 10 Tightening torque 1 5 1 7 Nm Planning the electrical installation 3ADWOOO194R0601 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
19. 70 C Weight 2 1 kg Dimensions in mm Remark max 116 The terminals on the primary side of the a transformer are in special design lug termi nals Handling hints First turn the screw counter clockwise to the end stop then swing out the e shrowding cover Put in the cable lug swing 3 in the shrowding cover and fasten the con A nection by turning the screw clockwise pe K i Eg 3 mm 52x77 QUE Lu 118 120 x 130 i Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 100 Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e Dimensional drawings 101 Dimensional drawings of the DCS800 are shown below The dimensions are given in milllimeters 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 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 600 V types DCS800 S01 0290 DCS800 S02 0320 Z S 10 mm WO 8 rae XIIe gS HE ME Uteg V Wi Di pj 8 1 HO V 4
20. AI2 X3 7 8 Ry 200 kOhm 1 7 Range 10V 0V 10V 2 B Al2 X3 7 8 Ry 250 Ohm 1 7 Range ly 20mA 20mA F BS Jumper parking position 5 6 2 He Pull up resistor 4 74 kOhm activated at X3 7 1 7 for PTC temperature sensor S43 de Encoder mode differential RC load with 2 EHE R 121 Ohm and C 100 nF activated SHH 12 Encoder mode single ended or if IOB 3 5 n connected Pull up resistors 10 kOhm activated 3 42 Encoder supply 5 V sense X5 8 9 are active 2 A or SDCS POW 4 see section 1 10 Power supply board SDCS POW 4 3 Ai Encoder supply 24 V uncontrolled 2 10 Supplied from CON 4 Park position 3 1 When connecting an encoder to IOB 3 i 10 set jumper S4 on CON 4 board to park position S5 253 1 EEG Step 1 Preparation for Firmware download operation Step 2 Text download normal program execution default value 250 Ohm x 20 mA 5 V 100 Memory circuit 71 230 X17 E XD i Jumpers shown in default position E XI i X34 SE X8 SUAE mE Rs a ps 1 1 1 A X3 X4 xs xe x 12345678910123456789101234867891012345678910123 45678 SDCS PIN 4 VA SDCS CON 4 SDCS POW 4 SDCS CON 4 Jf 10 1112 24V 5V 10 1112 24V 5V gt T e 12V E ph 15V 24V Y X5 10 X5 10
21. ND 403 450 55 82 400 11 42 90 67 54 ND404 350 74 111 400 13 78 105 90 72 ND 405 250 104 156 400 19 91 105 127 101 ND 406 160 148 220 400 22 104 130 179 143 ND 407 120 192 288 400 23 117 130 234 187 ND 408 90 252 387 400 29 137 160 315 252 ND 409 70 332 498 400 33 170 215 405 324 ND 410 60 406 609 400 51 260 225 495 396 ND 411 50 502 753 400 56 260 300 612 490 5 5 5 7 5 ND 413 35 740 1105 400 75 312 410 900 720 Frequency 50 60 Hz Line reactors type ND 401 ND 402 Type A BID EF Ban ND 401 i60 i90 75 80 51 175 7 9 5 1115 75 7 Terminals WAGO Type 202 la 170 gt UL File E45172 AX BY CZ CN A EA EX FAX oH O Q or tin coated t O BE A E di x Y z B A 4 A B C amp PE Az T lt e Q O O aE v G 9 G 5 p Ft E12 4 B gt C 3ADWOOO194R0601 DCS800 Hardware Manual f e Line reactors type ND 403 ND 408 123 Type JA B C D JE F j OGJ OH OK IND 403 220 230 120
22. d e ses see 35A 5A D1 Ut vi wi pe Terminal X100 X101 earthing M6 ke MO crass section max AWG 7 DCF803 0035 3 67 36 5 N T N LI yen 28 DD e for mounting on mounting plate provide hole with diameter of min 5 mm for thermal sensor 90 R N o e N S 8 N sE o i e sese see e Ho S ESA 16A 5A D1 U1 vi W1 L A N kt n DCF803 0016 dsf DCF803 0016 Accessories 3ADWOOO194R0601 DCS800 Hardware Manual f e 300 DCF505 DCF506 Overvoltage Protection 115 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 suit able for 2 Q converters DCS800 S01 with simple non motoric inductive load 3 phase Field supply Overvoltage Converter protection eu DCF 505 DCS800 S Ez D1 Simple l
23. see manual Branching units NDBU 95 Technical specifications Layout of the NDBU 95 branching unit Optical links f Master channels 1 DDCS input and 1 DDCS output Slave channels 9 DDCS inputs and 9 DDCS out DBU puts A sd Data rate 1 4 MBd programmable Driving current 20 mA 30 mA 50 mA channel disabling programmable Monitoring a green LED for each channel switched on when NDBU is receiv I ing messages ABB N0299 Transmission device 10 Mb component for each channel ES Ole O UNIT Gr OU RXD Power supply E 8 Input voltage 24 VDC 10 a Q em 9 ADDRESS Input current 300 mA a 63 Monitoring a green LED switched on when the y 8 1 output voltage is normal eo TI a RXD Operating temperature 0 50 C Y 8 PCB dimensions s diagram beside E Omer 8 MBIT S Remark Only channels with the same components e g TI 9 HHHH 10 Mb component may be connected to each pa eG other Ex Q m col PXD Y e For further information see Appendix D in the DriveWindow cH O 9 User s Manual 264 co RXD P vios G9 Note aa O To A z i vis Q For addressing and automatic node numbering of the Se drives and branching units see DriveWindow documenta ny seansm E SETTING tion al oag ee xt a LONG oum eal a co Eo ES a O Y El O o o Technical data 3ADWOOO194
24. 04 05 1500 1200 1800 1156 1734 1104 2208 D5 25 i DCS800 S02 2000 04 05 2000 1479 2219 1421 2132 1361 2722 DCS800 S02 2050 05 2050 1550 2325 1480 2220 1450 2900 DCS800 S02 2500 04 05 2500 2000 3000 1930 2895 1790 3580 D6 DCS800 S02 3000 04 05 3000 2330 3495 2250 3375 2080 4160 DCS800 S02 3300 04 05 3300 2416 3624 2300 3450 2277 4554 DCS800 S02 4000 04 05 4000 2977 4466 2855 4283 2795 5590 D7 DCS800 S02 5200 04 05 5200 3800 5700 3669 5504 3733 7466 600 V 690 V DCS800 S02 0320 06 320 256 384 246 369 235 470 D3 DCS800 S02 0650 06 650 514 771 508 762 462 924 D4 DCS800 S02 0900 06 07 900 684 1026 670 1005 594 1188 D5 25A DCS800 S02 1500 06 07 1500 1200 1800 1104 1656 1104 2208 48164 DCS800 S02 2050 06 07 2050 1520 2280 1450 2175 1430 2860 DCS800 S02 2500 06 07 2500 1940 2910 1870 2805 1740 3480 D6 DCS800 S02 3000 06 07 3000 2270 3405 2190 3285 2030 4060 DCS800 S02 3300 06 07 3300 2416 3624 2300 3450 2277 4554 DCS800 S02 4000 06 07 4000 3036 4554 2900 4350 2950 5900 D7 DCS800 S02 4800 06 07 4800 3734 5601 3608 5412 3700 7400 800 V DCS800 S02 1900 08 1900 1500 2250 1430 2145 1400 2800 DCS800 S02 2500 08 2500 1910 2865 1850 2775 1710 3420 D6 DCS800 S02 3000 08 3000 2250 3375 2160 3240 2000 4000 DCS800 S02 3300 08 3300 2655 3983 2540 3810 2485 4970 DCS800 S02 4000 08 4000 3036 4554 2889 4334 2933 5866 D7 DCS800 S02 4800 08 4800 3734 5601 3608 5412 3673 7346 990 V DCS800 S02 2050 10 2050 1577 2366 1500 2250 1471 2942 DCS800 S02 26
25. 10 E l ui ES E a UN 1 AS a l l Ei Size A L 1 7 62 8 90 3 9 105 Size a b C d 10 120 5 50 29 30 76 6 80 14 30 76 Remark Given dimensions may be exceeded in some cases Please take them only for information 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 with universal Phoenix clamp 1202713 it is possible to mount the card holder on standard rail system in horizontally or vertically direction Dimensional drawings 3ADWOOO194R0601 DCS800 Hardware Manual f e Accessories DCF803 0035 and FEX 425 internal 109 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 measurement channel het SAL S o X100 5A Setting of switchable burden a X100 35A resistors by rated field current X101 U1 X101 V1 Field X101 W1 X100 D1 Fex4x1_a dsf L
26. 14 gt 1 voltage It should not exceed 10 uy due to considerable voltage drops at converter output Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 28 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 ne and Z y constitute the total series impedance of the installation The ratio between the line impedance and the line reactor impedance determines the voltage dip at the connecting point In such cases line chokes with an impedance around 4 are often used Example calculation with Uk Line 1 Ux 472426 Voltage Dip Zi jne ZLine ZL 1 20 Detailed calculation see Technical Guide 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 uy is gt 1 Yo Configuration C1 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
27. 170M 1558 OFAA 00 H10 10A FEX 425 Int lE 12A 170M 1559 OFAA 00 H16 16A DCF803 lE SIGA 170M 1561 OFAA 00 H25 25A DCF804 lE x25 A 170M 1564 OFAA 00 H25 35A DCF803 lp x35 A 170M 1564 OFAA 00 H50 50A DCF804 DCF803 lE 50A 170M 1565 OFAA 00 H63 63A DCF804 Type of protection Semiconduct LV HRC type circuit breaker elements type fuse for for 690 V fuse for 500 V or fuse holder hold OFAX 00 690 V type OFAX 00 F8 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 for field current Transformer 00 V 50 60 Hz lE type 50 60 Hz external supply Uprim 500 V DCF803 0035 lt 6 A T 3 01 Autotransformer dsf FEX 425 Int lt 12 A T 3 02 lt 16 A T 3 03 DCF803 4 0050 30A T 3 04
28. 3ADWOOO194R0601 DCS800 Hardware Manual fe Line reactors type ND 401 ND 413 Line reactors uy 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 Urated supply 400 V DC curr 1 90 of nominal current for Urated 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 Accessories Type reactor rated Weight Power loss Load Load L Ims lpeak Voltage Fe Cu DC curr 1 DC curr 2 iH Line AC A A Un kg WI IW f Usuppiy 400V f Usyppiy 500V ND 401 1000 18 5 27 400 3 5 13 35 22 6 18 ND 402 600 37 68 400 7 5 13 50 45 36
29. 5 E 195 5 2 g 240 PIN 4 Tia 287 5 CON 4 E D4 dim b dsf Dimensional drawings 3ADWOOO194R0601 DCS800 Hardware Manual f e Module D5 DCS800 S0x 0900 DCS800 S0x 1200 DCS800 S0x 1500 DCS800 S0x 2000 Weight appr 110 kg 103 1005 2 T ts Fo 400 o Eg r 450 e g 2 358 kal 127 5 m 125 125 Le 855 12 E 5 for M10 zo A o M7 A e 26 Q 914 La e TE e NE e E s el po LY 7 SS L J Yy NN gt 510 LL x SS e min 480 7 A fa o e o e q Y E Y A 8 ble tr ri earthing M12 j gis ane Wo min a f of o o o oo earthing height 39 mm 8 M12 Ci B O OO Q oO L hol DI i N o 17 754 fan terminals e Ji S 1 o fan terminals 65 5 25 50 50 50 ES Le 400 ka pol o ZE 3 ES La 461 325 5 ES La 483 2m Busbars in mm DC 80 x 10 AC60x5 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 bus
30. 5 mA Curr source for 5 mA PTC or PT100 Encoder supply Remarks Inputs not isolated Impedance 120 Q if selected max frequence x300 kHz 5V lt 250 mA Sense lines for GND and supply to 12V 24V lt 200 mA correct voltage drops on cable only if 5V 12V encoder is in use 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 Al4 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 Al1 Al2 Al3 and Al4 If the gain is set to 10 by using S2 or S3 and the 500 Q burden resistor is activated the input signal level is changed to 2 mA 0 42 mA For input Al4 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 3ADWOOO194R0601 DCS800 Hardware Manual f e
31. 50 k 500 m 125k 500 m 250 k 250 m 500 k 100 m default and recommended setting 800 k 50m 888 k 35m 1000 k 25m The bus is designed for cable length up to 50 meters Larger distances on request Electrical installation 3ADWOOO194R0601 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 O The ambient operating conditions are allowed See Mechanical installation current ratings Ambient conditions O The unit is fixed properly on a vertical non flammable wall See Mechanical installation O The cooling air will flow freely O The motor and the driven equipment are ready for start See Planning the electrical installation O All screen terminals are checked for tightness O All cable connections are seated properly ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation O 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 to
32. 500 V 3 ph Standard 600 V 690 V fan voltage 525 690 V 3 ph S172 600 V 690 V fan voltage 400 500 V 3 ph Current measurement 8175 CMA D6 and D7 converter Voltage measurement 8186 120 V SDCS SUB 4 for D1 D4 converter modules S180 600 V for D6 and D7 converter modules 8181 690 V for D6 and D7 converter modules 8182 800 V for D6 and D7 converter modules 8183 990 V for D6 and D7 converter modules 8189 galvanic isolation for D6 and D7 converter modules SDCS DSL board 8199 SDCS DSL board 0S199 no SDCS DSL board plug in options Control panel 0J404 no DCS800 control panel J409 Door mounting Kit 3 m cable length Fieldbus K454 Profibus RPBA K451 DeviceNet RDNA K466 Ethernet IP Modbus TCP RETA K458 Modbus RMBA WO and DDCS L500 Analogue Extension RAIO L501 Digital Extension RDIO L508 DDCS Adapter 10 Mbaud CHO SDCS COM 81 L509 DDCS Adapter 5 Mbaud CHO SDCS COM 82 The DCS800 3ADWOOO194R0601 DCS800 Hardware Manual f e 17 t and control ircui In C Ma SOx D1 D4 400 V and 500 V units with Onboard field exciter Armature circuit converter DCS800 600 V units are always without Onboard field exciter 38p p mao S S gsod Jouuojsuen Q 40 0801 esnj aaeusaye 1ndino du enBojeue 2 indino andui jeyibip sjueuoduioo jo uoneubisap MOUS y NOD puobat play 0 ZO 1 Zezse Os Or ve are yi 1 8OI Xc gOI ary arg ared pasim xul soa t 1 v v X
33. DCF803 4 0050 SOA T 3 05 Uprim X600 V DCF803 0035 a ven FEX 425 Int IA T we lt 16 A T 3 13 Uprim lt 690 V lt 6A T 3 11 T3 autotransformer lt 12 A T 3 12 DCF803 4 0050 lt 16 A T 3 13 DCF803 4 0050 z30 T314 50A T3 15 Autotransformer data details see chapter Technical Data Planning the electrical installation 3ADWOOO194R0601 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 for field Reactor E ND 30 00 V 50 60 Hz current EE IF lph reactor a dsf IEC US ma DCF803 0016 16A ND 30 E ND 402 DCF803 0035 16 A KLR 45 CTB yonn FEX 425 Int 16A 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 3 ph according to their size The T2 auxiliary transformer is designed to supply the unit s electronic system and all the single phase fans includ
