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DCS800 Hardware Manual

1. 18122 ND15 16 c dsf H 2 CH 1o 1 th y y 2 5 _ alma 1 B X SIE ES y L Si di lt es cic 45 em e t ND7 to 12 c dsf 10 3 1 Type A B 1 I K L busbar 7 5 5 7 5 x 5 X ND 09 327 250 99 100 292 224 63 100 9x18 423 280 30 5 5 x 5 X ND 12 458 250 112 113 424 224 63 100 13x18 554 280 40x6 Line reactors type ND 13 14 Line reactors type ND 15 16 all busbars 40x10 all busbars 60x10 140 2 151 2 E 90 45 45 45 1 pe 3 4 M 3 da 5 82 N e DE i d e ae 4 5 5 3 123 2 5 8 8 147 83 213 15 9 4 g Y i LI C 4 dba 15 290 1 ji 150 2 40 ND13 14 c dsf 147 Last A A x x Accessories 3ADW000194R0511 DCS800 Hardware Manual e us 122 Line reactors type 401 ND 413 Line reactors for use in light industrial residential environme
2. lt X510 24V 5 X511 47 2 8 5 3 10k o TR 2 54 100 nF o I 4k7 9 2 ov X57 SDCS CON 4 ENCODER INPUT A lt X510 5 or 24V e 4 5 E 51 47 cox 3 E 5 8 10k zi o R 2 4 100 nF e 1 4 7 2 X52 E 4 5 57 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 5 or 12V or 24V X51 tera 190 10 AKT 5 TA 2 5 424N 9 Lo 4 7 8 22 GND o P X510 SDCS IOB 3 ENCODER INPUT A push pull lt al X57 lt lt 5 or 12V or 24V r m 5 1 1000 10 i 1k0 4 7 3 S X 5 HH 52 10k 2 5 d gt L To do 4k7 4 4 5 ul 52 GND X5 10 SDCS IOB 3 ENCODER INPUT A terminal X5 2 X5 4 X5 6 must be connecte
3. Type Resistance Fuse F1 Size Fuse holder 7 55 170M 1559 21 20A 660V UR 0 OFAX 00 S3L Deis 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 1S3 5202 2 170 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 a e 0 78 5 85 21 15 BEN 35 69 45 45 PO Fa 2 150 69 55 55 6 B 150 668 76 ye 83 o 9 5 Size 4 5 11 I I 15 Es 17 ill Main dimensions of fuse holders Fuse holder HxWxD mm Protec tion 00 S3L 148 112 111 20 OFAX 1 S3 250x174x123 IP20 OFAX 2 S3 250x214x133 IP20 OFAX 3 S3 265x246x160 20 110
4. DCF505di d dsf Output X4 1 2 Potential isolated by relay NO contact Contacts no protected Contact rating AC lt 60 50 mA DC lt 60 lt 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 3ADW000194R0511 DCS800 Hardware Manual e us Dimensions Overvoltage Protection DCF 505 0140 0520 51 DCF 505 1200 51 DCF 506 0140 0520 51 Dimensions 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 117 220 SDCS FEP 1 500 V SDCS FEP 2 690 V 3ADW000194R0511 DCS800 Hardware Manual e us lt lt 42 I 145 I 145 MB 520 a dsf E MN MB 1500 a dsf Accessories 118 Fuses and fuse holders IEC Accessories
5. Rated current scaling 12 9 OFRO ihi ojo ojo Zero current detection code tab PIN1 PIN20 PIN51 e dsf Construction type 0 06 07 D7 D7 Conv nom voltage V Y 4 400V Y 6 600v Y 7 6907 Y 4 400V Y 6 6007 Y 7 690v 8 8007 9 Yat 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 51 25 o_o 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 5 9 and not lower than 55 for 4 Temp sensor coding R 57 as a temp sensor for D5 D6 D7 CL 33 40 woo oo 109 0 Board used as a spare part indicates a removed jumper e default all jumpers Wxx Rxx are condition ensure the correct converter type related settings Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 95 Typical armature circuit thyristor converter diagram with SDCS PIN 48 and SDCS
6. 76 0 70 0 7 0 Snap on mounting on DIN 46277 rail lt 50 0 5 5 0 60 0 3ADW000194R0511 065800 Hardware Manual e us DC DC transducer A92 Principle circuit diagram of the DC DC transducer A92 17 6 appr 280nF 9 Input Output voltage voltage 20 10 appr 3 9kQ 7 STEPS POWER SUPPLY 230 2 15V Data Selectable voltage gains 675 810 945 1080 1215 1350 1620 VDC Switch position 7 6 5 4 3 2 1 Output voltage 9 84 5 mA Auxiliary power 230 V 15 95 50 60 Hz 3 W 06000000000 Clearance in air Auxiliary power to Output gt 13 mm Input Output to Auxiliary power gt 14 mm Insulation voltage 2000 V mm x n9999000000 Insulation test voltage 5000 V Ambient temperature range 10 70 Weight appr 0 4 kg The voltage gain and frequency response is especially designed for DCS800 converters Dimensions in mm Location of terminals Side view Buttom view 112 0 2 0 Gain selector 7 Transformer T90 Principle diagram of the transformer T90 99 1U 2N 206 205 204 203 202 201 o s 5 o ABERRA
7. a EL A Ou ra rO 0158 cy ES 3ADW000194R0511 DCS800 Hardware Manual e us 17043006 119 Fuses and fuse holders North America The table shows the recommended fuses and fuse holders for each converter type for the incoming three phase AC line If DC fuses are also required use the same type and size Type of Converter Fuse Fuse Holder Design 2 Q Converter 4 Q Converter North America single pole Figure DCS800 SO1 0020 05 DCS800 SO2 0025 05 FWP 50B 1BS101 1 DCS800 SO1 0045 05 DCS800 SO2 0050 05 FWP 80B 1BS101 1 DCS800 SO1 0065 05 DCS800 SO2 0075 05 FWP 125A 1BS103 1 DCS800 SO1 0090 05 DCS800 SO2 0100 05 FWP 125A 1BS103 1 DCS800 SO1 0125 05 DCS800 SO2 0140 05 FWP 200A 1BS103 1 DCS800 SO1 0180 05 DCS800 SO2 0200 05 FWP 250A 1BS103 1 DCS800 SO1 0230 05 DCS800 SO2 0260 05 FWP 300A 1BS103 1 DCS800 SO1 0290 06 DCS800 SO2 0320 06 FWP 500A 1BS103 1 DCS800 SO1 0315 05 DCS800 SO2 0350 05 FWP 500A 1BS103 1 DCS800 SO1 0405 05 DCS800 SO2 0450 05 FWP 700A See Note 1 1 DCS800 SO1 0470 05 DCS800 SO2 0520 05 FWP 700A See Note 1 1 DCS800 SO1 0590 06 DCS800 SO2 0650 06 FWP 900A See Note 1 2 DCS800 SO1 0610 05 DCS800 SO2 0680 05 FWP 900A See Note 1 2 DCS800 SO1 0740 05 DCS800 SO2 0820 05 FWP 900A See Note 1 2 DCS800 SO1 0900 05 DCS800 SO2 1000 05 FWP 1200A See Note 1 3 Use 3 for the AC side D
8. 53 Tungroundedisysiemns 1154 Dt nde RC 54 0 2 16 gt Une di iva anas dae Par a 54 Connecting the power cables oc hei RR eet eee ae Rune ew 54 Location R Extension and Interface Modules 55 Board etd Grete lode EE EAS 56 Pulse encoder 57 Pulse encoder 58 Connecting the signal and control cables 60 Routing the cables rel Rep ep x e RE add 60 vtm eco UE D CER REUS P LAU t i s dx a aor dun 61 Installation checklist GhecklISU dulces i 63 Table of contents 3ADW000194R0511 DCS800 Hardware Manual e us 13 Maintenance What ihis chapter coritalris 22526 Re Fo rta ra ED ER 65 Safely _ __ br Ede d 65 Maintenance interval iii i Uk xe e CX PX RA ORC RR e aa 65 HeatsInkzs act e eve ie ee EE ee bsc era nae Nd a RE Y ate es 66 FAM Pace ib tn eS a ed ee dac qu
9. 4 BH 2 NZ Za DO7 lt DO8 ne cu LI 681 Dix Z pa X6 1 esl 11004 681 ak 9 Wi gt DI2 4 0 0 8 O 0O9 A gt W5 We 0 0 8 0 0 9 7 8 a 015 w9 W10 hi A gt 016 Wii W12 0 0 9 0 04 A gt 017 W13 W14 ooo 8 RB gt W15 W16 X74 n 2 E J m 3 up to revision D from ro revision E on 4 48 conductive supporti 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 2250 V lt 3 A DC lt 24 V 3 A or 115 230 V lt 0 3 MOV protected 275 V K6 K7 Firmware potential isolated by optocoupler Switching capacity lt 50 mA external voltage x24 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 ot
10. E ccce aS EE max 500 V tz t i 1 i 7 i SEL Ap E 84 13 i zi 4 33 i ki mm 9 5 D 8 i ic 58 58 58 3 Tal gs a3 ef gt gt gt H i PS E ES 1 i NY u 7 4 4 i 5 pr a a 4 Cona 1 8 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 3ADW000194R0511 DCS800 Hardware Manual e us 114 Accessories Dimensions 170 100 105 27 e 9 x s 21 3 2 1 Soo 35 5A DI urviwi DCF803 0035 earthing M6 3ADW000194R0511 DCS800 Hardware Manual e us DCF803 0035 dsf Terminal 100 101 cross section max AWG 7 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 hi
11. SDCS DSL 4 Software Supply Remarks x8 CON 4 24 200 24 V grounded supply for 425 510 V ENTERA internal and DCF803 0035 field 2 ac exciter units short circuit protected X523 250 2 E CANL 3 2 0 V4 DSL communication Remarks 52 Bus termination 344 Termination 200 kOhm S1 1 2 120 ohm 2 ico 2 3 no termination park position 3 Ground termination R X543 52 2 4 200 kOhm R C ground termination 2 1 3 0 Ohm ground termination 3 RxD 4 termination park position RS 485 communication Remarks DSL 4 dia a dsf no isolation Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 83 Digital board SDCS IOB 2 As described at the beginning of the chapter there are 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 outputs There are three different types existing which differ at the input voltage level SDCS IOB 21 24 48V DC SDCS IOB 22 115 V AC SDCS IOB 23 230 V AC The inputs are filtered and galvanically isolated by using optocouplers Inputs can form two galvanically separated groups by using either X7 1 or X7 2 If these boards are in use they have to be mounted Th ble length bet X1 X1 X2 X2 outside the DCS module They must be mounted in E able length petween and Xa Xas
12. 6 i A i EINO 8 00 sa ent A i M 9 Bet TESI Rete 2 2 2 ASH 84 793 ld RM et S 94 aan N 1 5 3ADW000194R0511 DCS800 Hardware Manual e us Planning the electrical installation 41 Converters D1 D3 3 phase exciter configuration ing ffers the highest degree of monitor iagram o is d ing to th ive accord the dr functions done by the drive iring je Buiweip ees ayun 3Sp v sue 8524 E 69150 epoo 5 10 jejeure Jed Aq paqes p ex 2 01 Jjeyoxe uo 909490 008594 si jeu uiu perddn pu Ly ped
13. Svr X6 1 4K75 4712 215 gt E I 1 DH 2 1 10 gt 02 3 10 gt 03 4 1 10 gt 5 10 5 gt 05 6 10 lt gt DI6 7 33 gt 017 8 Hr 3 3ms gt 08 9 24 V lt 125 mA 10 x X7 1 Relay driver lt DO1 2 Relay driver lt 002 i s fisaydie lt Dos 4 Relay driver lt DO4 5 Relay driver lt 005 6 Relay driver lt DO6 7 pM Relay driver lt 007 8 IGND Con4 I O a dsf Technical data short circuit protected gain can be varied 15 steps between 1 and 4 by software para meter 3ADW000194R0511 DCS800 Hardware Manual e us Resolution Input output Scaling Com Remarks bit values by mon Hardware mode range 90 270 15 sign 30 90 V Firmware 15 V 8 30 V 15 sign 10 0 10V Firmware x15 V 15 sign 10 0 10V Firmware x15 V 15 sign 10 0 10V Firmware x15 V 15 sign 10 0 10V Firmware 15V Power 10V lt 5 mA ext use 10 V lt MA Je g refer pot 11 sign 10 0 10 V Firmware x5 mA 11 sign 10 0 10 V Firmware x5 mA 10 0 10 Firmware lt 5 mA 4 V gt 325 of Hardw 99 03 max 230 of 4 05 Encoder supply Remarks Inputs not isolated Impedance 120 9 if selected max frequence x 300 kHz 5V 250
14. sie SIN IR Dot Bee EU 34 Three pHase 34 Converters 01 04 drive configuration using board field exciter 38 Converters D5 drive configuration using FEX 425 Int field exciter 39 Converters D5 D7 drive configuration using external field exciter DCF803 DCF804 40 Converters 01 03 3 phase field exciter 41 START STOP and E STOP 42 Drive configuration with reduced components 44 Fam Cooling eL 45 Thermal overload and short circuit protection 47 Mains cable AC line cable short circuit 47 Cross sectional areas Tightening 48 Typical Cable Sizing and Tightening Torque North America 49 Selecting the control cables 8 irte tem 50 DCS800 panel cable 7 wid Duck mare 50 Connection of a motor temperature sensor to the drive 51 Electrical installation What this oritur i ROS be USB FAIR Me and 53 Checking the insulation of the
15. SDCS COM 81 10Mb 5Mb 10 Mb 10 other interfaces Ch 0 2 3 50 mA SDCS COM 82 from D 5 Mb 5Mb 10 10 Mb Fieldbus adapter Ch 2 3 50 mA modules Nxxx xx Color of optical components 5Mb gt 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 3ADW000194R0511 DCS800 Hardware Manual e us 78 Ch2 SDCS COM 8 Master Follower connections SDCS COM 8x SDCS COM 8x SDCS COM 8x D200 Eve grey TxD com8 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 Tspcs cower E SDCS COM 81 TA 7 CH2 CH1 SHE 9 CH2 CH1 e N o ra 5 rj 1 1 1 a Q 2 22 B 2 d 8 gp 22 22 2 28 2 S IS ssl e sel e 2 lh lele 5 85 5 85 5 L LE 5 s l 8 5 5 L9 k IL 5 5 L5 L5 20 m SDCS COM 8 up to Rev C plastic optic fibre 30 m SDCS COM 8 Rev D and higher x NDBU 95 30 m plastic optic fibre AC80 Ch0 Drive Bus AC 800M CI 858 Drive Bus Module comicus dag PEC800 858 Drive Bus Module
16. Mao vo 1H me Less 1 T YT oT T 8 5205 sjauueyo 1ueuieunseeui OG OV gt I I i i n 51515 cie cioe cie cie cie eios sip sis 616 uas 05 05 Ue 02020 05005 020 Ue 508 d i amp cele UF UE Ajddns xne wor f 8 A 4 b 4 5 5 251 5 i 19 quewainseew jueuno 88 I I ees VW G 54015152 YP7 4 Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 98 Technical data
17. o Pin4 layout a dsf K301 K400 F400 F300 itty X96 X20 TOT Relay Input output Aux DOS8 supply 89 Power supply The power supply X99 operates on fly back configuration The internal DC link voltage is 310 V The power supply automatically adapts the supply input voltage either 230 V or 115 V and switches relays K301 In case of varying 230 V input voltage e g generator network the operation must be clamped to 230 V by Jumper S1 2 3 230 V operation Technical data AC Supply voltage 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 120 120 is available on request via your ABB tion representative Power loss 60 W 60 W Inrush current 20A 20ms 10A 20 ms recommended fus 6 AT 6 AT Ing Mains buffering min 30 ms min 30 ms Powerfal O5V 18 51 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 3 A DC 24 V 3 A or 115 230 V 0 3 A in output circuit b dsf X99 Input circuit PI
18. F3 1 Fuse KTK25 included in FEX 425 Int inside 05 converter module Fuses and fuse holders for 2 phase field supply Field conv Field F3 1 F3 2 3 3 Fuse Holder current North America DCF803 0035 170M 1558 OFAA 00 H10 10A FWP 10B 1BS101 FEX 425 Int lE 12A 170M 1559 OFAA 00 H16 16A FWP 15B 1BS101 DCF803 lt 16 170M 1561 OFAA 00 H25 25 A FWP 25B 1BS101 DCF804 25 170M 1564 OFAA 00 H25 35 A DCF803 x35 170M 1564 OFAA 00 H50 50A FWP 50B 1 5101 DCF804 DCF803 lt 50 170M 1565 OFAA 00 H63 63A FWP 60B 1BS101 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 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 500 V 50 60 Hz fz type