34. Sox 0260 xx 260 2x 35 1x 95 204 2x 25 1x 95 1x25 1xM10 2 DCS800 80x 0320 xx 320 2x 70 1x 95 220 2x 50 1x95 1x50 1xM10 2 DCS800 80x 0850 xx 350 2x 70 286 2x 50 1x50 1xM10 25 DCS800 SOx 0450 xx 450 2x 95 367 2x 95 1x50 ixMo 25 DCS800 SOx 0520 xx 520 2x 95 424 2x 95 1x50 ixMo 25 IDCS800 SOx 0650 xx 650 2x 120 555 2x120 1x120 1xM12 50 DCS800 SOx 0680 xx 680 2x 120 555 2x120 1x120 1xM12 50 DCS800 S0x 0820 xx 820 2x 150 669 2x120 1x120 1xM12 50 DCS800 S0x 0900 6 7 900 4x 95 3x150 734 4x 70 3x 95 1x150 2x M12 50 DCS800 S0x 1000 xx 1000 2x 185 816 2x150 1x150 1xM12 50 DCS800 S0x 1200 xx 1200 4x 120 979 4x 95 3x 120 1x185 2xM12 50 DCS800 S0x 1500 xx 1500 4x 185 1224 4x150 2x150 2x M12 50 DCS800 S0x 2000 xx 2000 8x 120 6x185 1632 4x 240 2x240 2xM12 50 DCS800 S0x 1900 xx 1900 8x 120 6x185 1550 4x 240 3x120 4x M12 50 DCS800 S0x 2050 xx 2050 8x 120 6x185 1673 6x120 5x 150 3x120 4x M12 50 DCS800 S0x 2500 xx 2500 7x 185 2040 8x120 6x185 4x120 4x M12 50 DCS800 S0x 2600 xx 2600 7x 185 2122 8x120 6x185 4x120 4xM12 50 DCS800 S0x 3000 xx 3000 8x 185 2448 7x185 4x150 4x M12 50 DCS800 S0x 3300 xx 3300 8x 185 2693 7x185 4x150 4x M12 50 DCS800 S0x 4000 xx 4000 7 x 300 3264 8x 240 4x240 4x M12 50 DCS800 S0x 4800 xx 4800 8x 300
35. 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 3ADWOOO194R0601 DCS800 Hardware Manual f e Line reactors Li 29 DCS Type Line choke Design J Line choke Design 400V 690V type for Fig type for Fig 50 60 Hz configur A configur B 2 Q Converter 4 Q Converter DCS800 S01 0020 04 05 DCS800 S02 0025 04 05 NDO1 1 ND401 4 DCS800 S01 0045 04 05 DCS800 S02 0050 04 05 ND02 1 ND402 4 DCS800 S01 0065 04 05 DCS800 S02 0075 04 05 ND04 1 ND403 5 DCS800 S01 0090 04 05 DCS800 S02 0100 04 05 NDO6 1 ND404 5 DCS800 S01 0125 04 05 DCS800 S02 0140 04 05 NDO6 1 ND405 5 DCS800 S01 0180 04 05 DCS800 S02 0200 04 05 NDO7 2 ND406 5 DCS800 S01 0230 04 05 DCS800
36. are intended for all who are responsible for the grounding of the drive Incorrect grounding can cause physical injury death or equipment malfunction and increase electromagnetic interference Ground the drive motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and pick up Make sure that grounding conductors are adequately sized as required by safety regulations In a multiple drive installation connect each drive separately to protective earth PE Minimize EMC emission and make a 360 high frequency grounding of screened cable entries at the cabinet lead through Do not install a drive with EMC filter on an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC stated by EN 50178 5 2 11 1 a fixed protective earth connection is required Safety instructions 3ADWOOO194R0601 DCS800 Hardware Manual f e Fibre 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 i WARNING Handle the fibre optic cables with care When unplugging optic cables Mechanical
37. black Figure 3 L gt orange l C Ir black Figure 4 Di blue blue l Li red red 3ADWOOO194R0601 DCS800 Hardware Manual f e for DCS 400 DCS 500 for DCS 600 DCS800 selected channels see manual NDBU 3ADW 000 100 R0201 DCS 600 DCS800 127 Other cables DCSLink cable dismantling for shield grounding g 2 p 30 mm 10 mm 40 mm ai E Screen 10 mm ra m Q1 1 F netting tinfoi red nulo E lac Ly black an Ze 2 white 7 E EP on a o Qa H F F 303 5 Ps blue Ji blue Ga a NE e CE ij 20 mm two cable pairs a RT Ot Q8 8 pa el not twisted od x Heat shrink tubing cable Heat shrink tubing x 140 mm e a DCS link cable dsf E 0 54 2 4 10 20m Unscreened cable for SDCS CON 4 SDCS IOB 2 IOB 3 connection 1700 mm Pull tab for cable marking EL IOB2 3 unscreened flat cab dsf Screened cable for SDCS CON 4 SDCS IOB 2 IOB 3 connection 1 4 3 2 4 m screen laid open NC 125 25 jo e a3 as Pull tab Pull tab for cable for cable marki
38. 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 i y Connection of a cable screen with the aid of metal clamp to the me tal surface of the PCB carrier at a DCS con verter 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
39. ds as 15 THEI DGS B00 usas eae end eave ais selecta tthe ann eias Me God arra zi abe soared ete nape Sebastes 15 Type Gode ux duree Reb AE wees Hee Re KS cet qu ru sd arie de 16 Main circuit and control usan han aed Pek wie a i unte edi 17 Armature circuit converter DCS800 SOXx D1 D4 0 0 0 0 eee 17 Armature circuit converter DCS800 SOx D5 D7 01 ees 18 Rebuild system DCS800 ROX 2 cocaina oe fe ede rs ER RE 19 Mechanical installation UNPACKING ING Unit t a e obo edet ketenes iting Boker dco Ra Pardo Pees mas edere 21 Delivery CHECK nis Sem eas staan ee eS BRE SUAE SRR Se we eee ert 21 Before installation sesso vies a kk one es ee eae ae de ea eA EAE ae 22 Requirements for the installation site cellier 22 Wall tara varas ba e a 22 ge n 22 Free space around the Unit is ssepe ey PV ee Oe ee ae ee Ske ee ER 22 Cabinet STAY ON Ise oc aceite Sox ir ordo ORC ES ER eb cibo ed O ole ee 22 Preventing cooling air recirculation 2 0 0 cee eee 22 Unit above another sss ede texte nh RR edes eds onum RR CR RE 22 Terminal options converter size D1 D4 llli 23 Connection of DC terminals of D4 converter module eeee eee eoooon 23 Terminal cover according to VBG 4 regulations eee e eee ee 23 Mounting the converter module D6 inside an enclosure eee eee 25 Mounting the converter module D7 inside an enclosu
40. 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 fai HOT pf Main air flow out i l E Air baffle plates m ES l al 4 COOL AREA X A max 40 C 104 F i Air baffle plate a Main air flow in cooling w baffle dsf Airflow Lead the exhaust cooling air away from the unit above Distances see chapter Dimensional drawings Mechanical installation 3ADWOOO194R0601 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 A i aa as Oe Id No Remark A 3ADV280706P0001 right ES Y 3ADV280706P0002 left 135 71 60 ou 95 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 Remark 3ADT631137P0001 D1 D2 3ADV400208P0001 D3 3ADV400207P0001 D4 Mechanical installa
41. 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 3ADWOOO194R0601 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
42. intended for controlling DC motors VL Size D1 D4 20 1000 A Size D5 900 2000 A Size D6 1900 3000 A Size D7 2050 5200 The DCS800 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 TypecodeDCS800 AAX YYY Y ZZ plus code Position A X Y Z B Position Plus code Product series DCS800 A Type SO Converter module IPOO RO Rebuild system EO Panel solution AO Enclosed converter X Bridge type 12 Single bridge 2 Q 2 2 Double bridge 4 Q Y Rated current YYYY Rated current e g 0025 25 amps ZZ Rated voltage 04 400V nominal rating in bold 05 500V 06 600 V 07 690 V 08 800 V 10 990 V 12 1200V B Power connection Standard D1 D6 L Leftside D7 R Right side D7 Internal field exciter 5164 with internal field exciter external supplied only D5 25 A Rebuild kit 25 A 16 A configuration 0S163 without internal field exciter only D1 D4 Fan voltage Size D4 Standard fan voltage 230 V 1 ph S171 fan voltage 115 V 1 ph Size D6 Standard 400 V 500 V 800 V fan voltage 400
43. max data transmission speed is 4 Mb for each optical channel e 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 e 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 e Connector X19 is used for CDP 312 panel as well as interface board NDPI k 148 gt SDCS COM 8 a 00 N I O V1 a 9 d 929329 E E s E a Bs a gt M gt gt aM gt gt o gt Bio 2 2 2 aeg 2 E o o2 Lo sak S LS al S 2 o e b NM u NI COM 8 layout b dsf conductive support Explanation of LEDs on SDCS COM 8 LED color Meaning V6 green 5 V supply ok V1 red blinking boot procedure permanent SDCS COM 8 fault Type Revision optical components Channel 0 used for max driver current Cunduc tive sup port Cho Chi Ch2 Ch3 PLC VO M F DW SDCS COM 81 from D F 10 Mb 5Mb 10 Mb 10 Mbjother interfaces Ch 0 2 3 50 mA SDCS COM 82 from D F 5Mb 5Mb 10 Mb 10 Mb Fieldbus adapter Ch 2 3 50 mA modules Nxxx xx SDCS COM 81 from G 10 M
44. supply voltage X99 Input circuit POW 4 Supply voltage 115 V AC 230 V AC NIC ay Tolerance 15 10 15 10 I Lh e Frequency 45 Hz 65 Hz 45 Hz 65 Hz xm gt RUN Power consumption 120 VA 120 VA SER X T E Power loss 60 W 60 W N F1 Inrush current 20 A 20 ms 10 A 20 ms Q mM e recommended fusing 6 AT 6 AT Mains buffering min 30 ms min 300 ms T Powerfail 95 V 95 V Aye Frequently switching ON and OFF increases inrush current m Output X96 DO8 Backup supply X95 Potential isolated by relay NO contact These two terminals are used to add addi MOV element 275 V tional capacitance to the existing ones to Contact rating AC 250 V lt 3 A increase the mains buffering time More DC lt 24 V SA detailed data is available on request via your or 115 230 V 0 3 A ABB representative Technical data 3ADWOOO194R0601 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 9 inside the module The board is used for supply voltages from 2
45. 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 electricity which can result in physical injury and or damage to the equipment Electrostatic discharge warning warns of electrostatic discharge which General warning warns about conditions other than those caused by 4 can damage the equipment Safety instructions 3ADWOOO194R0601 DCS800 Hardware Manual f e 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
46. tou vi An zx in 0014 gt v nn 4 00Sp VOOCL WLOS 1 000 voos vole L 00SL vale ve OF 94 OF OF OF sunao Buunseew eDeyoA OG OV ON St vn 2 SQQOMH S GOOMH A z OLNV VY SeouejsisoJ Guunseou jueuno einjeuuy pueog o4u09 99e493 U noun SIN UI Y ct bk WOGI OLX Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 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
47. z ki I o sls tr ui 8 U AKT di bd 0V GND Ri X5 10 SDCS IOB 3 ENCODER INPUT A CON 4 IOB 3 5V 12 24 V 5V 12 24 V differential S4 S4 10 10 voltage source 1 2 3 park 2 3 4 5 4 5 6 park 8 9 10 11 7 8 9 park 14 15 16 17 differential S10 current source 1 2 E 7 8 Z 13 14 In any case if SDCS IOB 3 is used see required settings of SDCS CON 4 board Electrical installation 3ADWOOO194R0601 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 parallel wires for Cable used power source amp GND 0 50m 1x 0 25 mm 12x 0 25 mm 50 100m 2x 0 25 mm 12x 0 25 mm 100 150 m 3x 0 25 mm 14x 0 25 mm2 Use twisted pair cable with pair shielding plus overall shielding Cable length parallel wires for Cable used power source amp GND 0 to 164 ft 1x24 AWG 12 x 24 AWG 164 to 328 ft 2 x 24 AWG 12 x 24 AWG 328 to 492 ft 3 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
48. 0 0 9 la OS W7 W8 2 sa A DI5 w9 W10 004004 ou a j A gt DI6 W11 W12 0 0 9 0 04 n A gt DI7 W13 W14 ooo 8 RB A gt W15 W16 X74 eere z 2L ee J m 3 up to revision D from dere revision E on 4 48V conductive support iob2x2_b dsf 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 lt 250 V lt 3 A DC lt 24 V 3 A or lt 115 230 V lt 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 mm cross sectional 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 Remarks Channel Firmware potential isolated by optocoupler 1 8 24 48V R1 R8 4 7 KQ 10B 21 gt 0 signal 0 8 V gt 1 signal 18 60 V 115V R1 R8 22 kQ IOB 22 gt 0 signal 0 20 V gt 1 signal 60 130 V 230 V R1 R8 47 kQ IOB 23 Firmware gt 0 signal 0 40 V gt 1 sig 90 250 V including tolerance absolute max valu
49. 0 1205 4014 10 ms 11 119 Q13 et 100 12 L Q oupa 77H Xe e AO1 2 ov 3 AO2 4 ET ov me fT 5 H l act 100nT t fh 8 V 325 99 03 6 HA ov R110 max 230 4 05 7 10V 8 ov 9 E T 10V u osr NA 1 5mA 10 s A 5 mA 3 11 ov 12 S10 S10 X51 456 NT ZS Vis ChA 2 o 9 o fd HE ChA 3 fonn BN TES Wt chB gt 4 ep m E S yy ChB 5 5 61718 pay ere At ChZ gt 6 roii HA ChZ 7 Power 8 Sense Power go Source Sense GAD 2 88 10 Sa GND O total smoothing time lt 2 ms O 20 0 20 mA by setting S1 4 20 mA by d Software function 1 0 1 V by setting S2 S3 CMR 10 V 2 0 2 mA by setting S2 S3 S1 CMR x10 V designated for PT100 evaluation per firmware and hardware should always be used directly at SDCS CON 4 X3 1 4 short circuit proof Technical data iob3x2_g dsf Resolution Input output Scaling Common Remarks bit values by mode Hardware range 15 sign 10 0 10 V Firmware 20 V OOOO 15 sign 10 0 10 V Firmware 20 V OO 15 sign 10 0 10 V Firmware x40 V DASO 15 sign 10 0 10 V Firmware 40 V 00000 15 sign 10 0 10 V Firmware 40 V OO Power 11 sign 10 0 10 V Firmware lt 5 mA 11 sign 10 0 10 V Firmware lt 5 mA analogue 10 0 10 V R110 lt 5 mA gain 0 5 5 R 30 lt 5 mA for external use lt 5 mA e g reference pot 1
50. 00 10 2600 2000 3000 1900 2850 1922 3844 D7 DCS800 S02 3300 10 3300 2551 3827 2428 3642 2458 4916 DCS800 S02 4000 10 4000 2975 4463 2878 4317 2918 5836 1190 V Data on request as option Note AC current lac 0 82 lpc Sizing Note 1 The ratings apply at ambient temperature of 40 C 104 F In lower temperatures the D5 D6 D7 ratings are higher except Imax Note 2 Use the Drive Size PC tool for a more accurate dimensioning if the ambient temperature is below 40 C 104 F or the drive is loaded cyclically Duty cycle loci Technical data locu 3ADWOOO194R0601 DCS800 Hardware Manual f e Control Board SDCS CON 4 Layout of the control board SDCS CON 4 Jumper coding S13 9 Jumper parking position fi Br No filter Normal DC Tacho 21 9 Filter for AC Tacho with rectifier 2 8 1 7 3 Are Tacho input X3 4 connected with 0 V GND 2 di 7 3 E Jumper parking position a 7 no grounding of Tacho input 3 H Tacho input 1 at X3 4 and X3 1 2 3 at ttl SDCS CON 4 3 9 reserved Tacho input 2 at X2 23 and X2 24 at 2 9 SDCS 10B 3 PS5311 S22ppt4 Al X3 5 6 Ry 200 kOhm 1 E Range 10V 0V 10V 254 AN X3 5 6 Ry 250 Ohm 123 Range l 20mA 20mA S3 28 B8
51. 1 3608 5412 3673 7346 990 V DCS800 S01 2050 10 2050 1577 2366 1500 2250 1471 2942 DCS800 S01 2600 10 2600 2000 3000 1900 2850 1922 3844 D7 DCS800 S01 3300 10 3300 2551 3827 2428 3642 2458 4916 DCS800 S01 4000 10 4000 2975 4463 2878 4317 2918 5836 1190 V Data on request as option Note AC current lag 0 82 lpc Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 70 Current ratings IEC regenerative Unit type Ipci lbc u lbc m Ipc iv Size Au continu 100 150 Yo 100 Yo 150 Yo 100 200 Yo 4 Q converters ous 15 min 60 s 15 min 120 s 15 min 10s 400 V 525 V A A A A DCS800 S02 0025 04 05 25 23 35 22 33 21 42 DCS800 S02 0050 04 05 50 45 68 43 65 38 76 DCS800 S02 0075 04 05 75 66 99 64 96 57 114 D1 6A DCS800 S02 0100 04 05 100 78 117 75 113 67 134 DCS800 S02 0140 04 05 140 110 165 105 158 99 198 DCS800 S02 0200 04 05 200 152 228 148 222 126 252 D2 15A DCS800 S02 0260 04 05 260 214 321 206 309 184 368 DCS800 S02 0350 04 05 350 286 429 276 414 265 530 DCS800 S02 0450 04 05 450 360 540 346 519 315 630 D3 20A DCS800 S02 0520 04 05 520 398 597 385 578 356 712 DCS800 S02 0680 04 05 680 544 816 538 807 492 984 DCS800 S02 0820 04 05 820 664 996 648 972 598 1196 D4 25A DCS800 S02 1000 04 05 1000 766 1149 736 1104 675 1350 DCS800 S02 1200 04 05 1200 888 1332 872 1308 764 1528 a DCS800 S02 1500
52. 1000 0y 1000A D4 NF3 690 1000 O NF3 690 1000 O DCS800 S01 0900 0y 900A DCS800 S02 0900 0y 900A D5 NF3 690 1000 O NF3 690 1000 O DCS800 S01 1200 0y 1200A DCS800 S02 1200 0y 1200A D5 NF3 690 1000 O NF3 690 1000 O DCS800 S01 1500 0y 1500A DCS800 S02 1500 0y 1500A D5 NF3 690 1600 O NF3 690 1600 O DCS800 S01 2000 0y 2000A DCS800 S02 2000 0y 2000A D5 NF3 690 1600 O NF3 690 1600 lt 3000A lt 3000A D6 NF3 690 2500 O NF3 690 2500 O Filter only available on request 3ADWOOO194R0601 DCS800 Hardware Manual f e Planning the electrical installation 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 dc current Filter type field supply unit A Umax 250 V DCF803 0016 8 NF1 250 8 DCF803 0035 16 NF1 250 20 FEX 425 Int DCF803 0050 50 NF1 250 55 DCF804 0050 50 NF1 250 55 O The filters can be optimized for the real field cur further filters for 12 NF1 250 12 rents Ifilter Field 30 NF1 250 30 single phase operation Planning the electrical in
53. 100V UR 6 170M 6151 DCS800 S0x 2050 06 07 D6 700A 1250V UR 6 170M 6145 DCS800 S0x 2500 06 07 D6 1000A 1250V UR D 6 170M 6148 DCS800 S01 3000 06 07 D6 1100A 1250V UR 6 170M 6149 DCS800 S02 3000 06 07 D6 1100A 1250V UR 6 170M 6149 DCS800 S0x 3300 06 07 D7 2500A 1000V UR 8 170M 7036 DCS800 S0x 4000 06 07 D7 3000A 1000V UR 8 170M 7156 DCS800 S0x 4800 06 07 D7 3000A 1000V UR 8 170M 7156 790 V DCS800 S0x 1900 08 D6 700A 1250V UR D 6 170M 6145 DCS800 S0x 2050 08 D6 700A 1250V UR D 6 170M 6145 DCS800 S0x 2500 08 D6 1000A 1250V UR 6 170M 6148 DCS800 S01 3000 08 D6 1100A 1250V UR 6 170M 6149 DCS800 S02 3000 08 D6 1100A 1250V UR 6 170M 6149 DCS800 S0x 3300 08 D7 2500A 1000V UR 8 170M 7036 DCS800 S0x 4000 08 D7 3000A 1000V UR 8 170M 7156 DCS800 S0x 4800 08 D7 3000A 1000V UR 8 170M 7156 1000 V DCS800 S0x 2050 10 D7 1800A 1250V UR 9 170M 7976 DCS800 S0x 2600 10 D7 1800A 1250V UR 9 170M 7976 DCS800 S0x 3300 10 D7 2500A 1250V UR 9 170M 7978 DCS800 S0x 4000 10 D7 2500A 1250V UR 9 170M 7978 O 12 fuses per bridge 2x per F1x 3ADWOOO194R0601 DCS800 Hardware Manual f e 107 Li L2 L3 Dimensional drawings 108 Size 5 6 Size 7 10 Indicator 15 max 105 epo NI Mi 4xM10 o D 9 min 10 deep t
54. 135 100 77 5 7 9 16 6 ND 404 220 225 120 140 100 77 5 7 9 6 6 IND 405 235 250 155 170 125 85 10 9 16 6 ND 406 255 275 155 175 125 95 10 9 l9 IND 407 255 275 155 175 125 95 10 9 11 ND 408 285 285 180 210 150 95 10 9 ii B e gt T c o o Of E tin coated ce rae iW ok AL A BC Y a 9 op J L 50 445 J 110 E 2 F 2 C gt D Line reactors type ND 409 ND 413 Type JA B C D JE F OGGHGK 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 i 4 Fus la 5f pr Qo o o QUI 2 us conten Oa ID A B C X aN cz A B C X Y Z OCOT o o o 9 G6 qe CR 12 E 2 F 2 C D 3ADWOOO194R0601 DCS800 Hardware Manual f e Accessories 124 Autotransformer T3 Type for Field curr Transformer s Weight Power loss Fuse F3 secondary current IF lsec kg Py W A prim 5 35 z T 3 01 lt 6 A TA 15 65 10 T 3 02 lt 12 A lt 13 A 20 100 16 T 3 03 lt 16 A lt 17 A 20 120 25 T 3 04 lt 30 A lt 33 A 36 180 50 T 3 05 lt 50 A lt 57 A 60 250 63 Uprim 690 V 50 60Hz T 3 11 lt 6 A TAO 15 80 10 T 3 12 lt 12 A 13A 20 125 16 T 3 13 lt 16 A lt 17 A 30 150 20 T 3 14 30A lt 33 A 60 230 50 T3 15 SOA lt 57 A 60 320 63 690 V
55. 30 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 O I B O is i E i i T100 Z5 i i L t i ki ai i Y i i 6A 4x i i de 25A 1x als t i i Zon i i i fo fie T i e l Ny i al i i l l 1 IT wir i aa N i x x i a 2 a Li i xs al T i l d Vi I l i gt ds 4 t Q SDCS PIN 4 AJ X5 x22 D x12 XA D kol i x3 S1 3 12 automatic detau x x2 X7 X31 E 23200 V ix din 2 mm X8 K301 o rc N o o o i i i K400 X10 F400 F300 LAc AL L em w dox X9 X9 X24 O y O X21 X25 OQ X23 O X20 O 9 conducting point __ T 2 Li 2 e D Relay Input m m output Aux E SEF DO8 supply Output field Pind_layout_b dsf current Different functional areas on SDCS PIN 4 Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 87 Power supply The power supply X99 oper
56. 332 872 1308 764 1528 x DCS800 S01 1500 04 05 1500 1200 1800 1156 1734 1104 2208 D5 es DCS800 S01 2000 04 05 2000 1479 2219 1421 2132 1361 2722 DCS800 S01 2050 05 2050 1550 2325 1480 2220 1450 2900 DCS800 S01 2500 04 05 2500 1980 2970 1880 2820 1920 3840 D6 DCS800 S01 3000 04 05 3000 2350 3525 2220 3330 2280 4560 DCS800 S01 3300 04 05 3300 2416 3624 2300 3450 2277 4554 DCS800 S01 4000 04 05 4000 2977 4466 2855 4283 2795 5590 D7 DCS800 S01 5200 04 05 5200 3800 5700 3669 5504 3733 7466 600 V 690 V DCS800 S01 0290 06 290 240 360 225 337 205 410 D3 DCS800 S01 0590 06 590 470 705 472 708 434 868 D4 DCS800 S01 0900 06 07 900 684 1026 670 1005 594 1188 DCS800 S01 1500 06 07 1500 1200 1800 1104 1656 1104 2208 D5 men DCS800 S01 2000 06 07 2000 1479 2219 1421 2132 1361 2722 DCS800 S01 2050 06 07 2050 1520 2280 1450 2175 1430 2860 DCS800 S01 2500 06 07 2500 1940 2910 1840 2760 1880 3760 D6 DCS800 S01 3000 06 07 3000 2530 3795 2410 3615 2430 4860 DCS800 S01 3300 06 07 3300 2416 3624 2300 3450 2277 4554 DCS800 S01 4000 06 07 4000 3036 4554 2900 4350 2950 5900 D7 DCS800 S01 4800 06 07 4800 3734 5601 3608 5412 3700 7400 800 V DCS800 S01 1900 08 1900 1500 2250 1430 2145 1400 2800 DCS800 S01 2500 08 2500 1920 2880 1820 2730 1860 3720 D6 DCS800 S01 3000 08 3000 2500 3750 2400 3600 2400 4800 DCS800 S01 3300 08 3300 2655 3983 2540 3810 2485 4970 DCS800 S01 4000 08 4000 3036 4554 2889 4334 2933 5866 D7 DCS800 S01 4800 08 4800 3734 560
57. 4 EFT Output field current Layout of SDCS SUB 4 and location on SDCS PIN 4 Technical data x109 D x105 w 03 X v k X x101 C x107 G sub4 layout dsf Armature firing X15 Q conducting point Ox X17 xx OY Mains chain Rc Rp Setting Size voltage 97 03 30 120V appr 1 17 MOhm 117 V D1 D4 A92 T90 600V 27 4 kOhm OV DI1 D4 ND Example chain Ro R109 R110 R111 Power supply X95 x23 3ADWOOO194R0601 DCS800 Hardware Manual f e Qo x31 X20 1 Q K301 K400 F400 m l gt 1 2 automatic L 2 3 230 V fix F300 X96 x99 1 2 12 Relay output DO8 Pin4 SUB4 layout dsf Input Aux supply 95 001 o YOxxOvvYOrv0 xo0sto0 eoeyejur noo pier 194 o vol 9IX ia e ji eo L EN H 12 YONXO YO XYOXYOoOxo TE l li vlel vise IIIS la l o 8IX uonnquisia jsp evans vurd jo
58. 400 i5 16 6 0 230 V 100 12 0 115 V 230 V 115V T2 a dsf ov ap 6 3 mm Faston Li o lio 2 eleleleleielelelelelelelele ojojo ojolololololololo jo lola ie ejeje e e e gt E k 106 128 k 125 a 148 T2 dim dsf e 100 4 5 E Application hint 230 V The transformer is designed to work as a 230 V 230 V transformer to open ES avoid ground loops This is done via the 380 V and 600 V taping according to the left picture gt gt gt gt gt gt gt gt gt gt o2o mMooninooo OO Q 10 Q NK O 0 0 T2 BO sE SE SE LO 10 10 CO CO CO 230 V 115V T2_a dsf ov Accessories 3ADW000194R0601 DCS800 Hardware Manual f e 126 Optical cables Accessories For the bus communication of the DCS converters there are different optical cables available Kind of cable Connector cable length Ident no Fig plastic fibre optic single cable plug 0 5 20 m 3ADT 693324 1 plastic fibre optic double cable plug 0 5 20 m 3ADT 693318 2 HCS silica double without plastic jacket plug 30 50 m 3ADT 693355 3 HCS silica double with plastic jacket plug 50 200 m 3ADT 693356 4 Figure 1 L blue Figure 2 black Lm cod
59. 500 V Frequency 50 Hz 60Hz AC input current field current Minimum Current 300 mA Size D1 D2 D3 D4 DC output current 6A 15A 20A 25A max cross sectional area 6 mm 6 mm 6 mm 6 mm AWG 10 AWG 10 AWG 10 AWG 10 min cross sectional area 1mm 2 5 mm 4 mm 6 mm AWG 16 AWG 13 AWG 11 AWG 10 Fuse type KTK 25 Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 89 Typical armature circuit thyristor converter diagram with SDCS PIN 4 board vh A et ee sieyenuoo p p Jo eseo ui juo gt 9 A ji A a EDIS bz gt ve lt oOoxeO YO rYO XO YX eoepelul 49419 Plata vex 6104 1 VOL Y yf ely ly V v ly XxOXOYOYO0OxXxOxO0 zz pg GND ASI ASI Aver A8p Aver IND QuvMHuo4 9 8 bus oL LA8H sjeuueyo esind Bully 3943 38 ev eus 9 Hu 9dza 6 Sdza de vdza S dza zaza uonnquisiq i gt L taza 9 vn Im exi zou oO IA gt
60. 7 68 600 3 8 9 20 DCS 0050 ND 04 168 55 82 500 5 8 10 33 DCS 0075 ND 05 135 82 122 600 6 4 5 30 DCS 0110 ND 06 90 102 153 500 7 6 7 41 DCS 0140 ND 07 50 184 275 500 12 6 45 90 DCS 0250 ND 08 56 3 196 294 600 12 8 45 130 DCS 0270 ND 09 37 5 245 367 500 16 0 50 140 DCS 0350 ND 10 25 0 367 551 500 22 2 80 185 DCS 0520 ND 11 33 8 326 490 600 22 6 80 185 DCS 0450 7 5 5 m ND 13 18 2 698 1047 690 46 8 170 160 DCS 0820 n 5 5 ND 15 10 9 1163 1744 690 84 0 190 680 DCS 1500 ND 16 6 1 1510 2264 500 81 2 210 650 DCS 2000 ND 17 4 0 1800 2700 800 86 0 250 700 DCS 2500 3ADWOOO194R0601 DCS800 Hardware Manual f e Ke al Ti ND1 to 6 a dsf jg 6 Type al a b c d e f g ES S adi mm o NDOT 120 100 130 448 65 6 4 8 FB NDO02 120 100 130 58 65 116 4 8 10 INDOS 148 125 157 63 80 143 5 To 10 NDO04 148 125 157 78 80 143 5 10 16 IND 05 148 125 157 78 80 143 5 10 25 ND 06 173 150 180 72 ao 170 5 10 35 om Ss a Accessories 120 Line reactors type ND 13 14 all busbars 40x10 18x13 3x Accessories
61. AS pok ve 4 39 IS Mp oe Ner MEC sjeuueuo asind Bully ipseoq JouoD TRES eo a AH O gt im bos 008 Ba 3 L gt IT v v gt ko de m juawalnseau aeon 30 9W Technical data 3ADW000194R0601 DCS800 Hardware Manual f e 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 EUER E lt Ruz Rus Rit vt y SI Rue R17 Rize E a gil dj e Xi x En Rigs ria Ris e S Riza Ria Rize x H S Ris Ria Rur iN i oe RH R117 R15 ve Field current measurement a M p X12 Field firing High voltage 8 X8 x e n X10 oO t X2
62. CS800 S0x 1900 04 05 08 D6 5 GR31M DCS800 S0x 3000 04 05 08 400 500 V DCS800 S0x 1900 06 07 D6 5 GR31M DCS800 S0x 3000 06 07 500 690 V DCS800 S0x 3300 yy D7 5 GR35C DCS800 S0x 5200 yy 400 V 690 V y voltage class Fan Data for DCS800 Fan CN2B2 W2E200 W2E 200 W2E 250 W2E 250 Rated voltage V 115 1 230 1 115 1 115 1 230 1 Tolerance 10 6 10 6 10 10 6 10 Frequency Hz 50 60 50 60 50 60 50 60 50 60 Power consumption W 16 13 64 80 64 80 120 165 135 185 Current consumpt A 0 2 0 17 0 29 0 35 0 6 0 7 1 06 1 44 0 59 0 82 Blocking current A lt 0 3 lt 0 26 lt 0 7 lt 0 8 1 5 1 8 1 8 1 8 4 0 9 lt 0 9 Air flow m3 h freely blowing 156 180 925 1030 925 1030 1835 1940 1860 1975 Air flow m3 h at working point Max ambient temperature C 60 75 75 60 60 Useful lifetime of grease appr appr appr 45000h 60 appr appr 40000 h 60 45000 h 60 40000 h 40000 h Protection Impedance Temperature detector internal connected Increased losses due to increased current with a blocked rotor will not result in a winding temper ature higher than permissible for the insulation class being involved Planning the electrical installation 3ADW000194R0601 DCS800 Hardware Manual f e 230 Vac 115 Vac Configuration 1 47
63. Characteristics for pulse encoder inputs single ended push pull 5V 12V 24V single ended open collector 24 24 23 23 22 22 12 2AV ke 24 23 22 default value When using SDCS IOB 3 encoder input the following S4 jumper setting S4 on SDCS CON 4 A on SDCS CON 4 has to be made 1 There is a card holder available as option for fastening the SDCS IOB 3 board For more information see chapter Dimensional drawings Technical data 3ADWOOO194R0601 DCS800 Hardware Manual fe 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 Terminals X3 except for connector 1 2 3 4 X4 and X5 on the SDCS CON 4 must not be used SDCS IOB 3 SDCS CON x Software Si 100k 100k X3 1 E inr 2 Lt 9 950 t00k4n E1004 D gt p AITAC s E GOU b AN 4 2 3 3 ms 3 o 99 o4 5 56 ox HO O zd x10 ES A gt Al2 6 Lo ne o1 3 3 ms 7 c y AS xojo A P AB m Ee mS Ge 10 ms m b A4 1
64. DCS800 Hardware Manual DCS800 Drives 20 to 5200 A AA ED ED P EP IP DCS800 Drive Manuals Language Public number E l ES CN RU DCS800 Quick Guide 3ADW000191 x x x DCS800 Tools amp Documentation CD 3ADWOOO211 X DCS800 Converter module Flyer DCS800 3ADWOOO190 x p x p Technical Catalogue DCS800 3ADWOOO192 x x x x x Hardware Manual DCS800 3ADWOOO1 94 x p p x x Hardware Manual DCS800 update DCF503B DCF504B 38ADW000194Z0301 x Firmware Manual DCS800 3ADWO00193 x p x x x Installation according to EMC 3ADWOOOO32 x Technical Guide 3ADWOOO163 Xx Service Manual DCS800 3ADWOOO195 Xx 12 Pulse Manual 3ADWOOO196 x CMA 2 Board 3ADWOOO1 36 p Flyer Hard Parallel 3ADWOOO213 x Drive Tools DriveWindow 2 x User s Manual 3BFE64560981 x DriveOPC 2 x User s Manual 3BFE00073846 x Optical DDCS Communication Link 3AFE63988235 x DDCS Branching Units User s Manual 3BFE64285513 x DCS800 Applications PLC Programming with CoDeSys CoDeSys_V23 x 61131 DCS800 target tool description Application Program 3ADWOOO199 x DCS800 Crane Drive DCS800 Crane Drive Manual suppl 3AST004143 R0101 x DCS800 Crane Drive Product note p DCS800 Winder ITC DCS800 Winder Product note PDC2 EN x DCS800 Winder description ITC 38ADW000308 x Winde