19. 4 E a UU ued Bunsix3 4 Joog 9d A006 tc The DCS800 3ADW000194R0511 DCS800 Hardware Manual us 20 The DCS800 3ADW000194R0511 DCS800 Hardware Manual e us 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 information on the type designation label of the drive to verify that the unit is of the correct type The label includes an IEC rating cULys 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 3ADW000194R0511 DCS800 Hardware Manual e us 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
20. O _ i Q For addressing and automatic node numbering of the drives and branching units see DriveWindow documenta ny SETTING tion al xt G4 LONG 23 co Eo GI ai El o o Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 82 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 DSL 4 drw dsf Jumper coding 61 Bus termination 3 1 120 Ohm 1 3 1 no termination park position 1 S2 Ground termination 2 4 200 kOhm R C ground termination 2 4 0 Ohm R C ground 1113 termination H no termination park position default value
21. X3 3 21 Set bus termination ON 51100 1 closed Baudrate max cable length 50 500 m 125 500m 250 250m 500 100m default and recommended setting 800 50m 888 35m 1000 25m The bus is designed for cable length up to 50 meters Larger distances on request Electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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 Theunitis fixed properly on a vertical non flammable wall See Mechanical installation The cooling air will flow freely motor and the driven equipment are for start See Planning the electrical installation E All screen terminals are checked for tightness O All cable connections are seated properly ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation The drive is grounded properly The mains input power voltage matches the drive nominal input voltage The mains input power connections at U1 V1 and W1 and their tightening torques are OK Appropriate mains input power
22. 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 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 not fasten the drive by riveting or welding Safety instructions 3ADW000194R0511 DCS800 Hardware Manual e us Operation These warnings are intended for all who plan the operation of the drive or operate the drive Ignoring the instructions can cause physical injury or death or damage the equipment Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the base speed Do not activate automatic fault reset functions of the Standard Application Program if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault Do not control the motor with the disconnecting device disconnecting switch instead use the control panel keys and Q or commands via the I O board of
23. 5800 501 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 5601 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 5800 501 3300 10 3300 2551 3827 2428 3642 2458 4916 5800 501 4000 10 4000 2975 4463 2878 4317 2918 5836 1190 V Data on request as option Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 70 Current ratings IEC regenerative Unit type Ipci lbc u lbc m Ipc iv Size 2 continu 100 150 100 150 100 200 4 Q converters ous 15 min 60s 15 min 120s 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 97
24. The figure shows the arrangement of the switch off elements in the armature circuit 2 DE IL converter H poe You will find further information in publication Technical Guide chapter Aspects for fusing For field supply 1 2 6 2 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 Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 30 Conclusion for 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 condi
25. Unit sizes D1 D2 D3 and D4 with rated currents up to 1000 A require external fuses nunit 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 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 DI 170M 1568 OFAX 00 S3L FWP 125A 1 5103 DCS800 S01 0090 04 05 DCS800 S02 0100 04 05 170M 1568 OFAX 00 S3L FWP 125A 1 5103 DCS800 S01 0125 04 05 DCS800 S02 0140 04 05 170M 3815 OFAX 1 S3 FWP 200A 1 5103 DCS800 S01 0180 04 05 DCS800 S02 0200 04 05 170M 3816 OFAX 1 S3 FWP 250A 1 5103 DCS800 S01 0230 04 05 DCS800 S02 0260 04 05 D2 170M 3817 OFAX 1 S3 FWP 300A 1 5103 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 0
26. 44 th reduced components ion wi Drive configurat field exciters on board Int field exciter but externally supplied 04 400 500 V using Converters D1 Converters D5 using FEX 425 Wiring the drive according to this diagram gives the same control performance but a lower degree of flexibility Dynamic Braking keeps the main contactor K1 in state ON during braking jeusexe jul G2p X34 Sd 90 10 x 008890 pjeu eseud e e 08 08 00 SHUN Ajddns pjay 1 eui esn suauno 104 v 92 02 91 9 0 dn sjueuno pue A 626 dn pesn eq ued pq a uo A 0055 pue A gt vq Lg edA uononasuoo 008600 si eu sjueuoduioo AJojoeoi an E sue 8590 uO i i 900 soa voa ZO
27. DCS800 S01 0405 05 DCS800 S01 0315 05 DCF506 0520 51 4 0 500V DCS800 S02 0025 05 DCS800 S02 0075 05 DCS800 S02 0100 05 DCS800 S02 0050 05 DCF506 0140 51 DCS800 S02 0200 05 DCS800 S02 0450 05 DCS800 S02 0350 05 DCF506 0520 51 for other applications Inductive load supply Overvoltage Protection 4 Q 500V DCS800 S02 1500 05 DCS800 S02 1200 05 DCF506 1200 51 4 Q 690V DCS800 S02 1500 07 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 3ADW000194R0511 DCS800 Hardware Manual e us Accessories 116 Diagramm x22 grey X1 3 H SDCS FEP 1 500 V SDCS FEP 2 690 V x23 A t X31 9 1 2 1 parts not built in at 2 Q unit jumpered i i i 1 H B B NE B grey oi 1 H i 1 H
28. Digital outputs are forced low e Programmable analogue outputs are reset to zero OV Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 74 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 Program is not running Normal situation Download firmware 55 1 2 Request download Firmware step 2 55 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 tte 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 51 PIN 41 SDCS PIN 4 see chapter Technical data X17 and X300 are routine test connectors X1 and X2 are used to connect SDCS IOB 2 and SDCS IOB 3 board see chapter Technical data X33 is used to connect DCS800 Panel It can be connected direct via 4
29. Electrical data Power circuit AC Field input voltage 110 V 15 525 V 10 single or three phase AC input current DC output current Frequency same as DCS Converter module AC isolation voltage 600 V Line reactor external or shared with D5 armature converter Line fuses KTK25 for FEX425 internal external for DCF803 0035 DC output current 300 mA min 25 A FEX425 internal 35 A DCF803 0035 Powerloss 130 W at rated current Auxiliary supply DC input voltage 24 V DC Input current 200 mA supplied from SDCS DSL 4 X51 Buffering 10ms Control unit The control includes the following main blocks Micro controller H8 for current control synchronization and fault handling e 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 curren
30. Size D6 1900 3000 A Size D7 2050 5200 The DCS800 3ADW000194R0511 DCS800 Hardware Manual e us 16 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 code 5800 22 plus code Position X Y Z B Position Plus code Product series DCS800 A Type S0 Converter module IPOO RO Rebuild system EO Panel solution Enclosed converter X Bridge type 12 Single bridge 2 0 2 2 Double bridge 4 Q Y Rated current YYYY Rated current e g 0025 25 amps 22 Rated voltage 04 400V nominal rating in bold 05 500V 06 600V 07 690 V 08 800V 10 990V 12 1200V B Power connection Standard 01 06 L Leftside D7 Right side 07 Internal field exciter 5164 with internal field exciter external supplied only 05 25 A Rebuild kit 25 A 16 A configuration 05163 without internal field exciter only D1 D4 Fan voltage Size 04 Standard fan voltage 230 V 1 ph 5171 fan voltage 115 V 1 ph Size D6 Standard 400 V 500 V 800 V fan voltage 400 500 V 3 ph Standard 600 V 690 V fan voltage 525 690 V 3 ph
31. Ch3 Star connection to tool DriveWindow Plastic opt fibre 30 m SDCS COM 8 Rev D and higher 20 instead of DriveWindow NETA internet module can be connected see Manual SAFE64605062 Technical data 7 CH3 H CH1 Internet Ethernet grey grey grey TxD grey TxD Plastic opt fibre max 30m 200 HCS Plastic HCS opt fibre Silicat max 30m max 200 m lt adapter PC 12 NDPA 02 a 3ADW000194R0511 DCS800 Hardware Manual e us grey TxD bus conn a dsf 81 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
32. LX atu xe s oldu Memory Card Slot 1 H 4 gt 858 298 gt 2 568 o GAI 5 gt lt 2115 LL e 5 c o o a Ajddns T e L e 1 4911 optical fibre vara 00859 ALL A OEZ Pm vs 0 VSIN ZLE E jeued 2 il n 005 A00S The DCS800 3ADW000194R0511 DCS800 Hardware Manual us 3Sp p mao 545 8504 0 1010201 mm esnj gt 7 4 indjno indui enBojeue 2 andino ar E sjueuoduioo jo 5 s ox pd sed Gq Auo play oi pue eseud eeJui 80l UL wg soa pa sim m H a d 28 sss Fs gt amp Eis i x gt P 128 c o o P 9 2 4 gt gt 5 ui 8v 9t Nid i 5 5 4 S t MOd 8 3 8 5 8 5 i i X0S 008S90
33. further filters for 12 NF1 250 12 rents lFilter Field 30 1 250 30 single phase operation Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 36 filters You will find further infor 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 Compliant Installa 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 exclu
34. 5 5 z T 3 01 lt 6 A lt 7 A 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 T3 11 lt 6 A TAO 15 80 10 T 3 12 lt 12 A lt 13A 20 125 16 T 3 13 lt 16 A lt 17 A 30 150 20 T 3 14 lt 30 A lt 33 60 230 50 T 3 15 lt 50 A lt 57 A 60 320 63 690 V transformer input cannot be used for the field converters SDCS FEX 4 isolation only 600 V max fi Line reactor L3 for single phase for DCF503 0035 as well as FEX 425 Int Type L uH lms A line reactor data L3 Weight kg ND30 2x gt 500 16 I 16 SADWOO0194RO051 1 DCS800 Hardware Manual e us F3 2 222 501500 8358858 9 0 12 A B C DT h JG T3 01 1T 3 11 210 110 112 75 240 10 18 95 Y 3 5 x 5 T 3 03 5 7 x 5 3 04 260 150 144 123 330 10x18 95 T 3 14 295 175 176 141 380 12x18 95 3 05 3 15 gt 3 RE 37 52 Accessories 126 Supply transformer T2 for electronics and fan The supply transforme
35. FCI CI 810 Adapter module Technical data 3ADW000194R0511 DCS800 Hardware Manual e us Cho Connection to overriding control Nxxx fieldbus adapter I 3 ES 1 9 Go 9 E E gt lx gt 5 5 5 5 5 55 5 ir ETR grey Fieldbus E E x pei E amp E amp EI gt Jes Jes zl 2 5 5 5 8515 ssl 5 8 5 o Ch3 Ring connection to PC tool DriveWindow max 20 m instead of DriveWindow NETA internet module can be connected see Manual 3AFE64605062 E 7 grey 5 grey TxD p SDCS COM 8x I I 8 B B 2 gt ESL s Rel I SIL B plastic optic fibre 79 com8 bus conn a dsf I I I I I I i 2 12 i H o o o v o o o 222 22 22 24 ye 8 8 8 2l gt gt gt gt le gt gt gt IN 1 plastic optic fibre PCI PCMCIA adapter PC 3ADW000194R0511 DCS800 Hardware Manual e us SDCS COM 8 Rev D and higher com8 bus conn a dsf Technical data 80
36. Planning the electrical installation What this chapter contains ipe Bees eee see FEAR UC 25 To which products this chapter applies 25 soa ica star ade CEI XT Qn ca ee NT RD io RR RE CR 25 Table of contents 3ADW000194R0511 DCS800 Hardware Manual e us 12 25 LIME reactors iu dud PR a 27 Line reactors LL1 for North 28 Aspects of fusing for the armature circuit and field supplies of DC drives 29 d dot dum de Sheet 29 Conclusion for the armature supply 29 Conclusion for the field 5 30 Semiconductor type F1 fuses and fuse holders for AC and DC power lines 31 Fuses F3 x and fuse holders for field 31 Single phase Transformer for field supply to match voltage 32 Single phase Commutating reactor 33 Auxiliary transformer T2 for electronic system fan 33 Residual current detection s oF ts ecol E cs ae po hae SLM Ar 33 EWC filters rie
37. 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 2600 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 Sizing Note 1 The ratings apply at ambient temperature of 40 C 104 F In lower temperatures the D5 D6 D7 ratings are higher except Imax Note 2 Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 C 104 F or the drive is loaded cyclically Duty cycle Technical data locu 3ADW000194R0511 DCS800 Hardware Manual e us 71 Current ratings North America non regenerative Type code Frame Input RMS interna m m oe Size Current le z Issipation TNR E ui fa 45 2Hd current ft min BTU Hr 500 Vdc Di 375 53 61 30 54 54 751 19 12 75 1M 60 104 D2 205 125 D3 264 150 204 825 200 D4 490 300 25A e sE ni ok ni ne 795 500 ps 979 1105 700 950 600 851 550 25 E maus EE 1632 1904 1100 1480 900 1479 900 Exierna em so 57 Exierna 600 Vdc 268 200
38. 50 60 Hz external supply lt 500 V DCF803 0035 Pid d FEX 425 Int lt 12 19 02 lt 16 A T 3 03 DCF803 4 0050 230 T 3 04 DCF803 4 0050 lt 50 A T 3 05 Uprim 600 V DCF803 0035 2 ik FEX 425 Int SIE A lt 16 A T 3 13 Uprim 5590 V DCF803 4 0050 lt 30 A T3 14 DCF803 4 0050 lt 50 A T3 15 Autotransformer data details see chapter Technical Data Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us autotransformer 33 Single phase Commutating reactor For DCF803 0035 and FEX 425 Int field power converter with external supply must be connected via additionally commutating reactor because of EMC considerations if the supply has a separate mains With DCF803 804 0050 and DCF503B 504B 0050 field power converters it is already installed Converter for field Reactor ND 30 500 V 50 60 Hz current lr reactor a dsf IEC US DCF803 0035 16 A 16A ND 30 FEX 425 Int 316A ND 402 KRascip AEN 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
39. 5172 600 690 V fan voltage 400 500 V 3 Current measurement 5175 D6 and D7 converter Voltage measurement 5186 120 V SDCS SUB 4 for D1 D4 converter modules 5180 600 V for D6 and 07 converter modules 5181 690 V for D6 and 07 converter modules 5182 800 V for D6 and 07 converter modules 5183 990 V for D6 and 07 converter modules 5189 galvanic isolation for 06 and 07 converter modules SDCS DSL board 5199 SDCS DSL board 05199 SDCS DSL board 4 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 YO 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 3ADW000194R0511 DCS800 Hardware Manual e us 17 t and control ircui In C Ma 50 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 SAS 8504 Jeuuojsue1 0 101061 esnj 2 indino indu sjueuoduioo jo yous 7 2 play 4 1 Qs ve are vi 1 8OI ary arg pasim xul soa
40. 70 C Pollution degree IEC 60664 1 IEC 60439 1 Vibration class IEC 60721 3 3 Site elevation lt 1000 m above M S L gt 1000 m above M S L 2 D1 D4 1 D5 D7 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 70 22 ms 600 VAC D3 60 dBA 73 dBA 0 5 g 9 200 Hz 1 0m 04 66 70 dBA 77 dBA depending on fan D5 73 dBA 78 dBA 0 25m 100 rms symmetrical amps at maxi 56 75 dBA mMm 2 9 P aste Shock monitor mum 600 VAC D7 82 dBA 80 dBA 1 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 5000 Current reduction to 110 Effect of the ambient temperature on the converter module load capacity 100 90 80 70 30 35 1 40 45 50 55 C Current reduction to for converter modules 3ADW000194R0511 DCS800 Hardware Manual e us Technical data 68 Regulatory Compliance The converter module a
41. Ds 734 600 665 500 665 500 1224 1428 1000 1325 1000 1325 1000 1479 Exierna esee v um rum wm rm 1750 D7 2380 1750 Exiemal 3507 2500 700 05 620 Exierna 1224 1428 1250 1160 1000 1160 1000 1250 1250 Exiemal 1750 D7 Exierna 2970 2500 3507 3000 360 800 line voltage DATA AVAILABLE UPON REQUEST 450 990 line voltage DATA AVAILABLE UPON REQUEST 540 1200 line voltage DATA AVAILABLE UPON REQUEST Normal Duty 11096 overload for 60 seconds then lt 100 for 10 minutes Standard Duty 150 overload for 30 seconds then lt 100 for 15 minutes Heavy Duty 150 overload for 60 seconds then lt 100 for 15 minutes Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 72 Current ratings North America regenerative Type code Input RMS Normall Duty Standard Duty Heavy Duty Internal Size Arms current 500 Vdc GA 40 s so 54 9 14 18s 78 5 75 60 163 190 100 166 100 166 100 05800 502 0260 05 D3 20 005800 502 045005 04 25 DCSS00 502 0820 05 S171 669 806 500 740 400 664 400 E cu RUM ECCE Ds S79 1105 700 950 600 851 500 25 DCS800 S02 1500 05 S164 1224 1450 900 1320 800 1280 DCS800 802 2000 05 8164 1632 1
42. JE 2 i ANE n A ddns 5 dn P 0 VSIN B 8 zroad Lad i G A c Qa 1 i p lt i o 7 1008 jnej uue3 A0004 18 The DCS800 3ADW000194R0511 DCS800 Hardware Manual e us 19 JSp P mao 545 8504 0 JO OEO m esnj andino 2 indu 258 sKsego9 Sjueuoduioo jo 11095 7 2 Qs pd 9d vi 44 1 eso eo i i I 1 1 i jueApy 1 i i e pasim xul sod i H H Y TE oo 1 gt 8 222 5 558 S IL 3 o a 553 E O E e 1 e Ez 1 o eo 1 iv e LU LL 1 LI m 6 H E NOE 4 Pa oc Br NId g 7 pn S 1 o 1 TAI I Xi xOH 008S90 Dei 1 H A ddns jones i Emm S 0 YSIN ivan gt jaueg vonod Zk odan gt L gt 0 J z S v gt
43. 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 x 2L A Screened cable for TMR hardware interface connection 2 board is strongly rec ommended Provide sufficient grounding of card holder electronics power supply 10B2 I0B3 switch screened cables converter Tan control cables pressure DOO QUUM A7 re air inlet b dsf A7 re air inlet b dsf Internal cable ducts are used for snubber circuit wiring Don t use these cable ducts for other cables or process signals Use cable straps for fan cable Do not have loose cables The air flow from fan will destroy the cables 3ADW000194R0511 DCS800 Hardware Manual e us 25 Planning the electrical installation What this chapter contains This chapter contains the instructions that you must follow when selecting the motor cables protections cable routing and way of operation for the drive system Always follow local regulations Note If the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Reference Technical Guide publ no 3ADW000163 To which products this chap
44. S0x 0025 xx DCS800 S0x 0045 xx DCS800 S0x 0050 xx DCS800 S0x 0065 xx AR N 4 4 230 260 290 7 7 320 1 350 6 405 0 450 7 470 4 520 4 590 1 8 650 0 680 5 740 4 820 23 25 26 28 33 36 38 2 8 49 53 55 60 73 97 DG8800 S0x 1500 1500 1224 DG8800 S0x 2000 2000 1632 DCSB00 S02050 0 2050 1673 DGS800 S0x 2500 0_ 2500 2040 DG8800 S0x 8000 3000 2448 5 0 50 3300 3800 2655 DGS800 S0x 4000 4000 3204 DCSB00 S04800 9X 4800 3917 DCSB00 SO 5200 0 5200 4245 Q Use wire rated for 90 ambient temperature The minimum ground cable recommendation assumes that the overcurrent protection for each drive is selected to provide protection at 12596 of the rated drive input current If the overcurrent protection e g circuit breaker is sized larger than this then larger ground cables will need to be determined manually Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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
45. Sag See ae 66 Fan replacement D6 D7 66 Technical data What this chapter contains si REIR EE exe aree rea 67 Environmental COMGINONS drug reb C ENG warms d Vac ob a ee 67 Current ratings IEC non regenerative 69 Current ratings IEC regenerative sies te kee tae gee ee Aa eels ee 70 SIZING Ais d 70 Dite EC 70 Current ratings North America 71 Current ratings North America regenerative 72 Control Board SDCS CON 4 5 dista ck se eto x deo Ro CR ODER 73 Layout of the control board SDCS CON 4 73 Memory S IFCUID eck M Rer c ee e cale 73 Watchdog es v aay da pat Psi e qc d 73 Seven segment display i uso ies Sd ALA 74 Terminal description vist oe cys Ee EE 74 Digital and analogue I O connection of the 50 5 4 76 Interface Board SDCS GOM 8 fed sx E eer ye Qe ee Fee dm der ed Fux durs 77 Ch2 SDCS COM 8 Master Follower connections 78 Drive Bus connection to Advant Controll
46. Size Type 400 V 500 V DCS800 S0x 1200 04 05 D5 800A 660V UR 5 170M 6162 DCS800 S0x 1500 04 05 05 1250A 660V UR 5 170M 6166 DCS800 S0x 2000 04 05 05 16004 660V UR 5 170M 6169 DCS800 S0x 2050 51 D6 1500A 660V UR 5 170M 6168 DCS800 S0x 2500 04 05 06 900A 660V UR D 5 170M 6163 DCS800 S01 3000 04 05 06 12504 660V UR D 5 170M 6166 DCS800 S02 3000 04 05 D6 1250A 660V UR D 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 05 630A 1250V UR 6 170M 6144 DCS800 S0x 1500 06 07 05 1100A 1250V UR 6 170M 6149 DCS800 S01 2000 06 07 05 14004 1100V UR 6 170M 6151 DCS800 S0x 2050 06 07 06 700A 1250V UR D 6 170M 6145 DCS800 S0x 2500 06 07 D6 1000A 1250V UR 6 170M 6148 DCS800 S01 3000 06 07 D6 1100A 1250V UR D 6 170M 6149 DCS800 S02 3000 06 07 D6 1100A 1250V UR D 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 790V 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 1100 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 3000
47. 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 DCS8 ans 1 2b dsf Field exciter unit FEX 425 Int Voltage levels 11 12 Seedescription Li Vi Wi a Legend DCS800 Converter Ut 23 5 par T av tide 38 1 i o i 9 i di 2 HERES 54 gt 27 5 dts 5 2i 5 84 x at i o H 84 2 8 gt 84 8 o ai E 54 iz T ozi i E amp Hi 50 8 i E o E is H zd c JS i 3 o x i i ira Ed t j L i 84 By 5 i at n i m i i EN x 5 2 i 8 I E I act 3 zd q E a m 5 i B 25 z i OE Q E en 1 1 H B u Q Li 36 818 84 853 E AN
48. connected Number of Data bits 8 Number of Stop bits 1 Parity Bit odd The programming procedure is activated by setting S2 3 4 during auxiliary voltage is switched ON Setting for field exciter mode is S2 1 2 default FEX425 INTERNAL Hardware configuration Ks i INE E EE Ns UU 1 mm i SDCS FEX 4 Plus code 5164 E v 2302 M 1 w 2303 wi 35A 425 INTERNAL i Supply voltage max 500 V 1 or 3 phase for supply i je voltages 500 600 V an i ic autotransormer is mandatory i i i i i CMM i 5 X i u gt sta 4 EE 9 atts 2 i gt 5 i mm ES 5 8 4 f 58 5 28 Tel g 121 8 i DI O RT amp x id TERRE 25 i 4 d i Z SSL E ins HW conf FEX4 dsf e 1 DI Plus code 164 SDCS FEX 4 i Supply voltage i 5A i MAGIA FEX425 INTERNAL E as ah
49. current must be considered You will find further information in publication Technical Guide chapter Line reactors Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us Line reactors 27 DCS Type Line choke Design 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 01 1 401 4 DCS800 S01 0045 04 05 DCS800 S02 0050 04 05 002 1 0402 4 DCS800 S01 0065 04 05 DCS800 S02 0075 04 05 004 1 0403 5 DCS800 S01 0090 04 05 DCS800 S02 0100 04 05 006 1 0404 5 DCS800 S01 0125 04 05 DCS800 S02 0140 04 05 006 1 0405 5 DCS800 S01 0180 04 05 DCS800 S02 0200 04 05 007 2 0406 5 DCS800 S01 0230 04 05 DCS800 S02 0260 04 05 07 2 407 5 DCS800 S01 0290 06 DCS800 S02 0320 06 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 D
50. 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 below then tracks amp A must be ce exchanged with inverted signals For o le single ended encoders Tracks A and 56 B must be exchanged Power source X5 10 X5 9 X5 8 GND Tet 65535 i IOB3x3 g dsf Forward 0 Electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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 4 or 510 IOB 3 depending on the board Line termination via 54 510 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 10 1 2 SDCS IOB 3 a s o Pulse encoder connection principles
51. fast as possible and prepares the drive for opening main contactor 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 3ADW000194R0511 DCS800 Hardware Manual e us 43 E STOP i K16 ELEC DISCONN speed iii bili i e it 1 15 5 Timer K16 Block current control K1 main contactor CON 4 014 X6 9 Block gt current command E Stop ramp Coast Stop Mode dsf Anschl special a dsf E Stop reaction Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us
52. fuses and disconnector are installed The motor connections at C1 D1 and F F and their tightening torques are OK Proper function of E Stop circuit and relay Fan power wiring connected The external control connections inside the drive are OK There are no tools foreign objects or dust from drilling inside the drive Drive motor connection box and other covers in place Installation checklist 3ADW000194R0511 DCS800 Hardware Manual us 64 Installation checklist 3ADW000194R0511 DCS800 Hardware Manual e us 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 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 3ADW000194R0511 DCS800 Hardware Manual e us 66 Heatsink Fan The heatsink fins pick up dust from
53. low voltage digital signals but single shielded twisted multipair cable Figure b is also usable 9 cali 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 3ADW000194R0511 DCS800 Hardware Manual us 51 Connection of a motor temperature sensor to the drive I O WARNING 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
54. 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 77 Interface Board SDCS COM 8 This board must be used together with a DCS800 to provide same serial communication DDCS options as 5800 Furthermore the board is equipped with four optical channels max data transmission speed is 4 Mb for each optical channel e Channel 0 is used to communicate data from the overriding control APC2 AC800M Nxxx xx adapter modules for fieldbus AC800M or via adapter modules from other controllers to the DCS800 drive e Channel 1 is used for DDCS 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 lt 148 gt SDCS COM 8 lt 2 grey TxD grey TxD COM 8 layout dsf Type Revision optical components Channel 0 used for max driver current Cho Ch1 Ch2 Ch3 PLC I O M F DW
55. mm 9 M12 Ci 0 1 hol DI N m 17 754 fan terminals e 5 1 S 1 o fan terminals 65 5 25 50 50 50 ES La 400 8 ES ka 461 325 5 ES La 483 2m Busbars in mm AC 80 x 10 DC 60x5 A5 dim a dsf Mounting the converter module D5 inside an enclosure Two supports should be mounted inside the enclosure in such a way that they can carry the converter s weight when placing the converter later on The minimum distance between the supports should not be less then 480 mm because of electrical clearance DC busbars A L shape support as indicated will allow to place the converter temporarily close to the front end of the support weight still taken by a lifting device and then push it back to the back plate of the enclosure The upper and lower holes in the back plate of the converter should be used to fix the converter in that position Dimensional drawings 104 Module 06 DCS800 S0x 1900 Hed DCS800 S0x 2050 375 DCS800 S0x 2500 250 409 gt Air outlet DCS800 S0x 3000 R 10 20 Weight appr 180 kg A E 3 Fw wc a 4 ER 5 99 o 55 a o 5 V o 3 g 8 gt W W To o 5 Pressure switch g 9 i 4 i E le 7221