65. DWOOO194R0601 DCS800 Hardware Manual f e JU c 422 Busbars in mm AC and DC 100 x 10 Dimensional drawings 106 Module D7 right hand for M10 DCS800 S0x 2050 xxR 8 O 8 DCS800 S0x 2600 xxR O z z o gt DCS800 S0x 3300 xxR e AB DCS800 S0x 4000 xxR Jo a e E DCS800 S0x 4800 xxR DCS800 S0x 5200 xxR 8 Weight appr 315 kg a E o 8 A Pressure switch TE 8 zo o0 ERA for M10 ou BRA TUTTI A7 dim a dsf Ac and De ta MOT AC and DC 100 x 10 eee taa a ENA D L J Dimensional drawings 3ADWOOO194R0601 DCS800 Hardware Manual fe Fuses installed inside the converter Converter type Model Fuse F1 Size Type 400 V 500 V DCS800 S0x 1200 04 05 D5 800A 660V UR 5 170M 6162 DCS800 S0x 1500 04 05 D5 1250A 660V UR 5 170M 6166 DCS800 S0x 2000 04 05 D5 1600A 660V UR 5 170M 6169 DCS800 S0x 2050 51 D6 1500A 660V UR 5 170M 6168 DCS800 S0x 2500 04 05 D6 900A 660V UR 5 170M 6163 DCS800 S01 3000 04 05 D6 1250A 660V UR 5 170M 6166 DCS800 S02 3000 04 05 D6 1250A 660V UR W 5 170M 6166 DCS800 S0x 3300 04 05 D7 2500A 660V UR 7 170M 7026 DCS800 S0x 4000 04 05 D7 3000A 660V UR 7 170M 7028 DCS800 S0x 5200 04 05 D7 3500A 660V UR 7 170M 7057 600 V 690 V DCS800 S0x 0900 06 07 D5 630A 1250V UR 6 170M 6144 DCS800 S0x 1500 06 07 D5 1100A 1250V UR 6 170M 6149 DCS800 S01 2000 06 07 D5 1400A 1
66. E ite M E gem aat du 110 Power secin s oki me ti a elodel os e tib A BO EN SWR 110 DCS LINK communication l nn n l n nn n n n a n na RR wa a a a n an aa 111 Diagnosis sonene ux Gee DR tel each RR CEPI RR EX EO Idae Serge ports a fulvus ni E 112 RS232 POU secs 113 FEX425 INTERNAL Fex 425 Int Hardware configuration size D5 0oooooooo 113 Dimensions cuu Rai aS as Nd t ee eae Bie teed oyster e n a Sed 114 DCF505 DGF505 Overvollage Protection ios iria 115 Buses and tuse holders EG RR dal aad rupes haan eed pb te ashes 118 LING re actors EG ct PTT 119 Line reactors type ND 01 ND 17 sal a eux uu px Re mU Se da d 119 Line reactors type ND 07 ND 12 uiro a a ee ta 120 Line reactors type ND 401 ND 413 ewo chen os IARE ee eee Sees 122 Autotranstormer T9 zona pe Saw DIA Area GAS bad Ba one eri Ren Gato ba dls an 124 EMCO ACTOS ore meto eee br da e DER reet Seagal a tps Ue at dee 124 Supply transformer T2 for electronics and fan iliis 125 Optical cables laa yx eoe ein o Deacon c e P n eo A a 126 Other cables o sene esos Rm Core eee oh ak Det a ime icit ata ee ae De a 127 Table of contents 3ADW000194R0601 DCS800 Hardware Manual f e The DCS800 What this chapter contains 15 This chapter describes briefly the operating principle and construction of the converter modules in short The DCS800 The DCS800 S size D1 D7 are
67. ELE d i SEM M vem M M xy 1 gt i 1 1 l al kan D S EE RE A OEA KA PE RO AE AN KAN PAN EE RARA kam ozm orm etm Zim Xd i ty po i AN m o m Re 1owounseow abeyon Da av A anana i Y 4 gt _ di60x i Vi WE KIM WE GM WE M wr aw Wi SM Em d H M H I I I 1 gt i Mod Soas AN Sa om Sw zi MAN y A f SPE ET ET ET ET ET ET ETE TETE TETE TET ETE TETE TETE i y Y SiS SS SISMSISOSBISOSOSISISISISBLSLINARLE OV A OEZ 773 2 e ello lo as Le ls lio Jo ks fo lo A ld e Ur Us Ue Us Ue Je Us Ue Ue 5 Aiddns xne l amp Ue le De e e We Ve ve ETETETETETE TETE f ee B zd fash ETETE E LS i S L L Isis quewainseew juouno eanjeuuv ells i i v YY y a E E E E E oor bS NId SOOS QHVO8 3O9VHH3INI H3MOd I eset AN ON KE Oa E n ER EE EEE A E E e LE ON L ee A A ener S LM LA LA 910Jeq ajqel ees senjea puq y UN G O Jejjered ur peepjos eq 0 s ozs sa NET Xy e p ff e SOJIM P8AOWAL VA Technical data 3ADWOOO194R0601 DCS800 Hardware Manual fe 98 DC DC transducer A92 Principle circuit diagram of the DC DC transducer A92 17 appr 280nF 9 Input Output voltage voltage 20 10 appr 3 9kQ 7 STEPS 1 POWER SUPPLY a 230 V AC 2 15V Data Selectable voltage gains 675 810 945 1080 1215 1350
68. Filter 0 8 IMOT max the factor 0 8 respects the current ripple Lines with 500 V to 1000 V are not public They are local networks inside factories and they do not supply sensitive electronics Therefore converters do not need EMC filters if they shall run with 500 V and more Type of converter Constr Filter type f y 4 Filter type f y 5 type 2 QConverter IDC A 4QOConvrter IDC A DCS800 S01 0020 0y 20A DCS800 S02 0025 0y 25A Di NF3 440 25 NF3 500 25 DCS800 S01 0045 0y 45A DCS800 S02 0050 0y 50A D1 NF3 440 50 NF3 500 50 DCS800 S01 0065 0y 65A DCS800 S02 0075 0y 75A D1 NF3 440 64 NF3 500 64 DCS800 S01 0090 0y 90A DCS800 S02 0100 0y 100A D1 NF3 440 80 NF3 500 80 DCS800 S01 0125 0y 125A DCS800 S02 0140 0y 140A D1 NF3 440 110 NF3 500 110 DCS800 S01 0180 0y 180A DCS800 S02 0200 0y 200A D2 NF3 500 320 NF3 500 320 DCS800 S01 0230 0y 230A DCS800 S02 0260 0y 260A D2 NF3 500 320 NF3 500 320 DCS800 S01 0315 0y 315A DCS800 S02 0350 0y 350A D3 NF3 500 320 NF3 500 320 DCS800 S01 0405 0y 405A DCS800 S02 0450 0y 450A D3 NF3 500 600 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 740A D4 NF3 500 600 NF3 500 600 DCS800 S02 0820 0y 820A D4 NF3 690 1000 O NF3 690 1000 O DCS800 S01 0900 0y 900A DCS800 S02
69. IO Analog I O Extension RDIO Digital I O Extension Branching units NDBU 95 Environmental Conditions System connection Voltage 3 phase Voltage deviation Rated frequency Static frequency deviation 50 Hz or 60 Hz 50 Hz 2 GO Hz 2 Yo Dynamic frequency range df dt 0 5 to 30 cycles 50 Hz 5 Hz 60 Hz 5 Hz 17 s Please note Special consideration must be taken for voltage devi ation in regenerative mode Degree of protection Converter Module and options line chokes fuse holder field supply unit etc Enclosed converters Paint finish Converter module Enclosed converter IP 00 NEMA TYPE OPEN IP 20 21 31 41 light grey RAL 9002 light grey RAL 7035 230 to lt 1000 V acc to IEC 60038 10 continuous 15 short time publ no 3AFE64484567 publ no 3AFE64485733 publ no 3ADWO00199 publ no 3ADWO00100 Environmental limit values Permissible cooling air temp at converter module air inlet 0 to 55 C with rated DC current 0 to 40 C w different DC curr acc Fig 30 to 55 C below Options 0 to 40 C Relative humidity at 5 40 C Relative humidity at 0 5 C Change of the ambient temp 5 to 9596 no condensation 5 to 50 no condensation lt 0 5 C minute Storage temperature 40 to 55 C Transport temperature 40 to 70 C Pollution degree IEC 60664 1 IEC 60439 1 2 Vibration class 3M3 D1 D4 IEC 60721 3 3 3M1 D5 D7 Site e
70. Lal 4x45 180 Gr e A B C D E F G H Gewicht D1 370 350 142 200 67 98 145 M6 ca 11kg D2 370 350 209 267 121 5 165 5 212 M10 ca 16kq D3 459 437 5262 5 310 147 5 205 252 mO ca 25kg e 2 a Z 53 vo JN aD o 22 2 gg ES E g ra 8 er Sere c 2 E A 2 o E 5 2 2 a 5 8 Signal terminals 359 TEREN o 0 B B oo a 29 Field and power o y supply terminals Power connection 8 xa aa E e 28 o o 90 154 2 Le 8 55 amp HB2 1 S EE T EE E gg 28 a ES ii eee T 8 AR G 7 D1toD3 dim b dsf 3ADWOOO194R0601 DCS800 Hardware Manual f e Dimensional drawings 102 Module D4 S S DCS800 S01 0610 7 S 10 mm for size D4 DCS800 S01 0740 DCS800 S01 0900 270 A 225 DCS800 S02 0680 i 48 5 r fan terminal f M6 DCS800 S02 0820 id A DCS800 S02 1000 lasa 600 V types DCS800 S01 0590 DCS800 S02 0650 Weight appr 38 kg 644 625 40 80 dus M12 L 52 80 80 Power terminal Busbar 40x5 mm Weight appr 38 kg arance 345 2 3 da 298 e amp 1 fan terminal Y E T Direction of air flow M 5 o A co q me 2 1 j o Earthing 3 T1 M12 E 147
71. NG ia serie etd Sa rs Beet PERS a eg ade eae Tbe 70 Diciendo wn QUIESCERE le oa M RR 70 Control Board SDCS CON 4 it OS De OS aes sce a ORC RO RU LAA Oa ee 71 Layout of the control board SDCS CON 4 0 eens 71 Memory of 010 esM pK T cp P 71 Watchdog TUACHOAN yg oes a Bec E YU c XI EE ee Dae ERU d eges he 71 Seven segment display sooo RE verte de x en NUR A e NON 72 T rminaldescripllOIT ais mai cante tte Pree aes a een Bae Run dote egre alte piece ie e god de ee 72 Digital and analogue I O connection of the SDCS CON 4 0 000000 74 Interface Board SDCS COM 8 es edes sk eee Re x RR CERE ERI ER c Re A e Ron ki RE 75 Ch2 SDCS COM 8 Master Follower connections 000 cece tee 76 ChO Drive Bus connection to Advant Controller star llle 76 Ch0 Connection to overriding control Nxxx fieldbus adapter ooooooooooo 77 Ch3 Ring connection to PC tool DriveWindow llli 77 Ch3 Star connection to PC tool DriveWindow sess 78 DDCS Branching unit NDBU 95 5 nd geek Rie WE A RE dw e I ELMO MUR x 79 SDCS DS Board sas st xat ebat e o eat dcn e Eos fus Vee eee edo Sea dos as 80 Digital O board S DO S NOB 2 5 usce iy koa ld dod sot Ub Seda tq xeu dodo reed 81 Analogue and encoder I O board SDCS IOB 3 0 0 Le ess nu ellen 83 Power Supply Board SDCS POW 4 nananana anaana 85 Interface Board SDOS PINA icu cad Rit ox een eas dp WOR Lea DAL 86 Generals acuerdo aire Moa e dla KR ACR REA R
72. R0601 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 drw b dsf Jumper coding S1 Bus termination 3 1 120 Ohm 3 T x no termination park position S2 Ground termination 2 4 0 Ohm direct ground ES termination 204 200 kOhm R C ground 1 3 termination e H no termination park position default value SDCS DSL 4 Software Supply Remarks x8 CON 4 24 200 m 24 V grounded supply tor 425 51 A avama internal and DCF803 0035 field 2 s exciter units short circuit protected X523 E 250 mA 2 es E 5 CANL 3 Li 9 cana V4 DSL communication Remarks EE S2 noe Bus termination 4 34 Termination 200 kOhm S1 1 2 120 ohm 2 fe ota
73. S02 0260 04 05 NDO7 2 ND407 5 DCS800 S01 0290 06 DCS800 S02 0320 06 ND08 2 on request DCS800 S01 0315 04 05 DCS800 S02 0350 04 05 ND09 2 ND408 5 DCS800 S01 0405 04 05 DCS800 S02 0450 04 05 ND10 2 ND409 5 DCS800 S01 0590 06 DCS800 S02 0650 06 ND13 3 on request DCS800 S01 0470 04 05 DCS800 S02 0520 04 05 ND10 2 ND410 5 DCS800 S01 0610 04 05 DCS800 S02 0680 04 05 ND12 2 ND411 5 DCS800 S01 0740 04 05 DCS800 S02 0820 04 05 ND13 3 ND412 5 DCS800 S01 0900 04 05 DCS800 S02 1000 04 05 ND13 3 ND413 5 DCS800 S01 0900 06 07 DCS800 S02 0900 06 07 ND13 3 on request DCS800 S01 1200 04 05 DCS800 S02 1200 04 05 ND14 3 on request DCS800 S01 1500 04 05 06 07 DCS800 S02 1500 04 05 06 07 ND15 3 on request DCS800 S01 2000 04 05 DCS800 S02 2000 04 05 ND16 3 on request DCS800 S01 2000 06 07 ND16 3 on request with forced cooling 1m s Fig 1 Fig 4 Fig 2 3ADWOOO194R0601 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 s
74. WI A0004 18 The DCS800 3ADW000194R0601 DCS800 Hardware Manual f e 19 3Sp p mao S S 8590 jeuuojsuea Q gt JO OEO m asn lt eAneuieye ndino 1ndui enBojeue A indino indu jepp 498 sAsagog sjueuoduioo jo uoneubisap LOUS t NOO Qs x pd 9d puobar vi yi XZ bn 1 l 901 sol i H i Josnuoo2 E i d l i jueApy n E wow e l 1 E H 1 i i l i red peisiw xui soa 1 1 kenaan H H 1 I y mu oo 1 gt 8233 OS 8 apk i 3 00 l Q ko 2 i 1 a E e E 1 l o e t l n Ez Slleo 8 i i S Li l 1 eo E co u 1 o LL o l 2 4 a9eJ19 ul amp 9 Oo o i br BS snqpjal4 a a o i irnia v MOd 2 e l I 5 S i l l 8 o i A X0H 009S2 O i i l Sd LNINO WA A l ISengaN Q I i 1 Gerd i 4 i l LI 5 A ddns I i 2 VS 0 WSIN DN J MOd 1 ZLE da a 2 a L jaued romoose gaan Sa I ki ia Qu m 3 i se O Bununoui MOPUIMSALIQ 5 4 4 zd 91d 100 9d 3 a ued Gunsixa A008 a The DCS800 3ADWOOO194R0601 DCS800 Hardware Manual fe 20 The DCS800 3ADWOOO194R0601 DCS800 Hardware Manual f e 21 Mechanical installation Unpacking the unit open box take out shock dampers Separate manual and accessories do notlift the drive by cover Delivery check Check that there are no signs of damage Before attempting installation and operation check the informatio
75. 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 inter 8601A1 42000D3 3ADT 745047 nal AC and DC voltage measurement channels are 42001D3 opened and connected to the T90 and A92 units Technical data Hard and software settings Voltage coding on measuring board 05 8 07 Conv nom voltage V Y 4 400V Y 6 600V Y 7 690V Y 8 800V Y 9 990V Y 1 1200V Y 5 500V Rated mains voltage V AC 220 500 270 600 300 690 350 800 450 990 530 1200 Value f conv nom volt at 1200 SET TINGS block Measuring board SDCS PINS1 PIN 51 aa es 9 505 8 all resistors are 0 Q Galvanic isolation Resistors Rx on PIN51 27 4 kQ 27 4 KQ 27 4 KQ 27 4 KQ 27 4 KQ 27 4 kQ DC DC transducer A92 8680A1 Switch position Rg 7 675V 6 810V 5 945V 4 1080V 2 1350 V 1 1620 V DC DC transducer A92 42000D3 DC DC transducer A92 42001D3 Transformer T90 3ADT 745047 2V1 2W1 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 97 Typical armature circuit thyristor converter diagram with SDCS PIN 48 an
76. 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 3ADWOOO194R0601 DCS800 Hardware Manual f e WARNING The printed circuit boards contain components sensitive to electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the AA boards unnecessarily Grounding These instructions