56. 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 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 3ADW000194R0511 DCS800 Hardware Manual e us 49 Typical Cable Sizing and Tightening Torque North America Based on NEC Table 310 16 No more than 3 current carrying conductors per raceway Maximum Ambient Temperature 40C Conductor Temperature Rating 75C except where noted Converiertype PE TihteningTorque input Ground Terminal Torque tb 20 5 37 5 4AWG 41 5 2AWG 53 75 2 00580 50 0090 05800 50 0280 05800 50 0260 212 05800 50 0290 DC5800 S0x 0815 515 DCS800 S0x 0320 05800 50 0350 05800 50 0405 DCS800 80x 0450 DCS800 S0x 0470 0 DCS800 S0x 0520 0 58 0 50 0590 05800 50 0610 610 DCS800 SO cO650 1x DCS800 SO cOS80 1x DCS800 S0 c0740 xx 00580 50 0820 00580 50 0900 4 DCSB00 S0x 100030 1000 816 DOSB00 S0x 120030 1200 5 DCS800 S0x 0020 xx DCS800
57. 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 Tm Example right side connection Mechanical installation 24 Mounting the converter module 07 inside an enclosure Cooling air entry The cooling fan takes the air from the backside both sides and from the area underneath the converter module View from front left side right side View from bottom Free space around the converter module Do not place the converter module in a corner In case the fan cannot take the air through the bottom plate of the enclosure none of the remaining entries can be blocked i 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
58. the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean In a normal environment not dusty not clean the heatsink should be checked annually in a dusty environment more often Clean the heatsink as follows when necessary 1 Remove the cooling fan see section Fan 2 Blow clean compressed air not humid no oil from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 3 Assemble back the cooling fan The cooling fan lifespan of the drive is about 50 000 operating hours The actual 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 3ADW000194R0511 DCS800 Hardware Manual e us 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 mark
59. the drive Mains connection You can use a switch disconnector with fuses in the power supply of the thyristor power converter to disconnect the electrical components of the unit from the power supply for installation and maintenance work The type of disconnector used must be a switch disconnector as per EN 60947 3 Class B so as to comply with EU regulations or a circuit breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker s main contacts to open The mains disconnector must be locked in its OPEN position during any installation and maintenance work EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function Pressing the STOP button on the control panel of the thyristor power converter will neither cause an emergency motor stop nor will the drive be disconnected from any dangerous potential To avoid unintentional operating states or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals RUN drive OFF or Emergency Stop respectively control panel or PC tool Intended use the operating instructions cannot take into consideration every possible system configuration operation or maintenance Thus they mainly give such advice only which is required by qualified personnel for normal operation o
60. the master and it can be delivered also to other slaves if necessary Several NDBU 95s can be used in parallel in series or in any combination of these The maximum distance between the master and NDBU 95 as well as between two NDBU 95s see manual Branching units NDBU 95 Technical specifications Layout of the NDBU 95 branching unit Optical links Master channels 1 DDCS input and 1 DDCS output Slave channels 9 DDCS inputs and 9 DDCS out DBU puts 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 ing messages ABB 0805 Transmission device 10 Mb component for each channel ES Ole UNT Gr CH RXD Power supply E Input voltage 24 VDC 10 em 9 ADDRESS Input current 300 mA et i Monitoring green LED switched on when the 9 1 output voltage is normal eo 8 ci RXD Operating temperature 0 50 C 9 PCB dimensions s diagram beside E 9 MBIT S Remark Only channels with the same components e g 10 Mb component may be connected to each TG other m col PXD 9 For further information see Appendix D the DriveWindow 9 User s Manual 264 co RXD lt vios 69
61. the power section s radiated heat and any changes in the cooling air temperature and volume Since the cooling air volume can Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 47 only be detected indirectly 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 which means the drive may be enabled There 15 no need to set any specific differential pressure recommendation center setting Thermal overload and short circuit protection The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive Mains cable AC line cable short circuit protection Always protect the input cable with fuses Size the fuses accord
62. 0 RDIO RAIO x x x R Fieldbus adapter x SDCS COM 8 x Second fieldbus RMBA x x Memory Card x 3ADW000194R0511 DCS800 Hardware Manual e us Technical data 76 Digital and analogue connection of the SDCS CON 4 SDCS CON 4 4 Firmware 5 90 270 V dis 2 X3 SE oi 30 90 V 98 gt ice 2 aa 86 8 7 ATACH 3 8 30 V 20 7 sg BK kes gt 81 4 ATACH1 51 TA 5 3 4 55 b gt 6 eens 405 8 3 ms 8 10V 5 533 4 55 D 3 3 ms 9 DEB 10 10 ms gt gt AM 2 10 ms 3 GND 4 10V 5 10V 6 GND AOx 7 ET 8 A AO2 9 10 GND 1 5 1 Cone x 094 _ gt 2 121 100 128 ChA RI 3 A 10k ChB 4 25 p ChB RI ChZ 5 84 g 6 Wer 7 low GND 8 H Sense 0 V 9 Sense 5 V to
63. 0 600 NF3 500 600 DCS800 S02 0820 0y 820A D4 690 1000 690 1000 DCS800 801 0900 0y 900A DCS800 S02 1000 0y 1000A D4 690 1000 690 1000 DCS800 801 0900 0y 900A DCS800 S02 0900 0y 900A 05 690 1000 NF3 690 1000 DCS800 801 1200 0y 12004 DCS800 S02 1200 0y 1200A 05 690 1000 NF3 690 1000 DCS800 801 1500 0y 15004 DCS800 S02 1500 0y 1500A 05 690 1600 NF3 690 1600 DCS800 S01 2000 0y 20004 DCS800 S02 2000 0y 2000A 05 690 1600 690 1600 lt 3000 lt 3000 06 NF3 690 2500 NF3 690 2500 Filter only available on request Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 35 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 0035 8 NF1 250 8 FEX 425 Int 16 NF1 250 20 DCF803 0050 50 NF1 250 55 DCF804 0050 50 NF1 250 55 The filters can be optimized for the real field cur
64. 0 mm jack or via CAT 1 1 cable RJ45 X34 is used for download firmware for DWL and IEC61131 programming connection 3ADW000194R0511 DCS800 Hardware Manual e us 75 The 85232 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 412V 12V Data format UART Message format Modbus Protocol Transmission method half duplex Baudrate DriveWindow Light variable CodeSys download 38 4 kBaud FDT firmware download self adapting Number of Data bits 8 Number of Stop bits 1 Parity Bit odd X34 Description 1 not connected 2 TxD 3 RxD 4 not connected 5 SGND Signal ground 6 9 not connected 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 Extension see chapter SDCS COM 8 board X20 Slot 4 is used for Memory Card see description IEC61131 programming Prepared function of Hardware extension Digital Extension DCS800 61131 Programming target Slot 1 Slot 2 Slot 3 Slot 4 X9 X10 X11 X2
65. 00 10 355 AM x Air entry from the front right left and 468 2 back lt 136 gt Dimensional drawings 3ADW000194R0511 DCS800 Hardware Manual e us Module 07 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 1 5 350 for M10 N sl P 3 N N O N svi N svi Pressure switch M 10 o for M10 E A7 dim a dsf 90 180 80 80 80 93 gt 3ADW000194R0511 DCS800 Hardware Manual e us iS 422 Busbars in mm AC and DC 100 x 10 Dimensional drawings 106 Module 07 right hand for M10 DCS800 S0x 2050 xxR 8 O a DCS800 S0x 2600 xxR o gt DCS800 S0x 3300 xxR AB DCS800 S0x 4000 xxR Jo DCS800 S0x 4800 xxR DCS800 S0x 5200 xxR 8 Weight 315 kg 4 Pressure switch TE 8 ERA for M10 o BRA I A7 dim a dsf AC and DC 1 i AC and DC 100 x 10 Dimensional drawings 3ADW000194R0511 DCS800 Hardware Manual e us Fuses installed inside the converter Converter type Model Fuse F1
66. 00 1200 29004 36004 700 2200 A 3300 Current consumpt A 2 50 3 4 1454 2 0 A 0 9 1 2 A 6 5 A 4 9 A 0 91 23A 3 0 Blocking current 3 75 4 5 at450V A at500 VA 690 at 500 V A 400 V A at 400 V A 8 5 8 5 4 4 8 5 gt 25 gt 30 Air flow m3 h freely blowing Air flow m3 h 800 750 1500 1600 1500 1600 4200 4250 at working point 25A 32A 1 26A 1 6A 0 7A 1 65 3 6 41 450 500 A 690V 500V A 400V A 400V A Max ambient temperature C 55 Useful lifetime of grease appr 30000 40 Protection Temperatur detector Uy 230 V Iy 2 5 A Fan connection for DCS800 Terminals on top of converter housing Converter housing 230 230 Vac al 115 230 115 Vac or 115 Vac at Connection M57 M58 gt Configuration 1 Configuration 2 Configuration 3 Configuration 4 Configuration 5 Monitoring the DCS800 power section a The size D1 D5 power section is likewise monitored by an electrically isolated PTC thermistor detector which is installed on the heat sink in an isolated configuration Evaluation of the resistance and the protection effect correspond to max temperature of type code b The size D6 and D7 power section isolated PTC thermistor is used for air entry temperature The detector thus measures
67. 00 V filters for 440 V lines outside Europe The filters can be optimized for the real motor currents IFitter 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 4 Filter type f y2 5 type 2 Q Converter 4QOonvrter IDC A DCS800 S01 0020 0y 20A DCS800 S02 0025 0y 25A 01 440 5 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 801 0125 0y 125A DCS800 S02 0140 0y 140A D1 NF3 440 110 500 110 DCS800 801 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 801 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 801 0470 0y 470A DCS800 S02 0520 0y 520A D3 NF3 500 600 NF3 500 600 DCS800 801 0610 0y 610A DCS800 S02 0680 0y 680A D4 NF3 500 600 NF3 500 600 DCS800 S01 0740 0y 740A D4 NF3 50
68. 05 235 250 155 170 125 85 10 9 6 6 ND 406 255 275 155 175 125 95 10 9 09 IND 407 255 275 155 175 125 95 10 9 11 ND 408 285 285 180 210 150 95 10 9 11 o o OY e tin coated N AL lt rho 50 445 10 2 2 gt D tt gt Line reactors type ND 409 ND 413 Type B C D OG OH OK 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 2 11 ND 412 385 350 205 280 175 115 12 13 2 11 ND 413 445 350 205 280 175 115 12 13 2 11 B gt uu 5f Qo us conten Da B X X 7 A B C X 2 OTT 9 o 20 6 12 E 2 F 2 C D 3ADW000194R0511 DCS800 Hardware Manual e us Accessories 124 Line reactors North America Unit Type Line Reactor for Config A Line Reactor for Config B 2Q Converters 4Q Converters 1 5 Imp 5 Imp 500 Vdc 5800 501 0020 05 DCS800 S02 0025 05 KLR21BTB KLR21CTB DCS800 S01 0045 05 DCS800 S02 0050 05 KLR45BTB KLR45CTB DCS800 S01 0065 05 DCS800 S02 0075 05 KLR80BTB KLR80CTB DCS800 S01 0090 05 DCS800 S02 0100 05 KLR110BCB KLR110CCB DCS800 S01 0125 05 DCS800 S02 0140 05 KLR130BCB KLR130CCB DCS800 S01 0180 05 DCS800 S02 0200 05 KLR200BCB KLR200CCB DCS800
69. 2 598 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 DCS800 S02 1500 04 05 1500 1200 1800 1156 1734 1104 2208 D5 25 M DCS800 S02 2000 04 05 2000 1479 2219 1421 2132 1361 2722 400 V 500 V 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 5164 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
70. 24 2x 95 2 1x 50 1xM10 25 DCS800 S0x 0650 xx 650 2x 120 555 2x 120 n 1x120 1xM12 50 DCS800 S0x 0680 xx 680 2x 120 555 2x120 gt 1 120 1 12 50 DCS800 S0x 0820 xx 820 2 150 669 2 120 1x120 1xM12 50 DCS800 S0x 0900 6 7 900 4x 95 3 150 734 4x 70 3x 95 1x150 2xM12 50 5800 50 1000 1000 2 185 816 2x150 1x150 1xM12 50 DCS800 S0x 1200 xx 1200 4x 120 979 4x 95 120 1x185 2xM12 50 DCS800 S0x 1500 xx 1500 4x 185 3 1224 4x150 2 150 2 12 50 DCS800 S0x 2000 xx 2000 8x 120 6x185 1632 4x 240 E 2x240 2xM12 50 DCS800 S0x 1900 xx 1900 8x 120 6x185 1550 4x240 3x120 4xM12 50 DCS800 S0x 2050 xx 2050 8x 120 6x185 1673 6x120 5x150 3x120 4xM12 50 DCS800 S0x 2500 xx 6 2500 7 x 185 2040 8 120 6 185 4 120 4 12 50 DCS800 S0x 2600 xx 2600 7 x 185 2122 8x120 6x185 4x120 4x M12 50 DCS800 S0x 3000 xx 3000 8x 185 2448 7x 185 4x150 4xM12 50 DCS800 S0x 3300 xx 3300 8x 185 2693 7x185 gt 4 150 4 12 50 DCS800 S0x 4000 xx 4000 7 x 300 3264 8x 240 4x240 4xM12 50 DCS800 S0x 4800 xx 4800 8x 300 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
71. 24V 15 default value Relay output 12 NL AC supply X37 and X137 are connected in parallel Pow 4 dsf Auxiliary supply voltage X99 Input circuit POW 4 Supply voltage 115 V AC 230 V AC NIC ay Tolerance 15 10 15 10 i 0 Frequency 45 Hz 65 Hz 45 Hz 65 Hz xm gt Power consumption 120 VA 120 VA OON Power loss lt 60 W lt 60 W FI Inrush current 20 A 20 ms 10A 20 ms n FERA recommended fusing 6 AT 6 AT 4 Mains buffering min 30 ms min 300 ms cz Powerfail 95V 95 V 40202 Frequently switching ON and OFF increases inrush current 41 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 250 V lt 3 A increase the mains buffering time More DC 224 V detailed data is available on request via your or 115 230 V lt 0 3 A ABB representative Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 88 Interface Board SDCS PIN 4 General Field firing 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 conne