77. ard one channel for residual current measurement digital I O s all isolated by means of optocoupler relay the signal status is indicated by LED current source for PT100 PTC element 3ADWOOO194R0601 DCS800 Hardware Manual f e Pulse encoder connection Connecting a pulse encoder to the DCS800 converter 57 The connection diagram for a pulse encoder to the electronics of a DCS converter is quite similar if the SDCS CON 4 or the SDCS IOB 3 is used The basic difference between these 2 boards is the galvanically isolated circuit and pulse receivers via opto coupler on the SDCS IOB 3 board Power supply for incremental encoder SDCS CON 4 and SDCS IOB 3 board have jumpers to select a supply voltage V17 LED on SDCS IOB 3 indicates supply is OK Hardware configuration Encoder supply SDCS CON 4 SDCS CON 4 SDCS IOB 3 supplied by PIN 4 supplied by POW 1 POW 4 5V sense controlled sense controlled sense controlled 12V no sense sense controlled 24 V no sense no sense no sense Sense feedback connection is recommended when power supply level for differential pulse encoder is 5 V The wiring is shown on figure below Commissioning hint Note DIFFERENTIAL twisted pair Chas x61 If the drive s measured direction of we kas rotation is wrong or does not chB X54 correspond to measured EMF speed Pe the SPEEDFB fault may appear Power source X5 10 during start up If n
78. ates 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 Backup supply Supply voltage 115 V AC 230 V AC The terminal X95 are used to add additional Tolerance 15 10 15 10 capacitance to the existing ones to increase Frequency 45 Hz 65 Hz 45 Hz 65 Hz the mains buffering time More detailed data Power consump 120 VA 120 VA is available on request via your ABB tion representative Power loss lt 60 W lt 60 W Inrush current 20 A 20 ms 10A 20 ms recommended fus 6 AT 6 AT ing Mains buffering min 30 ms min 30 ms Powerfail O5V po 1858W S1 1 2 gt automatic detection of input voltage range default 2 3 gt 230 V operation fix X96 Output DO8 Isolated relay NO contact Contact rating AC 230 V lt 3 A DC 24 V lt 3 A or 115 230 V lt 0 3 A PIN4_in output_circuit_b dsf X99 Input circuit PIN 4 275 V oo EE no Q X99 Ast lo BQ o MO Technical data 3ADW000194R0601 DCS800 Hardware Manual f e 88 Armature circuit interface The function for armature circuit interface consist of Firing the armatu
79. ation using on board field exciter 39 Converters D5 drive configuration using FEX 425 Int field exciter ooooooooooo 40 Converters D5 D7 drive configuration using external field exciter DCF803 DCF804 41 Converters D1 D3 3 phase field exciter configuration llle 42 START STOP and E STOP conttrol 5 c teer ete hte od et wes ee YU et 43 Drive configuration with reduced components e se eee va eee 45 PUTING us sd dee a uie ke A A d teret teu a cts regu 46 Thermal overload and short circuit protection ss sese ea eee 48 Mains cable AC line cable short circuit proteCtiON esse ennan eee 48 Cross sectional areas Tightening torques 00 00 cee tee 49 Selecting the control cables Loo reet a WS Dena ea Sawer eh PIRE 50 DESSUO parl 6able cosa re de pe etie Dave ur ats e cedem ete hake Phe Kote eke 50 Connection of a motor temperature sensor to the drive I O o oocoooooooooooo 51 Electrical installation What this chapter Contains ese RE ERE yg eee eR wk ux E RR EN Re le RR CR E RR 53 Checking the insulation of the assembly 0 000 eee 53 IT ungrounded systems 24 s cca a Mta o ed ea ke ta ad Ue x 54 Supply voltages rere rta uua oh tated Sr d esse v pat tie woth Bon Gee Rete e eee Woe tag E 54 Connecting the power cables casos Re qr ES MNT PERS Ex Saal cate we eee pi E 54 Location R Extension an
80. ayout of the SDCS FEX 4 board 240 XD ea P1 SID al cece asa j T110 O T113 G Field O w Xo 4 alg e 1112 TUM 7 X R106 s Q gt vi10 x Maing O xo gin zQ pe n X1 24 V supply X3 DSL Link X1 1 24 V DC X3 1 GNDB X12 OVDC X3 2 CANL X3 3 CAN H 3ADWOOO194R0601 DCS800 Hardware Manual f e D800 OP x YO S800 u7z300 S801 usa sa e 2 000000 1100 3 X e ao X i d Fex4_layout_a dsf Accessories 110 Accessories Electrical data Power circuit AC Field input voltage 110 V 15 500 V 10 single or three phase AC input current lt DC output current Frequency same as DCS Converter module AC isolation voltage 600 V Line reactor external Line fuses KTK25 for FEX425 internal external for DCF803 0035 DC output current 300 mA min 25 A FEX425 internal 35 A DCF803 0035 Powerloss lt 130 W at rated current Auxiliary supply DC input voltage 24 V DC Input current 200 mA supplied from SDCS DSL 4 X51 Buffering 10ms 3 phase or single phase operation Control unit The control includes the following main blocks Micro controller H8 for current control synchronization and
81. b 5Mb 10 Mb 10 Mbjother interfaces Ch 0 2 3 50 mA x SDCS COM 82 from G 5 Mb 5Mb 10 Mb 10 Mb Fieldbus adapter Ch 2 3 50 mA x modules Nxxx xx Color of optical components 5Mb 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 76 Ch2 SDCS COM 8 Master Follower connections SDCS COM 8x SDCS COM 8x SDCS COM 8x D200 Eve grey TxD con8 bus conn a dsf plastic optic fibre lt gt 30 m SDCS COM 8 Rev D and higher ChO Drive Bus connection to Advant Controller star En 7 Tspcs cower E a SDCS COM 81 TA 7 CH2 CH1 CHO SHE 3 CH2 CH 1 CHO l e a o ra a a o o o o rj 1 1 l 1 a Q Led a a a a a a 9 a 9 a a a Q 2 Q 8g 22 B 2 d B Q gp 22 22 2 e t 8 2 8 2 S IS v ssl e sel e s elt v ssl lzel el E a esl 8 slale 5 5 85 5 L k 5 S S 5 L9 k IL al 5 L5 L5 20 m SDCS COM 8 up to Rev C plastic optic fibre 30 m SDCS COM 8 Rev D and higher y a a x NDBU 95 30 m plastic optic fibre AC80 Ch0 Drive Bus AC 800M CI 858 Drive Bus Module Sone bue Gorn aaf PEC800 CI 858 Drive Bus Module FCI CI 810 Adapter module Technical data 3ADW000194R0601 DCS800 Hardware Manual f e Ch0 Co
82. bars 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 104 Module D6 DCS800 S0x 1900 Hed DCS800 S0x 2050 375 DCS800 S0x 2500 5 5290 409 gt Air outlet DCS800 S0x 3000 R 10x20 A Weight appr 180 kg P A C D E Fw wc a 4 EZ HE ico o ama o A D ki a zd o D V o 3 g J gt W W 000 te o S a Ee J Pressure switch g 4 dl i E te SO a y LA 123100 M10 355 AM x E Air entry O k from the front right left and 468 2 back mn a ILLI Ll lt 136 gt 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 105 230 530 7 i6 350 for M10 a A A j e e a L N D N e eo a L N e N o a Pressure switch M i o L N SN ri tee for M10 E A7 dim a dsf 90 180 80 80 80 937 3A
83. be used to improve local equalizing of potential A diagram of the cable routing is shown below 24V 115 230 V 24V 115 230 V Motor cable Control cable duct Drive Powercable min 300 mm 12 in Input power cable Motor cable min 200 mm Sin 90 Li min 500 mm 20 in Control cables Not allowed unless the 24 V Lead 24 V and 115 230 V cable is insulated for 230 V or control cables in separate insulated with an insulation ducts inside the cabinet sleeving for 115 230 V Electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 61 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 s
84. 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 Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 44 E STOP a K16 ELEC DISCONN iw speed Timer K15 Timer K16 EMER STOP Block current control K1 main contactor CON 4 Di4 X6 9 Block current E Stop ramp Coast com
85. cted see Manual SAFE64605062 Technical data r 7 spes com sx CH3 H CH1 CHO Internet Ethernet cH3 grey TxD grey TxD grey TxD grey TxD Plastic opt fibre max 30 m or 200 m HCS Plastic HCS opt fibre Silicat max 30m max 200 m 2 8 28 lt PCI PCMCIA adapter PC NDPC 12 a top NDPA 02 AE 7 sa 3ADWOOO194R0601 DCS800 Hardware Manual fe cH1 CHO grey TxD 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
86. d Interface Modules ee ve ke ee 55 I O BOaFOSANNQUFA NON EROR ROME EE ET TU COT Q2 Bie BA n oat at an A ent L Save Baki ke On 56 Pulse encoder CONNSCION 22 00 ux s ae inde lavan ki cepi con DRE a ie ki A enr ramus d a l ted 57 P lseencoder receiver wi cessus e nx mestre hare aK om e Ma SAT A ee 58 Connecting the signal and control cables ee lt aw kan wonn a n n an won a n n n n an 60 Ro ting NE GAD GS OC 60 DES Link WIRING supe lap ake ra is oa e ac rca ebd 61 Installation checklist CHECK IST es genie te Xx o ig Ah a ee ae a pec diia Bae A ahs areca a es 63 Table of contents 3ADW000194R0601 DCS800 Hardware Manual f e 13 Maintenance What inis chapter Contains s d s Vive ce Re Sides eWay Nee RN ie oe a Rae ER 65 Safely herce Me pet Ex pit it Roe dees As prar va Poem gate dirt eames Meads d 65 Maintenance interval ensem e ee Uk xe e CX em PX RA ORC RR e aa 65 Heads kosas ra Pr ie ee EE ee ver bsc era nae Nd a RE Y ate es 66 FAM tesa edes esr ear Pace ib tn eS a ed ee dac Kc qu Sag See ae Gite da Geter eg 66 Fan replacement D6 D7 ues tis to ber os de e RAE 66 Technical data What this chapter contains si REIR EE exe ka ty eee Xe eee EARS RES Kus 67 Environmental Gordifions cios drug reb C ENG de Ne e ara d Vac ob i Nod dao 67 Current ratings IEC non regenerative ooococccooocconcr ee 69 Current ratings IEC regenerative s soirs rte RIPE RR bee tae gee ee Aa eels ee bes 70 SIZI
87. d SDCS PIN 51 boards for a 4 Q D7 type converter with galvanic isolation 9 Ios 3Sp LV ts Ted i 8r Nid S00S m m IWONA i T T THTV I Sta TW SOCOM I zo 4 T ue i ESEYE TE EV l l i B E Tw ae ere 1 aoze i aie Bt EE qa s PH ew Hew eeM z8M 18M 08M I 5 L TO De Se i p wi i ase a i ZM IM OM I AV i sjeduin Guipoo MH i H e l 8t NId S90S i TAT TOPE i ama TE i FI ZES i yaw aw 2 T Frer TONS A Bt FW 9HOV t P yaza l Y Bt HR i Tc mE i i A n 5 FSA l n i l A I8IV i SIN TF yaza i i p iia aza po fi n an Pod R S e i i i poul W W sieuueuoesmdBunj t n i i 39 9939 on 1900 9 89 1 vo PP O A a An AAA AA eer 1 i T S pueog jonuoo i bo A 7 a AI RA A UNE i A TINY E AO Lu x Ee p
88. e 1 DCS800 S01 0470 04 05 DCS800 S02 0520 04 05 170M 6811 OFAX 3 S3 FWP 700A See Note 1 DCS800 S01 0610 04 05 DCS800 S02 0680 04 05 170M 6163 3x 170H 3006 FWP 900A See Note 1 DCS800 S01 0740 04 05 DCS800 S02 0820 04 05 D4 70M 6163 3x 170H 3006 FWP 900A See Note 1 DCS800 S01 0900 04 05 DCS800 S02 1000 04 05 170M 6166 3x 170H 3006 FWP 1200A See Note 1 DCS800 S01 0290 06 DCS800 S02 0320 06 D3 170M 5810 OFAX 2 S3 FWP 500A See Note 1 DCS800 S01 0590 06 DCS800 S02 0650 06 D4 170M 6813 OFAX 3 S3 FWP 900A See Note 1 Fuses and fuse holders details see chapter Technical Data Note 1 No fuse holder is available Attach fuses directly to busbar 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 33 Field conv Field F31 F32 F33 current DCF803 0035 lpx6A
89. e ache eee hop dita Top a d d bo ke 86 Power SUDply src ER Oral xc ERI bac a 87 TECNICA datas o aei eee ao 87 Armature circuit interface 2 22 88 Field Circuit iv eu cas ors a Baa Age YE RUE OR GRO RU Up des 88 Power Interface SDCS PIN 46 SDCS PIN 48 SDCS PIN 5X 2 0 0 0 ee noun 90 Interface Board SDOS SUB 4 at c ve da a ERU E ted Uu Ea en es 94 General ed t ets od aD Er M MEA afe NEUE D rM UT deo DET et 94 Galvanic isolation T90 AY 96 DG DG TFANSAUCOF A JA eise acd A INC ad A ear RA Belt dU da MO ev C CE d 98 Transformer F90 i sce m ess rere RR E ERA te GENTES T one Aree CE X ca ec es 99 Dimensional drawings Table of contents 3ADW000194R0601 DCS800 Hardware Manual f e 14 Module DT 2d A A REPE EMITE dC IBS edens nisi 101 Moue Da ud tie nei aed Hoh ae a teeta a tg qa fyUS SS SV d uM ne 101 Module D3 25 eS edet eR e a eedem cou A E at ded 101 Module Dd 2 2 00 Le oca uta ud ol tabe pe dD Ruel he Ago mtu BON ke pon a A o oe Dur 102 Module D5 22 atte ni a een xe debut mium hin 103 Module Do c RCM IDEA 104 Module D7 left hand RD S E Ne a ah 4 Sie ne S dae ek 105 Module DZ righthand dor opte dt etu ie ia ed heben me eer br CPC MR 106 Fuses installed inside the Converter 107 Accessories DCF803 0035 and FEX 425 internal enn nn nn nn an n nn RR RR RR RR res 109 Eleciricalidaiasz ke 2 ck Ei ost AN ec a e ule Ner Use cr io oe ROE a kat OE yk Ud afe nan KO po AE 110 GONTrOUNITE em aeu rt e ena O
90. ecessary correct by exchanging the field connection Sense power x5 9 Sense GND X5 8 GND X5 7 If with a positive reference the position signal 3 07 or 3 08 signal does not look like the illustration SINGLE ENDED E below then tracks A amp A must be cne pss exchanged with inverted signals For o le single ended encoders Tracks A and cnz x5 B must be exchanged Power source X5 10 X5 9 X5 8 GND Tet 65535 7 IOB3x3 g dsf Forward 0 Electrical installation 3ADWOOO194R0601 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 b single ended push pull connection voltage signals e used 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 Qis activated via jumper S10 1 2 on SDCS IOB 3 a s o Pulse encoder connection principles
91. es X6 X7 are screw clamp terminal types for leads up to 4 mm cross sectional 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 lt 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 83 Analogue and encoder I O board SDCS IOB 3 As described at the beginning of the chapter there are I O via SDCS IOB 2x IOB 3 and SDCS CON 4 various options for configuring the inputs out
92. f Technical data short circuit protected O gain can be varied in 15 steps between 1 and 4 by software para meter 3ADWOOO194R0601 DCS800 Hardware Manual f e Resolution Input output Scaling Com Remarks bit values by mon Hardware mode range 90 270 V O 15 sign 30 90 ViFirmware 15 V 8 30 V 15 sign 10 0 10V Firmware x15 V 15 sign 10 0 10 V Firmware x15 V 15 sign 10 0 10 V Firmware x15 V 15 sign 10 0 10 V Firmware 15V Power 10 V lt 5 mA for ext use 10 V lt 5 mA e g refer pot 11 sign 10 0 10 V Firmware x5 mA 11 sign 10 0 10 V Firmware x5 mA 10 0 410 V Firmware x5 mA 8 V gt min of 325 4 Hardw of 99 03 or 230 of 4 05 Encoder supply Remarks Inputs not isolated Impedance 120 Q if selected max frequence x 300 kHz 5V 250 mA Sense lines for GND and supply to 24V 200 mA correct voltage drops on cable only if 5 V encoder is in use Input value Signal defini Remarks tion by Firmware 0 7 3 V 0 status 7 5 50 V gt 1 status Output Signal defini Remarks value tion by 50 mA Firmware Current limit for all 7 22 V at no outputs 160 mA load Do not apply any reverse voltages 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