72. 325 99 03 6 110 max 230 4 05 7 10V 8 OV 9 TEES 10V lt 1 5 10 i SS 5 mA 3 11 OV 12 510 510 X531 456 EN ZA ChA gt 2 iter tgp e ChA gt 3 01112 NITES Yt 4 ChB 5 61718 ANN 2 6 om mM Eo eu Chz V17 Hill Power 8 Sense Power 9 Sense 99 2 55 10 Si GND total smoothing time lt 2 ms 4 20 mA by Software function 1 0 1 V by setting 52 53 CMR 10 V 2 0 2 MA by setting 52 53 51 CMR x10 V designated for PT100 evaluation per firmware and hardware should always be used directly at SDCS CON 4 3 1 4 short circuit proof Technical data iob3x2 f dsf Note When the SDCS CON 4 control board with the SDCS IOB 3 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 Resolution Input output Scaling Common Remarks bit values by mode Hardware range 15 sign 10 0 10 Firmware 20 V OOOO 15 sign 10 0 10V Firmware x20 V 00210 15 sign 10 0 10 V Firmware x40 V 02340 15 sign 10 0 10 V Firmware 40 V 15 sign 10 0 10V Firmware x40 V 00210 Power 11 sign 10 0 10 V Firmware lt 5
73. 4 05 D3 170M 6811 3 53 FWP 700A See Note 1 DCS800 S01 0470 04 05 DCS800 802 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 170 6163 3x 170H 3006 FWP 900A See Note 1 5800 501 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 Note 1 DCS800 S01 0590 06 DCS800 S02 0650 06 04 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 3ADW000194R0511 DCS800 Hardware Manual e us 32
74. 500 2 between current 5V 12V input terminal 10V 10V 1V 1V measure for 0 4 20 mA ment X311 X312 AITAC Temperature sensor supply PTC PT100 5mA 51 9 10 1 11 12 1 13 14 10 Characteristics for pulse encoder inputs single ended push pull single ended open collector 24 3 24 23 2 23 22 1 There is card holder available as option for fastening the SDCS IOB 3 board For more information see chapter Dimensional drawings 5 default value Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 86 SDCS IOB 3 8 SDCS CON Software X3 1 _51 Mook 100k 99 gt 5 pH AM 4 52 3 3 9 os 5 5 6 ro 6 NEO SIDE 3 3 ms 7 78 PRESO Se 8 95e ole P AIB mee c 10 ms 9 p HH b AM 10 1295014 10 ms 11 119 13 100 12 0 100 475 X41 mL ET n 2 ov 3 k AO2 100 ov PET 5 lt omg NI 4 V
75. 6 894 578 867 538 1076 D4 25 A DCS800 S01 0900 04 05 900 700 1050 670 1005 620 1240 DCS800 S01 1200 04 05 1200 888 1332 872 1308 764 1528 x DCS800 S01 1500 04 05 1500 1200 1800 1156 1734 1104 2208 D5 A DCS800 S01 2000 04 05 2000 1479 2219 1421 2132 1361 2722 400 V 500 V DCS800 S01 2050 05 2050 1550 2325 1480 2220 1450 2900 5800 501 2500 04 05 2500 1980 2970 1880 2820 1920 3840 D6 5800 501 3000 04 05 3000 2350 3525 2220 3330 2280 4560 5800 501 3300 04 05 3300 2416 3624 2300 3450 2277 4554 5800 501 4000 04 05 4000 2977 4466 2855 4283 2795 5590 D7 5800 501 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 03 DCS800 S01 0590 06 590 470 705 472 708 434 868 04 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 Re 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 5800 501 3300 06 07 3300 2416 3624 2300 3450 2277 4554 DCS800 S01 4000 06 07 4000 3036 4554 2900 4350 2950 5900 D7 5800 501 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 5800 501 3000 08 3000 2500 3750 2400 3600 2400 4800
76. 885 1100 1490 900 1479 900 DCS800 S02 2500 05 502 2500 05 DCS800 S02 DCS800 S02 3000 05 05 2040 2395 1500 1995 1250 1990 1250 ear 1212521 Air Flow Heat 60Hz Dissipation ft3 min BTU Hr Externa 10 5800 502 400005 3254 3690 2250 2890 1750 2890 1750 DCSs00 S02 5200 05 4243 4820 3972 2500 3800 2250 600 Vdc uri M OCC CONDE MA CO EN CONCERN E E A IT 1224 1428 1000 1925 1000 1325 1000 DCS800 S02 3000 06 07 External DCS800 902400006 E E TU S02 4800 06 700 e DCS800 S02 1500 07 502 1500 07 DCS800 S02 2500 07 502 2500 07 DCS800 S02 3000 07 07 External 360 800 Vac line voltage DATA AVAILABLE UPON REQUEST 450 990 line voltage DATA AVAILABLE UPON REQUEST 540 1200 Vdc line voltage DATA AVAILABLE UPON REQUEST Normal Duty 110 overload for 60 seconds then lt 100 for 10 minutes Standard Duty 150 overload for 30 seconds then lt 100 for 15 minutes Heavy Duty 15096 overload for 60 seconds then 10096 for 15 minutes Technical data 3ADW000194R0511 DCS800 Hardware Manual e us Control Board SDCS CON 4 73 Layout of the control board SDCS CON 4 Jumper coding S13 Jumper parking positio
77. A 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 12 fuses per bridge 2x per F1x 3ADW000194R0511 DCS800 Hardware Manual e us 107 L1 1213 Dimensional drawings 108 Size 5 6 Size 7 10 Indicator 15 18 105 8 d NI 4xM10 8 9 10 deep 8 O 5 1 5 1 B a LE 108 M 5 1 L a i 14 ___ PI t Size A 7 62 8 90 9 105 Size a b 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 card holder IOB2 3 dsf with universal Phoenix clamp 1202713 it is possible to mount the card holder on standard rail system in horizontally or vertically direction Dimensional drawings 3ADW000194R0511 DCS800 Hardware Manual e us Accessories DCF803 0035 and FEX 425 internal 109 The field exciter DCF803 0035 and FEX425intern are half controlled three phase field conve
78. A Enclosed Converters Flyer DCS800 A 3ADW000213 x System description DCS800 A 3ADWO00198 p p Installation of DCS800 A 3ADWO00091 p p DCS800 R Rebuild System Flyer DCS800 R 3ADW000007 DCS800 R Manual 3ADW000197 DCS500 DCS600 upgrade manual Extension Modules RAIO 01 Analogue IO Extension 3AFE64484567 RDIO 01 Digital IO Extension 3 64485733 x R slot extension 3AFE64661442 x Serial Communication Drive specific serial communication NETA Remote diagnostic interface 3AFE64605062 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 RMBA MODBUS 3AFE64498851 Fieldbus Adapter with DC Drives Ethernet 3AFE64539736 X X existing gt planned Status 01 2007 DCS800 Drive Manuals List c doc DCS800 Drives 20 to 5200 A Hardware Manual 3ADW000194R0511 Rev E EFFECTIVE 22 04 2007 2007 ABB Automation Products GmbH All rights reserved 3ADW000194R0511 DCS800 Hardware Manual e us 3ADW000194R0511 DCS800 Hardware Manual e us Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing operating and servicing the drive If ignored physical injury or death may foll
79. C fuses may be required by local safety regulations If so use 2 for the DC side Note 1 No fuse holder is available Attach fuses directly to busbar Dimensions Order Fig A B C D E F G H J FWP 5B 30B 2 87 0 563 1 855 2 477 2 477 0 25 0 405 0 063 0 25 FWP 35B 60B 4 375 0 813 2 75 3 708 3 312 0 344 0 725 0 125 0 542 FWP 70B 100B 4 406 0 947 2 594 3 625 3 563 0 344 0 75 0 125 0 375 FWP 125A 200A 5 09 1 5 2 84 4 19 3 5 0 41 1 0 25 0 75 FWP 225A 400A 5 09 2 2 84 4 28 3 53 0 41 1 5 0 25 0 78 FWP 450A 600A 7 09 2 5 2 84 5 72 4 19 0 53 2 0 38 1 3 FWP 700A 800A 6 63 2 2 844 5 562 5 062 0 625 1 5 0 25 0 875 a a a a Dimensions in inches sasi Fig 1 5 800 Amp Range Fig 2 900 1000 Amp Range Fig 3 1200 Amp Range Accessories 3ADW000194R0511 DCS800 Hardware Manual e us 120 Line reactors IEC Line reactors type ND 01 ND 16 Line reactors for use in industrial environment minimum requirements low inductive voltage drop deep commutation notches Line reactors NDO1 NDO06 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 Type reactor rated
80. CS800 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 3ADW000194R0511 DCS800 Hardware Manual us Planning the electrical installation 28 Line reactors L 1 for North America Unit Type Line Choke for Config A Line Choke for Config B 2Q Converters 4Q Converters 1 5 imp 5 imp eese Rss NEC wo DCS800 S01 1200 05 KLR1100CCB DCS800 S01 1500 05 DCS800 S02 1500 05 KLR1250CCB 600 Vdc DCS800 S01 1500 06 KLR1250ECB Recommended AC Line Reactors are available directly from TCI For information see their web page www transcoil com Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 29 Aspects of fusing for the armature circuit and field supplies of DC drives General Unit configuration Protection elements such as fuses or overcurrent trip circuits are required in all cases to protect against further damage In some configurations this will entail the following questions first at what point should which protective element be incorporated And secondly in the event of what faults will the element in question provide protection against damage AC supply public mains plant s mains
81. DC curr 2 uH Line AC A Un kg IW W f Usuppiy 400V f Usuppiy 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 ND 403 450 55 82 400 11 42 90 67 54 ND 404 350 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 ND 412 40 605 805 400 62 280 335 738 590 ND 413 35 740 1105 400 75 312 410 900 720 Line reactors type ND 401 ND 402 Type D ND 401 160 190 75 80 51175 7 9 ND 402 200 220 105 115 75 200 7 9 Line reactors type ND 403 ND 408 123 Type B C D OGJ OH OK IND 403 220 230 120 135 100 77 5 7 9 6 6 ND 404 220 225 120 140 100 77 5 7 9 6 6 IND 4
82. DCS800 Hardware Manual DCS800 Drives 20 to 5200 A Ai HD HD EP IP DCS800 Drive Manuals Language Public number E D ES F CN DCS800 Quick Guide 3ADW000191 x p p p p DCS800 Tools amp Documentation CD 3ADWO0021 1 x DCS800 Converter module Flyer DCS800 000190 x x p x p p Technical Catalogue DCS800 3ADW000192 x x x x x Hardware Manual DCS800 3ADW000194 X p p p p Firmware Manual DCS800 3ADW000193 x Installation according to SADWO00032 x Technical Guide 38ADW000163 x Service Manual DCS800 3ADWO00195 x p Planning and Start up for12 Pulse converters 3ADW000196 CMA 2 Board 3ADW000136 Flyer Hard Parallel 3ADW000153 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 x 61131 DCS800 target tool description Application Program 3ADW000199 x Winding with the DCS 800XXXXX 3ADW000058 Winder application description Flyer magnetic application Magnetic application description DCS800 E Panel Solution Flyer DCS800 E Panel solution 3ADW000210 x Hardware Manual DCS800 E 3ADW000224 x DCS800
83. DIMENSIONS oi ie ieri ipae meu e 114 DCF505 DCF506 Overvoltage 115 Fuses and f se holders 2 dal ad i eR dt 118 Fuses and fuse holders North 119 DIMENS d eet ur i i te ace Mete IRE E D 119 Linesreactors 1EGi s estote tere en Eie Tea nid mue dian bere Se dala 120 Line reactors type ND 01 ND 16 kiero bertus asd Musei pai ie lle cb dia 120 Line reactors type ND 07 12 121 Line reactors type ND 401 0413 122 Line reactors North 124 Autotransformer 242 eS Lie ASA VIL 125 line Teactor 3 zz coated tns eo 125 Supply transformer T2 for electronics and 126 Op cal cables uc GR diea db 127 Table of contents 3ADW000194R0511 DCS800 Hardware Manual e us 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 intended for controlling DC motors L Size D1 D4 20 1000 A Size D5 900 2000 A
84. E200 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 lt 1 8 lt 1 8 lt 1 8 lt 0 9 lt 0 9 Air flow m3 h freely blowing 156 180 925 1030 925 1030 1835 1940 1860 1975 Air flow at working point Max ambient temperature C 60 75 lt 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 3ADW000194R0511 DCS800 Hardware Manual e us 45 Planning the electrical installation 46 Fan D2E 160 GR31M GR31M GR35C 380 500 V 525 690 V 400 690 V Rated voltage V 230 1 400 450 400 500 500 690 500 690 A 400 500 450 500 500 600 690 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 8
85. EN types on request above for details see table Available for converter above modules including field exciter units Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 69 Current ratings IEC non regenerative The current ratings for 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 Ipc m Ipc iv Size T field curr continu 100 150 100 6 150 100 200 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 03 20 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 59
86. N 4 275 V oo X99 Ast _____ mm Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 90 Armature circuit interface The function for armature circuit interface consist of Firing the armature 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 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 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 e Snubber circuit are share
87. N t SQIUEJSISAI Duunseeui jueuno 5 c PI 5 P ch 9 A Pt i iv x T i 98 ius d OP ING 9 o sjeuueyo 3899 99 2 aus Bt M 9 m 947 9 sif 5 NT COE E i gt IT re 4 i ji cem i If gis P 5 69 9 i 22 4 1 i 2 i 2428 9 c Pl n T 9 E RSX vol 3 to EUH MAT 2014 5 5 id 5 i T 1013 5 a i an 5 EU m 5 Wo WS nen 2 i 2 eo i S OIN ere enjeu Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 92 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 applicat
88. PIN 51 boards for a 4 Quadrant D7 type converter J3Sp LV 8 Nid SOdS MRR 909 999 9 80 VO 8t NId S9dS V 7 975 9 TE de _ 9 9424 yaza z 2474 T TdZH preso 990 Xp 80 Yao vo ana RA ge 2 15 oe Ner MEC sjeuueuo asind _ eo 2265 ws 008 1 3 m gt FW v v gt amp m Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 96 Galvanic isolation T90 A92 Technical data The Galvanic isolation is an option for converters in the current range 2050 5200 A DC and rated voltages 1000 V For converters with a rated AC voltage of 1190 V and 12 pulse serial 2x 500 V the galvanic isolation is a standard equipment It is used to replace the high ohmic resistance voltage measurement and gives the advantage of a total isolation from power part to electronic part The transformer T90 and the DC transducer A92 are located outside the converter module The internal AC and DC voltage measurement channels are ope
89. RRRARARMARNARRNE 1V 2V6 2V5 2V4 2V3 2V2 2V1 1 1W 2 6 2W5 2W4 2W3 2W2 2 1 4 1N e 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 Weight 10 70 Weight 2 1 kg Dimensions in mm Remark 116 The terminals on the primary side of the transformer 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 the shrowding cover and fasten the con a nection by turning the screw clockwise 52x77 QUE Se 118 120 130 Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 100 Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 101 Dimensional drawings 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
90. S emsseig bo leros 12108 195 1 i L00 900 00 0 Ave 20 LOW AOL Jeyoxe uo i on board field exciter uo Bupuedap Ion using NOO x8 NO9 Wiring the drive according to this diagram offers the highest degree of monitoring i 9 y 2 gt MER dti DI 8 D 5 8 1 i 1 b 941 3 DI e IUVIS i Z 96X ara li T PE o gt ine LM 1 dois Fio gt Em 5 O 2 2 2 F 7 84 55 5 4 86 7A a Sje o o gt gt 8 3ADW000194R0511 DCS800 Hardware Manual e us Planning the electrical installation 39 Converters 05 drive configuration using FEX 425 Int field exciter Wiring the drive according to this diagram gives the most flexibility
91. S z 8 85 g ad 5 Ei 5 21 9 i 9 2 eT 34 9 ES x H E SN t ZA 2 i i 5 58 jets uz 2 1 8 4 el 2 lox E x 20 Ist jo t x 39 i 4 8 Es wi E p i j n ES i lt 2 8 88 x 4 E ott 4 sa zt 5 a 71 d gt gt gt ee s si Quel Oo _ Ei lt 5 5 lt 8 IET pee 2 v zi i i Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us external field exciter Ion using 0035 can be supplied with 3 phase aux supply 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 Converters D5 D7 drive configurat DCF803 DCF804 40 Jequnj 10 9201 sue 8504 n i 90 UNMS 55 i 10 SOG OG 04 200 100 910 ZOV AOL ac axe Wa 708550 E 9739 gy zv 08590 9 5
92. S01 0230 05 KLR200BCB KLR200CCB DCS800 S02 0260 05 KLR250BCB KLR250CCB DCS800 801 0315 05 DCS800 S02 0350 05 KLR300BCB KLR300CCB DCS800 S01 0405 05 KLR360BCB KLR360CCB 5800 501 0470 05 DCS800 S02 0450 05 KLR420BCB KLR420CCB DCS800 S02 0520 05 KLR480BCB KLR480CCB DCS800 S01 0610 05 DCS800 S02 0680 05 KLR600BCB KLR600CCB DCS800 S01 0740 05 DCS800 S02 0820 05 KLR750BCB KLR750CCB DCS800 S01 0900 05 KLR750BCB KLR750CCB DCS800 S02 1000 05 KLR850BCB KLR850CCB DCS800 S01 1200 05 DCS800 S02 1200 05 KLR1100BCB KLR1100CCB DCS800 S01 1500 05 DCS800 S02 1500 05 KLR1250BCB KLR1250CCB 600 Vdc 5800 501 0290 06 KLR250BCB KLR250ECB DCS800 S02 0320 06 KLR300BCB KLR300ECB DCS800 S01 0590 06 DCS800 S02 0650 06 KLR600BCB KLR600ECB DCS800 S01 0900 06 DCS800 S02 0900 06 KLR750BCB KLR750ECB DCS800 S01 1500 06 DCS800 S02 1500 06 KLR1250BCB KLR1250ECB Note Configuration A For most installations Configuration B For installations that require compliance with EN 61 800 3 or when AC and DC drives are on the same line See Chapter Planning the Electrical Installation for additional information Recommended AC Line Reactors are available directly from TCI For information see their web page www transcoil com Accessories 3ADW000194R0511 DCS800 Hardware Manual e us Autotransformer T3 125 Type Field curr Transformer s Weight Power loss Fuse secondary current IF kg prim
93. S01 0405 DCS800 S01 0470 DCS800 S02 0350 DCS800 S02 0450 DCS800 S02 0520 600 V types DCS800 S01 0290 DCS800 S02 0320 Z 10 mm AI 8 rae Selene 8 9 V 811 4x45 180 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 5 262 5 310 147 5 205 252 10 ca 25kg 2 58 JN 98 2 55 23 8 2 n 9 5 5 58 Signal terminals 359 TEREN o 0 5 8 Field power supply terminals Power connection 8 E 2 88 o 9 inf 2 i 8 55 1 S EE T 55 gg 88 a ES rn T 88 D1toD3 dim b dsf Dimensional drawings 3ADW000194R0511 DCS800 Hardware Manual e us 102 Module 04 5 5 DCS800 S01 061 0 7 10 mm for size 04 DCS800 S01 0740 DCS800 S01 0900 270 2 225 DCS800 S02 0680 i 48 5 r fan terminal f M6 DCS800 S02 0820 6 ST DCS800 S02 1000 Tuo 600 V types DCS800 S01 0590 DCS800 S02 0650 Weig
94. T on CE X ca ec E eS 99 Dimensional drawings Table of contents 3ADW000194R0511 DCS800 Hardware Manual e us 14 Module Die 101 uc eL neu E E EE 101 Module D3 25 eS edet eR Euer e sarei del ded 101 Module xt a fu ia ud PRU eA 102 Module D5 mE um nisu 103 Deanna ed Sohne ce 104 Module D7 left hand thon 2S at Bie ited et e dae ees 105 Module D7 righthand uso iena iene dol ber PB REC 106 Fuses installed inside the converter 107 Accessories DCF803 0035 and FEX 425 109 ost X ec e e ule Ner Use a afe li 110 ena ite aat da 110 Power secin sas aaa e par ea 110 DCS LINK communication 111 DIAGNOSIS so cosy Sur eee are Bar as areas Serger a RU ved e E 112 RS232 Polti ous ester 4 EU tee E 113 FEX425 INTERNAL Hardware configuration 113
95. V 10 uv yun jeyoxe 008890 i i Ajddns T 5 v 2 029 IM S t SEEMS on 4 1UVIS 5 T 96X e I Ty tenete a bate fa 3 Haak 3015 340 e e e 784 254 2 L 13 1 a n dW n ZHOS Ajddns Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us Fan cooling Fan assignment for DCS800 Converter type Model Configuration Fan type DCS800 S0x 0045 y1 D1 1 2x CN2B2 DCS800 S0x 00140 y1 DCS800 S0x 0180 y1 D2 1 2x CN2B2 DCS800 S0x 0260 y1 DCS800 S0x 0315 y1 D3 1 2x CN2B2 DCS800 S0x 0350 y1 DCS800 S0x 0405 y1 03 2 4x CN2B2 DCS800 S0x 0520 y1 DCS800 S0x 0610 y1 04 3 1x W2E200 230 V DCS800 S0x 0820 y1 DCS800 S0x 0610 y1 04 3 1x W2E200 115 V DCS800 S0x 0820 y1 Pluscode E171 DCS800 S0x 0900 y1 04 3 1x W2E250 230 V DCS800 S0x 1000 y1 DCS800 S0x 0900 y1 04 3 1x W2E250 115 V DCS800 S0x 1000 y1 Pluscode E171 DCS800 S0x 0900 y1 D5 4 D2E 160 DCS800 S0x 2000 y1 DCS800 S0x 1900 y4 5 8 D6 5 GR31M DCS800 S0x 3000 y4 5 8 400 500 V DCS800 S0x 1900 y6 7 D6 5 GR31M DCS800 S0x 3000 y6 7 500 690 V DCS800 S0x 3300 y1 D7 5 GR35C DCS800 S0x 5200 y1 400 V 690 V Fan Data for DCS800 Fan CN2B2 W2
96. Weight Power loss recommended L lms Ipeak Voltage Fe Cu for armature uH A A Un kg Ww Ww 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 37 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 ND 12 18 8 490 734 500 36 0 95 290 DCS 0680 ND 13 18 2 698 1047 690 46 8 170 160 DCS 0820 ND 14 9 9 930 1395 500 46 6 100 300 DCS 1200 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 Line reactors type ND 01 ND 06 b E 1 X 01 to 6 a dsf 9 1 al a b c d e f 4 5 mm ND 01 120 100 130 48 65 116 4 8 6 o ND 02 120 100 130 58 65 116 8 10 ND 03 148 125 157 63 80 143 5 10 10 04 148 125 157 78 80 143 5 10 16 ND 05 148 125 157 178 80 143 5 10 25 ND 06 178 150 180 72 190 170 5 10 35 en Accessories 3ADW000194R0511 DCS800 Hardware Manual e us 121 Line reactors type 07 ND 12
97. apter contains css ex Cage s RR ATE RR EAE TTE T 15 065800 eias Me tet arra Dee n Sebastes 15 Type duree Reb ur PEE MES a dee curs qu ru sd arie de 16 Main circuit and a e i unte edi 17 Armature circuit converter DCS800 S0x 01 04 17 Armature circuit converter DCS800 S0x D5 D7 18 Rebuild system DOSS800 RDX en aw PER ERSS UR rs ER RE 19 Mechanical installation Uripackirig ilie obo edet ketenes iting e Pardo foe 21 Delivery CHECK xcci stet ee eS BRE SUAE C ques e d ert 21 Before installation sesso e ae 22 Requirements for the installation 22 Mall t codici oer a __ _ cer 22 n 22 Free space around the 22 Cabinet acte ok se ordo ORC E Eo acea bci eet D e ROO REEL ole c xt 22 Preventing cooling air 22 Unit above another essc tede ea Re ed ed ede 22 Mounting the converter module 06 inside an enclosure 23 Mounting the converter module 07 inside an enclosure 24
98. before connecting the drive to the mains Make sure that the drive is disconnected from the mains input power 1 Check that the motor cable is disconnected from the drive output terminals C1 D1 F and F 2 Measure the insulation resistances of the motor cable and the motor between each circuit C1 D1 or F F and the Protective Earth by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm C1 D1 amp 0 PE Electrical installation 3ADW000194R0511 DCS800 Hardware Manual us 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 isolated supply must be limited of a range of an earth fault Supply voltage Check supply voltages of Aux X99 Fan Terminals AC voltage for field circuit U1 V1 WI 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 3ADW000194R0511 DCS800 Hardware Manual e us 55 Location R Extension and Interface Modules Connect the signal cables as described below Tighten the screws to secure the extension mo
99. cted 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 230 V up to 525 V 600 V The converter identification is made by TYPECODE 97 01 and not by hardware The converter identification the burden resistor setting and 2 Q or 4 Q bridges operation Field current measurement O T100 6A 4 25 1 12 a X5 x12 X4 High voltage X3 X8 X9 X10 0 SO Output field current Armature firing 1 2 1 8 i a S i 5 i i 5i Y i e i i x x i i i N i i i ai i i m E i 1 gt lt x i i 4 i i Y i Y I I 1 SDCS PIN 4 x22 xi X2 el EA 8 5 i i Os 0 conducting point Different functional areas on SDCS PIN 4 Technical data 3ADW000194R0511 DCS800 Hardware Manual e us X23 Power supply 9 1 l 1 i i vt 7 s o o X Si 10 xe F102
100. d via a resistor R to GND differential 4 5 lt X5 7 5 1 IL 4k7 lt Hi tr ui 8 U AKT 8 258 GND X5 10 SDCS IOB 3 ENCODER INPUT A CON 4 IOB 3 5V 12 24 V 5V 12 24 V differential S4 S4 510 510 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 510 current source 1 2 E 7 8 13 14 In any case if SDCS IOB 3 is used see required settings of SDCS CON 4 board Electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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 3x 0 25 mm 14x 0 25 mm 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 12x 24 ANG 164 to 328 ft 2x24 AWG 12x 24 ANG 328 to 492 ft 3 x 24 AWG 14 x 24 ANG 3ADW000194R0511 DCS800 Hardware Manual e us Electrical installation 60 Co
101. d 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 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 3ADW000194R0511 DCS800 Hardware Manual e us 91 Typical armature circuit thyristor converter diagram with SDCS PIN 4 board 002177 108 0005 VOO8 V97c 0041 Id L
102. ded Not applicable satisfied satisfied Medium voltage network Medium voltage network Supply transformer for a residential Light industry Supply transformer for a residential area rating normally lt 1 2 MVA area rating normally lt 1 2 MVA Residential area Residential area Earthed neutral Earthed public 400 V network with neutral conductor Earthed neutral Earthed public 400 V network with neutral F conductor Earthed public 400 V network with neutral conductor To other loads e g drive systems To other loads e g drive systems To other loads e g drive systems Commutaion notches 20 Line reactor Y capacitor Y power converters HF interference and commutation notches T il Converter g o 2 8 5 c c 9 E 5 uL 2 gt 5 5 To other loads which have to be protected from the system disturbances caused by gt 5 5 8 5 a S 2 2 2 A gt o 2 5 2 e a o g gt 8 9 S 9 5 Operation at public low voltage network Operation at public An isolating transformer together with other low voltage network with an earthed screen loads
103. different optical cables available Kind of cable Connector cable length no Fig plastic fibre optic single cable plug 0 5 20 m 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 1 blue black Figure 2 blue black 001 L gt Hi blue blue Agna red e 288 Coan TI Ann black blue 5 9 Figure 3 E gt 8 r1 orange orange 4 8 Ee BN 52 TI black 25 mm black Figure 4 3 5 88 oo oz Ss ce 59 Accessories 3ADW000194R0511 DCS800 Hardware Manual e us EP ED IP IP SADWO000194R0511 Rev E 04 2007 ABB Automation Products Wallstadter StraBe 59 68526 Ladenburg GERMANY Telefon 49 0 6203 71 0 Telefax 49 0 6203 71 7609 www abb com motors amp drives 194R0511A7180000
104. dinbe jou si einjeuue aq ospe ULI y uonduosep ees 100 900 100 0 AO 6 Aver 20 10 AOL ELNO x8 N09 peog 7 G AG LL 784 2 301 Aejap euin JUALIND puodas euo uey dn aye ueo 1 1v OO 01 papajas pinous lt 4015 3 gt GL indui se anywe jo 1SvOO SN 81 4e10xe 4015 3 1 si dOLS 3 dois au 2 2 MEI ld NOES eL Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 42 START STOP and E STOP control The relay logic can be split into three parts a Generation of the ON OFF and START STOP command The commands represented by K20 and K21 latching interface relay can be e g generated by a PLC and transfer
105. drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 52 Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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
106. dules DCS800 Panel connector X33 SLOT 1 R IO Extension module or R Fieldbus module SLOT2 R IO Extension module Interface connector SDCS IOB 3 X1 SDCS IOB 2 8 SLOT R IO Extension module or R DDCS interface board X34 PCTool DriveWindow Light AP Tool Commissioning assi stant Electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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 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 Standard one channel for res
107. e line reactor impedance determines the voltage dip at the connecting point In such cases line chokes with an impedance around 496 are often used Example calculation with Line 1 Ux 472426 Voltage Dip Zi ine Zi ine Zi 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 is gt 1 96 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 are based on commutation chokes if the drive system consists of any of the converters D1 02 03 4 D5 06 07 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