93. fault handling Two channel actual field current measurement of DC circuit e 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 term
94. ghten the screws to secure the extension modules DCS800 Panel connector X33 SLOT 1 R IO Extension module or R Fieldbus module SLOT2 R IO Extension module Interface connector X2 SDCS IOB 3 f X1 SDCS IOB 2 a SLOT 3 R IO Extension module or R DDCS interface board X34 PCTool DriveWindow Light AP Tool Commissioning assi stant Electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 l O s via SDCS CON 4 Analogue I O s standard Digital I O s not isolated Encoder input not isolated SDCS CON 4 l O s via SDCS CON 4 and SDCS IOB 3 Analogue l O s Standard one channel for residual current measurement digital I O s not isolated encoder input isolated current source for PT100 PTC element Electrical installation SDCS CON 4 I O s via SDCS CON 4 and SDCS IOB 2 Analogue l O s standard digital I O s all isolated by means of optocoupler relay the signal status is indicated by LED SDCS CON 4 IO poss b dsf rnc RR REUS d l O s via SDCS IOB 2 and SDCS IOB 3 Analogue l O s Stand
95. ial Light industry Supply transformer for a residential area rating normally lt 1 2 MVA area rating normally 1 2 MVA Residential area Residential area Earthed Mi neutral Earthed public 400 V network with neutral conductor Earthed neutral Earthed public 400 V network with neutral conductor Earthed public 400 V network with neutral 4 conductor Mains filter To other loads e g drive systems To other loads e g drive systems To other loads e g drive systems Commutaion notches lt 20 Line reactor i Y capacitor power converters HF interference and commutation notches power converters HF interference and commutation notches To other loads which have to be protected from the system disturbances caused by To other loads which have to be protected from the system disturbances caused by Operation at public low voltage network Operation at public An isolating transformer together with other low voltage network with an earthed screen loads of all kinds together with other and earthed iron core loads of all kinds renders mains filter and line reactor superfluous Operation at public An isolating transformer low voltage network with an earthed screen together with other and earthed iron core loads of all kinds renders mains filter and line reactor superfluous Planning the elec
96. ied EN 61000 6 2 EN 61000 6 1 PDS category C3 PDS category C4 Classification Medium voltage network Medium voltage network The following overview uti Supply transformer for a ki a a lises the terminology and Industrial zone residential area rating Industrial ostras indicates the action normally lt 1 2 MVA zone with earthed required in accordance with Converter n Product Standard I transformer EN 61800 3 Earthed iron core A For the DCS800 series the neutral Earthed 400 V network and earthed limit values for emitted inter with neutral conductor screen where ference are complied with 3 lt 400A To other loads e g drive systems Commutation notches lt 40 Line reactor i i Y capacitor Operation at low voltage network together with other loads of all kinds apart from some kinds of sensitive communication equipment Planning the electrical installation appropriate provided the measure indi cated is carried out PDS of category C2 formerly restricted distribution in first environment is intended to a fe be installed and commis sioned only by a profes sional person or organization with necessary skills in installing and or commissioning PDS includ ing their EMC aspects For power converters with out additional components the following warning applies This is a product of cate gory C2 under IEC 61800 3 2004 In a domestic res idential env
97. inal 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 3ADWOOO194R0601 DCS800 Hardware Manual f e Voltage ripple of Upc voltage depending on operation modes 111 0 75 4 0 5 single phase half controlled Voltage ripple Vsec 0 25 three phase half controlled o DCS LINK communication U dc field 5x three phase full controlled The field converter is controlled from armature converter via DCS link serial communication based on CAN hardware Fex4 DCSLink dsf X1 f 24 V 200 mA 1100 3 1100 2 Termination 200 kOhm Node address is set by S800 digit 0 S801 digit 10 Same node address must be selected in the corresponding armature converter S800 ki Supply Remarks 124 V lt 200 mA 24 V grounded supply f SDCS FEX 4 communication emarks Bus termination 1100 1 ON 120 ohm 1 OFF no termination Ground termination 1100 2 ON 200 kOhm R C ground termination 73 ON 0 Ohm ground termination 2 3 OFF no termination node address 00 is not possible example node address 13 gt S800 3 and S801 1 Selection of communication speed is set by 81100 1100 6 1100 5 S1100 4 Baudrate Selection
98. ing 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 Al4 by a current transformer Planning the electrical installation 3ADWOOO194R0601 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
99. installation These notes are intended for all who install the drive Handle the unit carefully to avoid damage and injury e DCS800 Size D4 D7 The drive is heavy Do not lift it alone Do not lift the unit N 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 e 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 e Ensure sufficient cooling e Do not fasten the drive by riveting or welding Safety instructions 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 A 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 disco
100. intenance 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 10 Note e 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 11 Table of contents DG SeDO Drive Manuals cux d pee coe Eur xe PIN ot sa AS VER Sek EAR Sah RH 2 Safety instructions What his chapter COMANNS ette cutis sth Env rece a re Rog RG eee he a e D CR RR 5 To which products this chapter applies 00sec tee 5 Use of warnings arid NOS is clas rapta rs go hes RA e MEHR Sees whinge babe POR 5 Installation and maintenance work sese 6 Eje CMT 7 FIBrS Opt cables wa te e a uou ou Do ee Led T a BRB a TE A AT D 8 Mechanical installation seomair a ta Ade 8 STAM ONE ores ewe di E a edo e seda m E E E fe E Se ae A 9 Table of contents The DCS800 What this chapter contalris css ex ei
101. ironment this product may cause radio interference in which case supplementary miti gation measures my be required To other loads e g drive systems Case referenced EMC analysis The field supply is not depicted in this overview diagram For the field cur rent cables the same rules apply as for the armature circuit cables emv_clssif_b dsf Legend 4 Screened cable 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 lt Unscreened cable with restriction 3ADWOOO194R0601 DCS800 Hardware Manual f e 39 on board field exciter lon using Wiring the drive according to this diagram offers the highest degree of monitoring functions done by the drive Converters D1 D4 drive configurat jSp pr T sue gsod ue JOJO N ae ep abed ye Guimeup ees uoneuvojui Jeyuny puaba7 10j0801 ME asny ki ERTI a en sj el 94 aan 1349x play pweoq uo ainpou JeueAUO9 008soa siena abeyon uonduosepees amp A 400 90a soa voa 00 zoa loa S euJua eyerpeuuejut ese 8134 JI einpoui 2q 18 you
102. ki X1 3 H SDCS FEP 1 500 V SDCS FEP 2 690 V x23 HS t X31 kz 1 2 m parts not built in at 2 Q unit R3 jumpered T l i i i i i H H 1 H H B B NE H Kra red 1 B i xi2 grey i H e po 1 H i i H 1 H 1 i l i l DCF505di d dsf Output X4 1 2 Potential isolated by relay NO contact Contacts no protected Contact rating AC 60 V 50 mA DC lt 60V 50 mA line potential SDCS FEP 1 FEP 2 Fepl 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 Accessories 3ADWOOO194R0601 DCS800 Hardware Manual f e Dimensions Overvoltage Protection DCF 505 0140 0520 51 DCF 505 1200 51 DCF 506 0140 0520 51 Dimensio
103. l 2 3 no termination park position 3 Ground termination R x54 1 A S2 2 4 200 kOhm R C ground termination 2 wD 1 3 0 Ohm ground termination 3 RxD J p 4 Inotermination park poston RS 485 communication Remarks DSL 4 dia a dsf no isolation Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 81 Digital I O board SDCS IOB 2 As described at the beginning of the chapter there are I O via SDCS IOB 2x IOB 3 and SDCS CON 4 various options for configuring the inputs outputs The board IOB 2x has 8 digital inputs and 8 digital ODE PE outputs There are three different types existing which differ at the input voltage level ap 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 The cable length between X1 X1 and X2 X2 outside the DCS module They must be mounted in a is max 1 7 m D1 D4 converters way that the conductive supports have a good con is max 4 m screened required for D7 converters nection to ground of the installation between X1 X3 is max 0 5 m because of EMC rea sons See chapter Other cables SDCS CON 4 SDCS IOB 2 Layout and jumper settings of the SDCS IOB 2x board m
104. l as the drive main circuit from other low voltage circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 52 Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 53 Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive qualified electrician Follow the Safety instructions on the first pages of this manual A WARNING The work described in this chapter may only be carried out by a 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 main
105. levation 1000 m above M S L gt 1000 m above M S L 100 without current reduction with curr reduct see Fig below Size Sound pressure level Lp 1 m dis Vibration Shock Transport in Short circuit withstand rating tance original Package The DCS800 is suitable for use in a circuit capa ble of delivering not more than as module enclosed conv as module D1 55 dBA 54 dBA 1 2m 65 kA rms symmetrical amps at maximum D2 55 dBA 55 dBA 1 5 mm 2 9 Hz 7 g 22 ms 600 VAC D3 60 dBA 73 dBA 0 5 g 9 200 Hz 1 0m D4 66 70 dBA 77 dBA depending on fan D5 73 dBA 78 dBA 0 25 m 100 kA rms symmetrical amps at maxi D6 75 dBA 73aBA 03 mMm 2 9 res Shock monitor mum 600 VAC D7 82 dBA 80 dBA p 9 9 200 Hz Effect of the site elevation above sea level on the converter s load capacity 100 90 80 70 60 50 1000 2000 3000 4000 5000m Current reduction to 96 Effect of the ambient temperature on the converter module load capacity 110 100 90 80 70 j 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 direc
106. m Program is not running Normal situation Download firmware S5 1 2 Request download Firmware step 2 S5 3 4 7seg DCS8 dsf Terminal description Technical data 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 73 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 RS232 12V 12V Data format UART Message format Modbus Protocol Transmission method
107. mal 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 The cooling fan lifespan of the drive is about 50 000 operating hours The actual lifespan depends on the drive usage and ambient temperature Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts Fan replacement D6 D7 Maintenance see Service Manual 3ADWOOO194R0601 DCS800 Hardware Manual f e Technical data What this chapter contains 67 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 Hardware extension DCS800 1131 Programming target RA
108. mand Stop Mode dsf Anschl special a dsf E Stop reaction 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 Rp The contactor should be controlled by signal 6 03 Bit 10 The acknowledge can be connected to parameter 10 21 MainContAck 10 23 DCBreakAck y Main contactor 6 03 b 7 Dyn Brake 6 03 b 8 DCS800 Converter i on board field exciter module i DC Contact US 6 03 b 10 gt W DC cont us dsf Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 45 using on board field exciters th reduced components D4 400 500 V ion wi Wiring the drive according to this diagram gives the same control performance but a lower degree of Converters D5 using FEX 425 Int field exciter but externally supplied flexibility Dynamic Braking keeps the main contactor K1 in state ON during braking Converters D1 Drive configurat jeusa x9 perddns 4eyoxe pay 1u G2v X34 Sa b NId Jeuoxe pjey preoquo 7q 1d 008890 Ajddns pjey eseud e e Jo v09 6084OQ SHUN Ajddns pay 19618 ixou eui esn sjueuno ple JeuBiu 104 v 92 0Z SL 9 0 dn sjuauno pel eAI IM pue A SZS 0 dn sabeyon eui ye pesn eq ueo pq La Jeuoxe pray preoq uo SUL A 008 gt Gq pue A SZS5 ba La adh Uon
109. ms ainssalg ba Avz ela Ia 910 sia via ela Zia LIG lovi ZOV LOV ETTE ASLL I in i 9A ELNO 4 p NOO preoq jouuog X8 WNOD peoq i uogeounwwon so DI 9 tax 02 023 dois 4 uawa vi 93V A 3 P cd El 1HVIS NO Z 96X red EVE l om fi veo dois 4 340 eL an AOE Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 2 phase l13 E AT wo oi i ki ja e 0 ib 1 f 4 DCS8 ans 1 2c dsf Field exciter unit FEX 425 Int Voltage levels Li 2 Ls Seedescription y Li Legend DCS800 Converter module Ut Vi WIPE i CER fuse NENN reactor
110. n 0 78 5 60 85 21 15 Set a 1135 e9 45 45 Bo Ze 2 150 69 55 55 26 o o B 150 68 76 ye B3 o 0 o i T 5 Size 4 E 139 a i TET Es 17 E I olders t 250x174x123 250x214x133 265x246x160 m 110 64 17043006 a daf 3ADWOOO194R0601 DCS800 Hardware Manual f e Line reactors IEC Line reactors type ND 01 ND 17 Line reactors u 1 for use in industrial environment minimum requirements low inductive voltage drop deep commutation notches 119 Line reactors NDO1 NDO6 are equipped with cables The bigger ones NDO7 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 Frequency 50 60 Hz Line reactors type ND 01 ND 06 Type reactor rated Weight Power loss recommended L lms Ipeak Voltage Fe Cu for armature uH A A Un kg W W converter type ND 01 512 18 27 500 2 0 5 16 DCS 0025 ND 02 250 37 68 500 3 0 7 22 DCS 0050 ND 03 300 3
111. n on the type designation label of the drive to verify that the unit is of the correct type The label includes an IEC rating gULys 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 Rated input voltage Rated internal field exciter current Rated input current Rated output current Rated fan voltage Plus code Mechanical installation 3ADWOOO194R0601 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 The wall should be as close to vertical as possible of non flammable material and strong enough to carry the weight of the unit Check that there is nothing on the wall to inhibit the installation Floor The floor material below the installation should be non flammable Free space around the unit Required free space around the drive to enable cooling air flow service and maintenance see chapter Dimensional drawings Cabinet installation The required distance between parallel units is
112. nd 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 ON MCW 7 01 RUN oO ET USED MCW RUN LL RESET Pa 704 HWI O used ON Aa Main Control Word RUN i H RESET local H remote command peers location 10 01 gen ctrl cmd dsf b Generation of control and monitoring signals The main contactor K1 for the armature circuit is controlled by a dry contact DO 8 located on the SDCS PIN 4 Status of fans and fans klixon can be monitored by means of fans ack signals MotFanAck 10 06 and ConvFanAck 10 20 c OFF2 OFF3 Stop function Beside ON OFF and START STOP the drive is equipped with two additional stop functions OFF2 and OFF3 according Profibus standard OFF3 is a scalable stop function rampstop max torque stop dynamic braking to perform stop category 1 This function should be connected to the E STOP
113. ng marking SDCS IOB x D SDCS CON x 1 IOB2 3 screened flat cab dsf Accessories 3ADWOOO194R0601 DCS800 Hardware Manual f e A4 EP ED P I IP SADWO000194R0601 Rev F 10_2008 ABB Automation Products Wallstadter StraBe 59 68526 Ladenburg e GERMANY Telefon 49 0 6203 71 0 Telefax 49 0 6203 71 7609 www abb com motors amp drives 194R0601A8410000
114. nnecting device disconnecting switch instead use the control panel keys and Q 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 ma
115. nnection to overriding control Nxxx fieldbus adapter I I I 3 o I I I E a o x o o o 1 a 9 OQ Go 82 SS amp E amp E ER EI gt lx gt z slz sl 3 5 85 s 5Is 5 I ir ETR grey Fieldbus a o E x P x o o o 1 Q ao QA Q QA QA Q E K amp E amp amp EI gt Jes Jes sls gt z z 3 3 5 8515 ssl 5L 8 5 I t Y Ch3 Ring connection to PC tool DriveWindow max 20m instead of DriveWindow NETA internet module can be connected see Manual 3AFE64605062 E 7 socs comx grey TxD 5 a grey TxD r p SDCS COM 8x I I I 2 I I I lt 5 x T x o o o o Q Q Q Q B B B B B B 2 gt ESL s I BG e 15 68 JTL B plastic optic fibre 77 com8 bus conn a dsf I I I I I I 2 i z 2 loz i z H o o o il v o o o I 222 22 22 24 ye t 8 8 8 8 2l gt lez gt lee gt gt B gt gt lez gt gt es e Pe a os os efe on J IN 7 plastic optic fibre Key PCI PCMCIA adapter PC 3ADWOOO194R0601 DCS800 Hardware Manual fe SDCS COM 8 Rev D and higher com8 bus conn a dsf Technical data 78 Ch3 Star connection to PC tool DriveWindow Plastic opt fibre 30 m SDCS COM 8 Rev D and higher max 20 m instead of Drive Window NETA internet module can be conne
116. ns in mm Weight appr 8 kg Overvoltage Protection DCF 506 1200 51 DCF 506 1500 51 DCF 506 1500 71 Dimensions in mm Weight appr 20 kg 117 Sf gt 20 SDCS FEP 1 500 V SDCS FEP 2 690 V 3ADWOOO194R0601 DCS800 Hardware Manual f e lt lt 42 I 145 I 145 MB 520 a dsf E BEEN LIL LI MILII ATT EMAS HH MEA MB_1500_a dsf Accessories 118 Fuses and fuse holders IEC Accessories Type Resistance mQ Fuse F1 Size Fuse holder 7 55 170M 1559 21 20A 660V UR 0 OFAX 00 S3L isis 170M 1561 15 25A 660V UR 0 OFAX 00 S3L 170M 1564 6 50A 660V UR 0 OFAX 00 S3L 170M 1565 4 63A 660V UR 0 OFAX 00 S3L 170M 1566 3 80A 660V UR 0 OFAX 00 S3L 170M 1568 1 8 125A 660V UR 0 OFAX 00 S3L 170M 3815 0 87 200A 660V UR 1 OFAX 1 S3 170M 3816 0 59 250A 600V UR 1 OFAX 1 S3 170M 3817 0 47 315A 660V UR 1 OFAX 1 S3 170M 3819 0 37 400A 660V UR 1 OFAX 1 S3 rst 170M 5810 0 30 500A 660V UR 2 OFAX 2 S3 170M 6811 0 22 700A 660V UR 3 OFAX 3 S3 170M 6813 0 15 900A 660V UR 3 OFAX 3 S3 170M 6163 0 15 900A 660V UR 4 170H 3006 170M 6166 0 09 1250A 660V UR 4 170H 3006 Dimensions mm Size 0 4 Size fa c d e l
117. oad with DCS800 S01 and 2 Q Overvoltage Pro tection DCF 505 DCF505b1 e dsf 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 C1 DCS800 S D1 9 Overvoltage protection DCF 506 Motor field supply with DCS800 S02 and 4 Q Overvolt age Protection DCF 506 Assignment Field supply converter to Overvoltage protection unit for motor fields Field supply converter Overvoltage Protection 2 Q 500 V DCS800 S01 0020 05 DCS800 S01 0065 05 DCS800 S01 0090 05 501 0045 05 DCF506 0140 51 DCS800 S01 0180 05 DCS800 S01 0405 05 DCS800 S01 0315 05 DCF506 0520 51 4 Q 500V DCS800 S02 0025 05 DCS800 S02 0075 05 DCS800 S02 0100 05 DCS800 S02 0050 05 DCF506 0140 51 DCS800 S02 0200 05 502 0350 05 DCF506 0520 51 DCS800 S02 0450 05 Inductive load supply Overvoltage Protection for other applications 4 Q 500V DCS800 S02 1200 05 DCF506 1200 51 DCS800 S02 1500 05 4 Q 690V DCS800 S02 0900 07 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 3ADWOOO194R0601 DCS800 Hardware Manual f e Accessories 116 Diagramm x22 grey Kk
118. of armature kBaud converter param 94 02 OFF OFF OFF 20 0 OFF OFF ON 50 1 OFF ON OFF 125 2 OFF ON ON 250 3 ON OFF OFF 500 4 ON OFF ON 800 5 ON ON OFF 888 6 ON ON ON 1000 7 see Parameter 94 08 94 09 3ADWOOO194R0601 DCS800 Hardware Manual f e S801 Switch 0 9 dsf Accessories 112 Accessories 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 green and yellow toggling X times yellow Y times green X 1 Y 1 Y 2 X 2 Y 1 Y 2 Y 3 Y 5 Y 6 Y 9 Y 12 Y 14 Y 15 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 Alarm phase missed Alarm maximum temperature heatsink Fault Fault Fault Fault Fault Fault Fault Fault Fault DCS link serial communication failed Synchronization fault Overcurrent Field AC supply voltage lt 30V Field AC supply voltage lt 650V maximum temperature heatsink Au
119. onusuoo 19119A009 NOSSO Y JO pipea si wesBerp Bum ay sjueuoduioo jo uonoosjos 1030891 NEN esnj E Jsp az sue gsod puobo1 i ainpow pieoq uo i NId Jeuenuoo E WUN jeyoxe PI 00esoa meanbguoojeqjuE neu uo Bupuadep 1 A ddns samog b NOD peoq josuog 029 ra ej D E mi Do aan an n ZHOS A007 Apldns xny Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual fe 46 Fan cooling Fan assignment for DCS800 Converter type Model Configuration Fan type DCS800 S0x 0045 04 05 D1 1 2x CN2B2 DCS800 S0x 00140 05 05 DCS800 S0x 0180 04 05 D2 1 2x CN2B2 DCS800 S0x 0260 04 05 DCS800 S0x 0315 04 05 D3 1 2x CN2B2 DCS800 S0x 0350 04 05 DCS800 S0x 0405 04 05 D3 2 4x CN2B2 DCS800 S0x 0520 04 05 DCS800 S0x 0610 04 05 D4 3 1x W2E200 230 V DCS800 S0x 0820 04 05 DCS800 S0x 0610 04 05 D4 3 1x W2E200 115 V DCS800 S0x 0820 04 05 Pluscode E171 DCS800 S0x 0900 04 05 D4 3 1x W2E250 230 V DCS800 S0x 1000 04 05 DCS800 S0x 0900 04 05 D4 3 1x W2E250 115 V DCS800 S0x 1000 04 05 Pluscode E171 DCS800 S0x 0900 0y D5 4 D2E 160 DCS800 S0x 2000 0y D
120. puts 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 tem perature measuring devices If these boards are in use they have to be mounted outside the DCS module They must be mounted in a xi xi way that the conductive supports have a good con E Fo nection to ground of the installation SDCSIOE SIT SOUS ee SUES OB Sa The cable length between X1 X1 and X2 X2 E 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 rea sons SDCS CON 4 SDCS CON 4 Layout and jumper settings of the SDCS IOB 3 board 233 5 pecans supports SDCS IOB 3 xi Functionallity of analogue inputs S4 Pulse encoder supply Paralleingof gan 1 x gain 10 Residual Ch 500 2 between current 5V 12V input terminal 10V 10V 1V 1V measure for 0 4 20 mA ment X3 11 X3 12 1 N R H lt cos SS Na Temperature sensor supply P 0 TC PT10 1 5 mA 5mA Ee ERE 3 4 3 la Al4 S1 9 10 _ 8 1211 12 S1 13 14 S10
121. r Questionnaire 3ADWO00253z x DCS800 E Panel Solution Flyer DCS800 E Panel solution 3ADWOOO210 x Hardware Manual DCS800 E 3ADWOOO224 x DCS800 A Enclosed Converters Flyer DCS800 A 3ADWOOO213 x Technical Catalogue DCS800 A 3ADWOOO198 x Installation of DCS800 A 3ADWOOOO91 p DCS800 R Rebuild System Flyer DCS800 R 3ADWOOOOO7 x DCS800 R Manual 3ADWOOO197 x DCS500 DCS600 Size A5 A7 C2b C3 and C4 Upgrade Kits 3ADWOOO256 x Extension Modules RAIO 01 Analogue IO Extension 3AFE64484567 x RDIO 01 Digital lO Extension 3AFE64485733 x AIMA R slot extension 3AFE64661442 x Serial Communication Drive specific serial communication NETA Remote diagnostic interface SAFE64605062 X Fieldbus Adapter with DC Drives RPBA PROFIBUS 3AFE64504215 x Fieldbus Adapter with DC Drives RCAN 02 CANopen Fieldbus Adapter with DC Drives RCNA 01 ControlNet 3AFE64506005 x Fieldbus Adapter with DC Drives RDNA DeviceNet 3AFE64504223 x Fieldbus Adapter with DC Drives RUMBA MODBUS 3AFE64498851 x Fieldbus Adapter with DC Drives RETA Ethernet 3AFE64539736 x x gt existing p gt planned Status 10 2008 DCS800 Drive Manuals List_h doc DCS800 Drives 20 to 5200 A Hardware Manual 3ADW000194R0601 Rev F EFFECTIVE 15 09 2008 2008 ABB Automation Products GmbH All rights reserved 3ADWOOO194R0601 DCS800 Hardware Manual f e 3ADWOOO194R0601 DCS800 Hardware Manual f e Safety instructions What this chapter contains This chapter contains
122. re erer eee 26 Planning the electrical installation Table of contents 3ADW000194R0601 DCS800 Hardware Manual f e 12 What this chapter COMAINS sesi Sid AA betes BARE A A aid PE hae ees 27 To which products this chapter applies lm Rar RE ERREUR ERREUR eee a ed x 27 OPptons Tor TAS drive sue nut iras E ers al a dra Re PC a ER curetur uod 27 ENISATE AGIONE S29 os setis Oto o Mic uM ore A OM eda ii oU Mr ba De 27 liie reactor rise cms thal R a Pa ea teo Sox eat oid em Pan 29 Aspects of fusing for the armature circuit and field supplies of DC drives 30 General ax es vies tiger ls kn 30 Conclusion for the armature Supply soi eL RET Rr e W RO ALE RERO REDE 30 Conclusion for the field Supply rmm xr RR ae xx Rma 31 Semiconductor type F1 fuses and fuse holders for AC and DC power lines 32 Fuses F3 x and fuse holders for field supply s e e vannen aonono 32 Single phase Transformer T3 for field supply to match voltage levelS 33 Single phase Commutating reactor L se ee kn un kk kan won kw w n kn non an kok kn non 34 Auxiliary transformer T2 for electronic system fan supply eeoeo 34 Residual current detection oce pases waa ate oS IR S exu Se Sawa i XE Rd 34 EME Ale Std RUE REP ES aa eiae e is reete stades 35 Thareecphase MONS we ee a de od uu n eee AON aa AAA dea EE Ea E 35 Converters D1 D4 drive configur
123. re 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 x N ES Ae N N x N N oO O k N O O o 3ADWOOO194R0601 DCS800 Hardware Manual f e Free space around the converter module optimum compromise II m Mi A Top view Cooling air outlet To avoid circulating air inside the enclosure it is recom mended to make sure the exhaust air leaves the enclo sure 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 connec tion can be made m Tm 777 MEME TM TI o 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 conver
124. re bridge of 6 or 12 thyristors e High ohmic measurement of DC and AC voltage e Interface for AC current transformer for current measurement e Snubber circuit for the thyristor protection together with resistor R1 on heatsink e Interface for heatsink temperature measurement with a PTC resistor e 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 e Measurement of DC field current the scaling is automatically selected via rated motor field current Snubber circuit are shared with armature bridge e Fuses F100 F101 F102 for cable and motor field protection e 600 V converter are always without Onboard field exciter Ratings AC voltage range 110 500 V 525 V AC insulation voltage
125. rques 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 nuunmnmumrmmrmsr 0 Drive motor connection box and other covers are in place Installation checklist 3ADWOOO194R0601 DCS800 Hardware Manual f e 64 Installation checklist 3ADWOOO194R0601 DCS800 Hardware Manual f e 65 Maintenance What this chapter contains This chapter contains preventive maintenance instructions Reference Service manual publ no 3ADW000195 Safety performing any maintenance on the equipment Ignoring the safety instructions can A WARNING Read the Safety instructions on the first pages of this manual before cause injury or death Maintenance intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Maintenance Interval Instruction Heatsink temperature check Depends on the dustiness of See Heatsink and cleaning the environment every 6 to 12 months Cooling fan change Every six years See Fan Maintenance 3ADWOOO194R0601 DCS800 Hardware Manual f e 66 Heatsink Fan 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 nor