108. er star 78 Cho Connection to overriding control Nxxx fieldbus 79 Ch3 Ring connection to PC tool 79 Ch3 Star connection to tool DriveWindow 80 DDCS Branching unit NDBU 95 lilla liti liana 81 SUGS DSL Board Ju vs oasis Ra ed ib de Sud oed 82 Digital board SUCS NOB 2 tts E ED RE 83 Analogue and encoder I O board 520 05 08 3 85 Power Supply Board 5 5 4 87 Interface Board rar iatale hw exor Vea ded E wo x da 88 Generalia s spa an AA Cana ean v ps ro acd oC bos d Y ha See eed 88 Power Supply iu m uf aqq us 89 Technical data x use ce aaa ge Ves aes Aaa ak RR ERO 89 Armature circuit interface 90 Field Circuit interna CE uoce E exce re Ra o ed rc 90 Power Interface 5 5 46 5 5 48 5 65 5 92 Galvanic isolation T90 92 96 DC DC IransducBt A92 Ge Belt Re take Became 98 Transformer F90 rere RR Y ERA te ANTES
109. f 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 3ADW000194R0511 DCS800 Hardware Manual e us 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 3ADW000194R0511 DCS800 Hardware Manual e us 11 Table of contents DCS800 Drive Manuals d pee coe xe ot sa AS VER Sek EAR ERI RH 2 Safety instructions What his chapter contalliS ette cutis sth re Rog RG eee he RE e D CR RR 5 To which products this chapter applies 5 Use of warnings arid NOS suerte rs e MEHR babe POR 5 Installation and maintenance sese 6 CMT 7 Fibr opic ee Led D 8 Mechanical installations lt 2 sassate iene ta RUE EET n 8 STAM OG ores m Se ae A 9 Table of contents The DCS800 What this ch
110. gh 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 Simple load with DCS800 S01 and 2 Q Overvoltage Pro tection DCF 505 DCF505bl 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 01 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
111. h 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 3ADW000194R0511 DCS800 Hardware Manual e us 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 WARNING Handle the fibre optic cables with care When unplugging optic cables Mechanical installation These notes are intended for all who install the drive Handle the unit carefully to avoid damage and injury
112. her Input value Signal definition by Remarks Channel Firmware potential isolated by optocoupler 1 8 24 48V R1 R8 4 7 108 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 47kQ IOB 23 Firmware gt 0 signal 0 40 V gt 1 sig 90 250 V including tolerance absolute max values 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 0 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 inp
113. ht appr 38 kg 644 625 40 80 12 52 _ 80 80 Power terminal Busbar 40x5 mm Weight appr 38 kg 345 o 298 amp fan terminal Y E T Direction of air flow M 5 o Pla E Ei Earthing 8 T1 M12 E 147 5 E 195 5 8 240 PIN 4 nos 287 5 CON 4 E D4 dim b dsf Dimensional drawings 3ADW000194R0511 DCS800 Hardware Manual e us Module 05 DCS800 S0x 0900 DCS800 S0x 1200 DCS800 S0x 1500 DCS800 S0x 2000 Weight appr 110 kg 103 1005 3ADW000194R0511 DCS800 Hardware Manual e us T gt ta 400 o Eg r 450 g 8 88 1275 125 125 855 1 26 E 5 for M10 o 117 1 26 014 n Q TE e NE s 6 el po LY 22 XS L J SS gt 510 LL Vv 480 lt 27 A e 0 o e Y Y 1 8 ble tr ri earthing M12 gis ane a0 min of o o o earthing height 39
114. idual 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 3ADW000194R0511 DCS800 Hardware Manual e us 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 12 V no sense sense controlled 24 V no sense no sense no sense Sense feedback connection is recommended when power supply level for differential pulse encoder is 5 V The wiring is shown on figure below Commissioning hint Note DIFFERENTIAL twisted pair Cha If the drive s measured direction of rotation is wrong or does not chB correspond to measured EMF speed Pe the SPEEDFB fault may appear Power source fX5 10 during start up necessary correct by
115. ing 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 3ADW000194R0511 DCS800 Hardware Manual e us 48 Cross sectional areas Tightening torques Recommended cross sectional area to DINVDE 0276 1000 and DINVDE 0100 540 PE trefoil arrangement up to 50 ambient temperature The necessary wire torque at 60 C wire temperature is the same as recommended in the following tables Armature Converter type D1 AM1 1 U1 V1 W1 AK1 AK3 5 PE 1 2 1 2 A mm mm2 A mme mme mm Nm DCS800 S0x 0025 xx 25 1x 6 41 1x 4 1 4 1x M6 6 DCS800 S0x 0050 xx 50 1x 10 41 1x 6 z 1x 6 1x M6 6 DCS800 S0x 0075 xx 75 1x 25 61 1x 25 1x16 1x 6 5800 50 0100 100 1 25 5 82 1x 25 1 16 1 6 DCS800 S0x 0140 xx 140 1x 35 E 114 1x 35 1x 16 1x M6 6 DCS800 S0x 0200 xx 200 2x 35 1x 95 163 2x 25 1x 95 1x 25 1xM10 25 DCS800 S0x 0260 xx 260 2x 35 1x 95 204 2x 25 1x 95 1x 25 1xM10 25 DCS800 S0x 0320 xx 320 2x 70 1x 95 220 2x 50 1x 95 1x 50 1xM10 25 DCS800 S0x 0350 xx 350 2x 70 286 2x 50 1x 50 1xM10 25 DCS800 S0x 0450 xx 450 2x 95 367 2x 95 1x 50 1xM10 25 DCS800 S0x 0520 xx 520 2x 95 4
116. ings and warranty policy Hardware extension RAIO Analog Extension Hardware extension RDIO Digital Extension DCS800 1131 Programming target Branching units NDBU 95 Reference Environmental Conditions System connection Voltage 3 phase Voltage deviation Rated frequency Static frequency deviation Environmental limit values Permissible cooling air temp at converter module air inlet with rated DC current w different DC curr acc Fig below Options 230 to lt 1000 V acc to IEC 60038 10 continuous 15 short time 50 Hz or 60 Hz 50 Hz x2 60 Hz x2 6 Dynamic frequency range df dt 2 0 5 to 30 cycles Please note Special consideration must be taken for voltage devi ation in regenerative mode 50 Hz 5 Hz 60 Hz 5 Hz 17 s Relative humidity at 0 5 C Change of the ambient temp Relative humidity at 5 40 C publ no 3AFE64484567 publ no 3AFE64485733 publ no 3ADW000199 publ no 3ADW000100 0 to 55 C 0 to 40 C 30 to 55 C 0 to 40 C 5 to 95 no condensation 5 to 50 no condensation lt 0 5 C minute 40 to 55 C Degree of protection Converter Module and options line chokes fuse holder field supply unit etc Enclosed converters Paint finish Converter module Enclosed converter 00 NEMA TYPE OPEN IP 20 21 31 41 light grey RAL 9002 light grey RAL 7035 Storage temperature Transport temperature 40 to
117. ion U dc field three phase full controlled The field converter is controlled from armature converter via DCS link serial communication based on CAN hardware X1 Fex4 DCSLink dsf 24V 200mA S1100 3 S1100 2 Termination 200 Node address is set by S800 digit 0 S801 digit 10 Supply Remarks 24 V 200 mA 24 V grounded supply f SDCS FEX 4 communication emarks Bus termination S1100 1 ON 120 ohm 1 OFF no termination Ground termination 51100 2 200 kOhm R C ground termination 3 ON 0 Ohm ground termination 2 3 OFF no termination node address 00 is not possible Same node address must be selected in the corresponding armature converter example node address 13 gt S800 and S801 1 Selection of communication speed is set by 51100 51100 6 51100 5 51100 4 Baudrate Selection of armature kBaud converter param 94 02 20 0 OFF OFF ON 50 1 ON OFF 125 2 OFF ON ON 250 3 500 4 ON OFF ON 800 5 ON OFF 888 6 ON ON ON 1000 7 see Parameter 94 08 94 09 3ADW000194R0511 DCS800 Hardware Manual e us 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 mi
118. ion no parallel thyristors Construction type D5 D6 D7 8 X22 X122 X24 X25 Vi4 VII V16 V13 V12 V15 i G G G G G G i e gt i 1 je Gi 1 jt Lr i a0 gt o 0 5 i B C D E F Foe i x x dishes 2 5 E 2 i Z SDCS PIN 46 PIN 48 o eg 2q 034 b dsf Lo N e ME A x X 4 Quadrant application no parallel thyristors Construction type D5 D6 D7 SDCS PIN 46 PIN 48 V25 V12 23 16 V21 V14 SD LD AD zx l 3 X22 X122 X23 X24 X25 v24 VII 26 V13 V22 V15 ER 5 E a ej ej 4 i Ci Cr Cr i 8 F j 9 ni OO 9 B C D E F x xX XL 9 o o o F Soca I x SDCS PIN 46 PIN 48 9 a 4q c3a b dsf Xx 6 X Pulse transformer board SDCS PIN 46 PIN 48 Layout of the SDCS PIN 46 PIN 48 pulse tran
119. is selected for typical twisted pair cable It must be located in both ends and activated by jumper or switch Preferred cable type DEVICENET Supplier Helu Kabel Germany type 81910PUR Belden USA type 3084A 120 ohm 1 1 4 W 120 ohm 196 1 4 W asf CAN Bus termination Electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 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 FEX 425 Int 2 51100 2 GNDB p Set bus termination ON 51100 1 closed Bus termination CAN Bus termination b dsf SDCS DSL SDCS DSL DCS800 D5 Converter FEX 425 Int 1100 2 Termination OFF optional Termination OFF next drive next converter 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 0 Bus termination Set bus termination ON 51 1 2 closed Cable length The cable length influences the maximum baudrate DCF803 0035 FEX 4 1100 2 GNDB
120. mA 11 sign 10 0 10 V Firmware lt 5 mA analogue 10 0 10 V R110 lt 5 mA gain 0 5 5 Rj 3 0 lt 5 mA external use lt mA reference pot 1 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 X200 correct voltage drops on cable only if 5V 12V encoder is in use Residual current detection is selected as default The jumpers 51 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 current transformer This detection is based on a sum current transformer where the secondary is connected through a diode bridge to 100 W resistor Voltage will appear across the resistor if the sum of the 3 phase current is not zero In case should be used for a different purpose use the inputs jumpers accordingly and take the block diagram as 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 53 settings for inputs AI2 and 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 2 mA For input there are the following co
121. max 1 7 m and between X1 X3 is max 0 5 m because of way that the conductive supports have a good con EMC reasons nection to ground of the installation gt SDCS CON 4 SDCS IOB 2 Layout and jumper settings of the SDCS IOB 2x board ms 97 5 70 1 Line potential X5 Y Jumper coding supports are conductive input time constant diameter of all supports 4 3 mm 2ms 10ms this dimension may vary 4 5 mm S7 DI7 E depending revision 2 2 S8 Dis Tli W100 as printed circuit default value There is card holder available as option for fastening the SDCS IOB 2 board For more information see chapter Dimensional drawings Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 84 SDCS IOB 2x Software a F a lt 001 lt MUN s lt rua 2 DO4 5 1 ne Ed 2 lt DO5 sev i F i
122. mmutating reactors will be required emv clssif b dsf The following overview uti lises the terminology and indicates the action required in accordance with Product Standard EN 61800 3 For the DCS800 series the limit values for emitted interference are complied with provided the measure indicated is carried out PDS of category C2 for restricted distribution in first environment is intended to be installed and commissioned only by a professional person or organization with necessary skills in installing and or commissioning PDS 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 environment this product may cause radio interference in which case supplementary miti gation measures my be required 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 Legend Screened cable Unscreened cable with restriction Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 38 ye Buimelp ees ayun jSp or sue 8524 2 ye YM
123. n 2 gt No filter Normal DC Tacho sf 9 Filter for AC Tacho with rectifier 2 8 1 7 3 9 Tacho input X3 4 connected with 0 V GND 2 1 7 3 i Jumper parking position 5 7 no grounding of Tacho input 3 B Tacho input 1 at X3 4 and 3 1 2 3 at spes con 4 3 9 Tacho input 2 at 2 23 X2 24 at 9 SDCS OB 3 PS5311 2rp4 X3 5 6 Ry 200 kOhm S2 IN Range 10V 0V 10V ta 5 6 250 Ohm N 3 Range 1 20 20 53 2 3 7 8 200 kOhm 7 Range 10V 0V 10V 2H Al2 X3 7 8 Ry 250 Ohm 1 7 Rangel 20mA 20mA 2 TES Jumper parking position 5 6 2 98 Pull up resistor 4 74 kOhm activated at X3 7 1 7 forPTC temperature sensor S43 i Encoder mode differential RC load with o R 121 Ohm and 100 nF activated 3 12 Encoder mode single ended or if IOB 3 5 hi connected Pull up resistors 4 75 kOhm activated 3 12 Encoder supply 5 V sense X5 8 9 are active 2 D or SDCS POW 4 see section 1 10 Power supply board SDCS POW 4 3 12 Encoder supply 24 V uncontrolled 10 supplied from CON 4 S5 Step 1 Preparation for Firmware download 1 operation 2 Hat Step 2 Text download 1 3 normal prog
124. nd enclosed converter components are designed for use in industrial environments In EEA countries the components fulfil the requirements of the EU directives see table below European Union Directive Manufacturer s Assurance Harmonized Standards Converter module Enclosed converter Machinery Directive 98 37 EEC Declaration of Incorporation EN 60204 1 EN 60204 1 93 68 EEC IEC 60204 1 IEC 60204 1 Low Voltage Directive 73 23 EEC Declaration of Conformity EN 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 6007 eseeULLising ULtypes on request www ul com certificate no E196914 Approval 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