126. s 97 5 70 1 Line potential X5 Y Jumper coding e supports are conductive input time constant diameter of all supports 4 3 mm 2ms 10ms 5 this dimension may vary 4 5 mm S7 DI7 A E depending on revision 2 2 e rr S8 Dis a TE W100 as printed circuit default value Topan a agf There is a card holder available as option for fastening the SDCS IOB 2 board For more information see chapter Dimensional drawings Technical data 3ADWOOO194R0601 DCS800 Hardware Manual f e 82 SDCS IOB 2x Software a F a p lt DOI eras lt Do2 A e s a rua DO4 a coh X51 ne Ed p lt DO5 sev p e A e o x olo salo v BH Q 2 NZ Za DO7 ja DO8 ne cu LI 681 Dix Z X6 1 a y T100N 681 ak 9 Wi M I b gt DI2 W3 W4 0 0 8 0 04 Mo A gt Dia W5 W6 0 0 8
127. s 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 6 C PE 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 ion U1 nmm _ V1 n mm wi Voltage shiftin y Earth fault case of earth fault earth fault volt shift dsf Supply voltage Check supply voltages of Aux X99 Fan Terminals AC voltage for field circuit U1 V1 W1 if used AC voltage for armature circuit U1 V1 W1 Connecting the power cables Grounding and 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 55 Location R Extension and Interface Modules Connect the signal cables as described below Ti
128. sformer 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 ND30 F3 1 built in Te L 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 ET Configurations for field supplies um l ND30 F3 3 built in gt F3 1 XN num FF ASP b dsf Planning the electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 wi
129. stallation 3ADWOOO194R0601 DCS800 Hardware Manual f e 37 EMC filters You will find further infor The paragraphs below describe selection of the electri the product s actual emissions mation in publication cal components in conformity with the EMC Guideline The EMC Guideline expects EMC to be taken into Technical Guide chapter The aim of the EMC Guideline is as the name implies account when a product is being developed however EMC Compliant Installa to achieve electromagnetic compatibility with other EMC cannot be designed in it can only be quantita tion and Configuration for a products and systems The guideline ensures that the tively measured Power Drive System emissions from the product concerned are so low that they do not impair another product s interference immu Note on EMC conformity nity The conformity procedure is the responsibility of both In the context of the EMC Guideline two aspects must the power converter s supplier and the manufacturer of be borne in mind the machine or system concerned in proportion to their ethe product s interference immunity 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 Medium voltage network Supply transformer for a resident
130. tage measurement uses 5 resistor 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 MQ resistors cutting out short circuit wires which are represented by low ohmic resistors Layout of the SDCS PIN 51 board U1 W1 to W5 V1 W6 to W11 W1 W12 to W16 C1 W17 to W21 D1 W22 to W26 Ifthere is a need for voltage adaptation all 5 chains must be han dled 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
131. ter module View from front left side right side mr air flow ir flow al 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 NN 20 N Nom L UN _ lt 50 SN ka a NI 4 ur 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 rec ommended to make sure the exhaust air leaves the enclosure Mechanical installation 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 OL c A Screened cable for IMR hardware interface connection IOB2 10B3 board is strongly rec ommended Provide sufficient grounding of card ij holder electronics power supply 10B2 10B3 o screened cables converter a control cables pressure switch DUCI t ITI A7 re air inlet b dsf A7 re air inlet b dsf Internal cable ducts are used for snubber circuit wiring Don t use
132. th rated currents up to 1000 A require external fuses Inunit sizes D5 D6 and D7 with rated currents of 900 A to 5200 A the branch semiconductor fuses are installed internally no additional external semiconductor fuses are needed The third column of the table below assigns the AC fuse type to the converter type In case the converter should be equipped with DC fuses according to the hints use the same type of fuse as on AC side at DC side C1 D1 Blade type fuses are used for all the converters construction type D1 D4 except the converters 610 A 680 A 740 A 820 A 900 A 1000 A Type of converter Size Fuse type Fuse holder Type Fuse Holder 2 Q Converter 4 Q Converter North America DCS800 S01 0020 04 05 DCS800 S02 0025 04 05 170M 1564 OFAX 00 S3L FWP 50B 1BS101 DCS800 S01 0045 04 05 DCS800 S02 0050 04 05 170M 1565 OFAX 00 S3L FWP 80B 1BS101 DCS800 S01 0065 04 05 DCS800 S02 0075 04 05 DA 170M 1568 OFAX 00 S3L FWP 125A 1BS103 DCS800 S01 0090 04 05 DCS800 S02 0100 04 05 170M 1568 OFAX 00 S3L FWP 125A 1BS103 DCS800 S01 0125 04 05 DCS800 S02 0140 04 05 170M 3815 OFAX 1 S3 FWP 200A 1BS103 DCS800 S01 0180 04 05 DCS800 S02 0200 04 05 170M 3816 OFAX 1 S3 FWP 250A 1BS103 DCS800 S01 0230 04 05 DCS800 S02 0260 04 05 D2 170M 3817 OFAX 1 S3 FWP 300A 1BS103 DCS800 S01 0315 04 05 DCS800 S02 0350 04 05 170M 5810 OFAX 2 S3 FWP 500A 1BS103 DCS800 S01 0405 04 05 DCS800 S02 0450 04 05 D3 170M 6811 OFAX 3 S3 FWP 700A See Not
133. these cable ducts for other cables or process signals Use cable straps for fan cable Do not have loose cables The air flow from fan will destroy the cables 3ADWOOO194R0601 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 3 Configuration A Line g When using the power converter a minimum of impedance is Fa PCC required to ensure proper performance of the snubber circuit A line reactor can be used to meet this minimum impedance requirement l The value must therefore not drop below 1 uy relative impedance Uy
134. tion 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 3ADWOOO194R0601 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 q the right side l air flow the back the left side ll I Tum air flow A O Cable entries the module must be fixed at the upper side with TMR Top Mounting Rail do not unscrew these bolts A6 li air inlet c dsf electronics power supply pressure control cables switch converter fan left and right side V III A Corm A6 li air inlet dsf 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 22 o O O ga o e e s step eg pele ox e Piae 250 A When mounting the right angle busbars or connecting cables directly please make sure the correct bolts a
135. tives see table below European Union Directive Manufacturer s Assurance Harmonized Standards Converter module Enclosed converter Machinery Directive 98 37 EEC Declaration of Incorporation EN 60204 1 EN 60204 1 93 68 EEC IEC 60204 1 IEC 60204 1 Low Voltage Directive 73 23 EEC Declaration of Conformity EN 61800 1 EN 61800 1 93 68 EEC IEC 61800 1 IEC 61800 1 EN 60204 1 EN 60204 1 IEC 60204 1 IEC 60204 1 EMC Directive 89 336 EEC Declaration of Conformity EN 61800 3 EN 61800 3 93 68 EEC IEC 61800 3 IEC 61800 3 Provided that all installation instructions concerning cable in accordance with in accordance with selection cabling and EMC filters 3ADW 000 032 3ADW 000 032 3ADW 000 or dedicated transformer are fol 091 lowed North American Standards In North America the system components fulfil the requirements of the table below Rated supply voltage Standards Converter module Enclosed converter to600V eseeULLising ULtypes on request www ul com certificate no E196914 Approval UL ys The spacings in the mod ules 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 e or on request gt 600 V to 990 V EN IEC xxxxx see table EN IEC types on request above for details see table Available for converter above modules including field exciter units
136. transformer input cannot be used for the field converters SDCS FEX 4 isolation only 600 V max Line reactor L3 F3 F3 T3 THIS 13 zzezBBRDO ss S O GI SES IEEE tn A PERMET Type AIBIC IDIh e G T3 01 T3 11 210 110 112 75 240 10x18 95 T3 02 T 3 12 210 135 112 101 240 10x18 95 T 3 03 l 5 7 x 5 T 3 04 260 150 144 123 330 10x18 95 E 51175117 x 5 T 3 05 T 3 15 for single phase for DCF503 0035 as well as FEX 425 Int Input voltage 500 V Frequency 50 60 Hz Type line reactor data L3 Weight Pow er L lems Ipeak loss uH A IA ko W ND30 2x 5500 16 16 1 1 8 Accessories 3ADWOOO194R0601 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 Input voltage 230 380 690 V 1 10 F2 Frequency 50 60 Hz Output voltage 115 230 V 1 O SS SSLBSARSES T2 NY IO 19 19 Type Power Weight Fuse F2 Isec Power loss SUI Je t taa a VA ka A A W T2 1
137. trical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 38 For compliance with the protection objectives of the German EMC Act EMVG in systems and machines the following EMC standards must be sat isfied Product Standard EN 61800 3 EMC standard for drive systems PowerDriveSys tem interference immunity and emissions in resi dential 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 Standards Second environment industry with PDS categories C3 C4 EN 61800 3 Not applicable EN 61000 6 3 satisfied on customer s request satisfied EN 61000 6 4 satisf
138. tt x at te voltages 500 600 V an i a 7 Wins 12 autotransormer is mandatory i d q ET AN q a i 5 i viw H viv i E i 7 3 3 s e T i el E 4h 38 3 38 4h 388 i UE Un i i Eum T ala T gt H O 3 l mm gt iy b i uf kff j 1 y E 53 88 gs l amp Tel 8 fel 8 fertl l 3 E 5 3 5 i VV th a ak LI fk Eg er WI gd ILC IDIII I Ope i NY NY NZINZ 8 EN INZ a E i a i A 3 O DAP E e e i amp HW conf FEX4 dsf i Lg o7 meme meme me meum Temm mmm mmm mmm meme mmm meme 4 l D1 Plus code S164 SDCS FEX 4 i Supply voltage i 5A i max 600 V i 35A FEX425 INTERNAL i i i max 500 V t z Be t a 1 phase 3 d a i 8 p al ES i ui al xi Ol xl a i NZINZ A i j AT LT i si B 8 ap 3 8 i a j AW 4 m Eat gt E i Dl sg wu FP di E gl l 3 Tel giel y ef l gt gt Pq E gt a i l EN EN LI ta i ENIPE I ELS E IL a i NY u NZINZ a aNZINZ a E i a E a S a ZO I ab 4 e 4 LS 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 114 Dimensions 170 6 kg 105 g o 2 Qu H
139. upply public mains plant s mains por The figure shows the arrangement of the switch off elements in the armature circuit converter You will find further information in publication l l I For field supply I see Fig 2 6 2 l Technical Guide chapter Aspects SI toy E D E ae 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 Semiconductor fuses fuses DCS converter DCS converter 4 Q resp 2 Q non regen 2 Q regenerative Semiconductor O fuses GY 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 4 quadrant bridge some of the fault sources may not always be applicable Due to special system conditions such as supply via an autotran
140. usable 9 Eee 9 99 gt A double shielded twisted A single mom twisted pair cable 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 3ADWOOO194R0601 DCS800 Hardware Manual f e 51 Connection of a motor temperature sensor to the drive I O A WARNING IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non conductive 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 leve
141. witch Preferred cable type DEVICENET Supplier Helu Kabel Germany type 81910PUR Belden USA type 3084A 120 ohm 1 1 4 W 120 ohm 196 1 4 W asf CAN Bus termination Electrical installation 3ADWOOO194R0601 DCS800 Hardware Manual f e 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 CAN_Bus_termination_c dsf DCS800 D5 Converter SDCS DSL FEX 425 Int 1100 2 Set bus Termination OFF termination ON S1100 1 closed Bus termination Termination OFF SDCS DSL FEX 425 Int 3 1 3 21 X53 next drive next converter e 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 X51 1 9424 V X51 2 90 V GNDB Set bus termination ON S1 1 2 closed Bus termination Cable length DCF803 0035 FEX 4 Set bus termination ON S1100 1 closed The cable length influences the maximum baudrate Baudrate max cable length
142. x atu xe r s Olve oldu Memory Card Slot 1 H aseyajul snqplel4 b Nid ex oo gt ess a 1823 a BRE 2 31 6538 o 00 a 3 X a 3 m _ 00 LL a1 e S e o a e m D L c o o o a c kiddns JOMOd T e L e L Joyuow 3nej uue3 19414 JWI optical fibre ta ta x0S 008S9d ALL A 082 W l vs 0 VSIN ZLE daJ E joued viowoa St IJAN Z0 VdQN Wi Gununou MOPUIM3ALIQ 100 9d CO a a L o l a A005 A00S The DCS800 3ADWOOO194R0601 DCS800 Hardware Manual f e 3Sp p mao sds gsoa Jouuojsuen Q J0 0891 mm asnj 4 A aAneuloje indjno 1ndui enBojeue Y indino dur jepp ar Ga zezSu sjueuoduioo jo uoneufisep LOUS p NOD Os ox pd puobe1 sed Gq Auo play oi ZQ pue 9q eseud eeJui 80l api UL wg uy soa 1 dred pasim 5 A i 28 j l a ae Ge i P amp Eis 3 X m rar o c E e o OOD c o aa c 3 o lt t o o P co 1 2 a S lt 8r 9t Nld O o ceo t E a ui 8b 9b Nld 5 i li y 998 19 u1 g 6 sngpjel4 S E t MOd 6X g 8 8 8 8 3 i Ie 3 aSa xos ooesoa J E 2 i aes L o n oO A ddns 5 dn i vs 0 VSIN 2 B L a vowoo zroad N Lal i i G c El Qa E 1 i l f p Gununou MopuiMeAug a i y o I za aid 100 9d A008 10juoui jnej uue3 touy J
143. xiliary voltage No RESET No RESET general hardware general software 3ADWOOO194R0601 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 X2 Description follows 1 not connected Signal level RS232 2 TxD Data format UART 3 RxD Message format Modbus Protocol 4 not connected Transmission method half duplex 5 SGND Signal ground Baudrate 9 600 Baud 6 9 not connected Number of Data bits 8 Number of Stop bits 1 Parity Bit odd 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 ais iia a A o kk n ee 1 E SDCS FEX 4 Plus code S164 i v F302 y 5A M RI po i i w F303 Wi 35A FEX425 INTERNAL i Supply voltage max 500 V s clicar aetna E er LL ume emi a ect EES A 1 or 3 phase for supply l g

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