125. ned and connected to the T90 and A92 units Hard and software settings Voltage coding on measuring board Construction Construction type D5 D6 D7 ERI TTE nom voltage V 4 400V 6 600V 7 690V 8 800V 9 990V 1 1200V 5 500V Value f conv nom volt at 1000 1200 coo WessuingboadSBOS Wisi Psi all resistors are 0 Q Galvanic isolation Resistors Rx on PIN51 27 4 kQ 27 4 27 4 27 4 kQ 27 4 kQ 27 4 DC DC transducer A92 8680A1 Switch position 7 675V 6 810 V 5 945 V 4 1080 V 2 1350V 1 1620 V Transformer T90 745047 Secondary Terminals 2U1 2V1 2W1 2N 12 pulse serial and sequential have a different selection between SConvScaleVolt 97 03 and the scaling of measurement channel See 12 pulse manual for DCS 800 3ADW000194R0511 DCS800 Hardware Manual e us 97 Typical armature circuit thyristor converter diagram with SDCS PIN 48 and SDCS PIN 51 boards for a 4 Q D7 type converter with galvanic isolation JSp LY 8 5205 HM sJedunf 6uipoo MH LJ 99 UJ U UJ cio Lu Jets Mao do PYxi620
126. nfigurations available input range 20mA input range 10V or earth fault monitoring by Isum not equal to zero via X3 11 and X3 12 3ADW000194R0511 DCS800 Hardware Manual e us Power Supply Board SDCS POW 4 87 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 07 21000 and rebuild system DCS800 R The SDCS POW 4 works on a switched mode basis in fly back configuration It generates all necessary DC voltages for the SDCS CON 4 and all other electronic boards The input voltage is automatically detected and set to either 230 V AC or to 115 V AC The following figure shows the instructions for the selection of the encoder supply voltage If SDCS CON 4 input X5 is used for encoder speed measurement the incremental encoder supply voltage for 5V 12 V or 15 V must be selected by jumpers S3 S4 and S5 SDCS POW 4 SDCS CON 4 E 101112 24 He 54 X5 10 encoder supply The 24 V encoder supply can be selected either directly from CON 4 board 54 11 12 or from POW 4 board 54 10 11 S4 is located on the CON 4 board Jumper coding S3 Encoder supply selection 54 55 54 53 Sense function S5 ate AH15v 12 Af sv 15V AA sv 79
127. nnecting the signal and control cables The cables for digital signals which are longer than 3 m and all cables for analogue signals must be screened Each screen must be connected at both ends by metal clamps or comparable means directly on clean metal surfaces if both earthing points belong to the same earth line Otherwise a capacitor must be connected to earth on one end In the converter cubicle this kind of connection must be made directly on the sheet metal as close as possible to the terminals and if the cable comes from outside also on the PE bar At the other end of the cable the screen must be well connected with the housing of the signal emitter or receiver Connection of a cable screen with the aid of metal clamp to the me tal surface of the PCB carrier at 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 tray
128. nt 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 1 72 of nominal current For easier reading the maximum average DC load current is listed instead of the percentage in the next table Line 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 4 170 AX CZ IE lt PE PE O O O v 1 gt gt Accessories Terminals WAGO 202 UL File E45172 x Y 8 B 0 G 5 Ex 3ADW000194R0511 DCS800 Hardware Manual e us Type reactor rated Weight Power loss Load Load L Voltage Fe Cu DC curr 1
129. of all kinds together with other 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 earthed iron core loads of all kinds renders mains filter and line reactor superfluous Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us For compliance with the protection objectives of the For emitted interference the following apply EN 61000 6 3 Specialised basic standard for emissions in light industry can 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 37 be satisfied with special features mains filters screened power cables in the lower rating range 50081 1 61000 6 4 Specialised basic standard for emissions in industry 50081 2 For interference immunity the following apply EN 61000 6 1 Specialised basic standard for interference immunity in residen tial areas 50082 1 61000 6 2 Specialised basic standard for interference immuni
130. ow 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 3ADW000194R0511 DCS800 Hardware Manual e us Installation and maintenance work These warnings are intended for all who work on the drive motor cable or motor Ignoring the instructions can cause physical injury or death Only qualified electricians are allowed to install and maintain the drive Never work on the drive motor cable or motor when main power is applied Always ensure by measuring with a multime
131. r 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 1 10 F2 Frequency 50 60 Hz E d Output voltage 115 230 VA SSS m LE de ME ru 28253645886 T2 mM 00 10 Type Power Weight Fuse F2 Power loss nq VA kg A A W T2 11400 15 16 6 0 230 100 12 0 115 V 230 115V T2 a dsf 6 3 mm Faston 150 E ARRE ki 2 T2 dim dsf 100 5 Application hint 230 V The transformer is designed to work as a 230 V 230 V transformer to open avoid ground loops This is done via the 380 V and 600 V taping according to the left picture F2 gt gt gt gt gt gt gt gt gt gt 0 5 0 5 T2 M SE SE LO 10 10 CO CO CO 230V 115V T2 a dsf Accessories 3ADW000194R0511 DCS800 Hardware Manual e us 127 Optical cables For the bus communication of the DCS converters there are
132. ram execution default value 250 Ohm x 20 mA 5 V 100 Memory circuit Con4 layout b dsf PEES X11 X10 o amp e N x 2 Jumpers shown in default position 8 E XI XSTM S2 3 12 5 1 5 2 s4 1 1 1 1 X3 x x x AE ETE SDCS POW 4 7 SDCS CON 4 SDCS PIN 4 4 10 1112 24V lt 4 S4 1 5 10 The 24 V encoder supply can be selected either directly from CON 4 board 54 11 12 or from POW 4 board 54 10 11 S4 is located on the CON 4 board 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 e Writing to FPROM is disabled e Thyristor firing control is reset and disabled
133. red 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 RI USED MCW RUN i 704 T d HW I O use ON EN A Main Control Word RUN RESET local command dl 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 Stop function Beside ON OFF and START STOP the drive is equipped with two additional stop functions OFF2 and OFF3 according Profibus standard OFF3 is a scalable stop function rampstop max torque stop dynamic braking to perform stop category 1 This function should be connected to the E STOP button without any time delay In case of ramp stop selection the K 15 timer relay must be set longer than EStopRamp 22 04 For COAST selection the drive opens the main contactor immediately OFF2 switches off DC current as
134. rter Both field converters are based on the same controller board SDCS 4 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 BEI 5 p r X100 Setting of switchable burden i X100 35A resistors by rated field current X101 U1 X101 V1 Field X101 W1 X100 D1 Fex4x1l a dsf Layout of the SDCS FEX 4 board 240 XD uA P1 SID a T110 T113 G Field 210 alg e T112 TUM emn R106 110 gt lt 5 P gin X1 24V supply X3 DSL Link X1 1 24V DC X3 1 GNDB 1 2 OVDC X3 2 CANL X3 3 3ADW000194R0511 DCS800 Hardware Manual e us D800 OP x 10 5800 0730 5801 0731 8 52 e e 000000 1100 3 9 e ao X 5 Fex4_layout_a dsf Accessories 110 Accessories
135. s must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is shown below 24V 115 230 V 24V 115 230 V Motor cable Control cable duct Drive Power cable min 300 mm 12 in Input power cable Motor cable min200mm 8in 9041 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 3ADW000194R0511 DCS800 Hardware Manual e us 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
136. se of that a current of less than 1 mA will flow to earth When galvanically isolated measurement is needed please contact your ABB representative PTC 4 see diagram Conductive Ws line potential power part supports R123 N HE X23 2 X24 2 4 X25 2 1 ws ws we wi uo X22 X122 lesse uem 125 e EH ee E 623 4 TwoPTC RI R21 11 12 OnePTC 1 wii wo ws WwW we MR co 4 P 4 Fd T 126 4135 wie wis Wi4 wi3 w12 x M E pos Ren MEL Pa 159 3135 1 wei weo wig wig wi7 i i gt gt gt z 2 81 I e e e e E Isolating Di wes wes wee i en jell EU jell jell supports LE PP SDCS PIN 51 i 305 Technical data 3ADW000194R0511 DCS800 Hardware Manual e us 94 Settings of the SDCS PIN 51 board if a DCS converter is equipped with it by ABB Current coding R5 180 Ri 180 Ino 180 Rio 180 RI R12 802 13 180 Ria 9 215 180 __ 180 680 19 1209
137. sformer board 270 gt 16 Gate The board consists of six C C Cathode pulse transformers with amplifiers e SDCS PIN 4x Y Pin4x dsf Technical data 3ADW000194R0511 DCS800 Hardware Manual e us Measuring board SDCS PIN 51 93 This board is always used together with SDCS PIN 4x board On this The voltage 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 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 If there is a need for voltage adaptation all 5 chains must be han dled in the same way Note Actual voltage signals U1 V1 W1 1 and D1 of the main circuit are not galvanically isolated from the control board Becau
138. should be as close to vertical as possible of non flammable material and strong enough to carry the weight of the unit Check that there is nothing on the wall to inhibit the installation Floor The floor material below the installation should be non flammable Free space around the unit Required free space around the drive to enable cooling air flow service and maintenance see chapter Dimensional drawings Cabinet installation The required distance between parallel units is five millimetres 0 2 in in installations without the front cover The cooling air entering the unit must not exceed 40 C 104 F Preventing cooling air recirculation Unit above another Prevent air recirculation inside and outside the cabinet nai HOT pf Main air flow out 1 E Air baffle plates m ES 4 COOL AREA i 40 104 F Air baffle plate a Main air flow in 001419 baffle dsf Airflow Lead the exhaust cooling air away from the unit above Distances see chapter Dimensional drawings Mechanical installation 3ADW000194R0511 DCS800 Hardware Manual e us 23 Mounting the converter module 06 inside an enclosure Cooling air entry The cooling fan takes the air from the backside both sides and from the area underneath the converter module View from the right side the back
139. t 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 and three phase connection to armature bridge Above 400 V supply the internal supply must be removed and connected by independant line reactors direct to the supply see drawing in chapter The DCS800 section Armature circuit converter DCS800 S D5 D7 This internal supply can be removed and connected to an independent AC field supply The snubbers are designed to operate in parallel with armature bridge and sharing the armature line reactor If the unit is used as a single phase supply the terminal U and W must be used For single phase supply an autotransformer for voltage adaptation is recommended Please see comparison of output voltage ripple between single phase and three phase supply 3ADW000194R0511 DCS800 Hardware Manual e us Voltage ripple of Upc voltage depending on operation modes 111 0 75 4 0 5 single phase half controlled Voltage ripple Vsec 0 25 o PEN mcn three phase half controlled DCS LINK communicat
140. ter 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 3ADW000194R0511 DCS800 Hardware Manual e us WARNING printed circuit boards contain components sensitive to electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Grounding These instructions are intended for all who are responsible for the grounding of the drive Incorrect grounding can cause physical injury deat
141. ter 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 z Configuration A Line g When using the power converter a minimum of impedance is a PCC required to ensure proper performance of the snubber circuit A line reactor can be used to meet this minimum impedance requirement The value must therefore not drop below 1 relative impedance Uy 14 gt 196 voltage It should not exceed 10 due to considerable voltage drops at converter output Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 26 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 and Z 4 constitute the total series impedance of the installation The ratio between the line impedance and th
142. the left side air flow gt L 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 converter fan ENS 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 pop pele ox 250 When mounting the right angle busbars or connecting cables directly please make sure the correct bolts are used The converter module is equipped with a thread hole at left side Because of that the length of the remaining threads is limited to 35 mm see drawing below o 5 S N pu a N amp M da E 5 X zd N 3ADW000194R0511 DCS800 Hardware Manual us Free space around the converter module optimum compromise m 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
143. tions such as supply via an autotransformer or an isolating transformer new protection conditions may additionally apply The following configurations are very often used In contrast to the armature circuit supply fuses are never used on the DC side for the field supply since a fuse trip might under certain circumstances lead to greater damage e g small but long lasting overcurrent fuse ageing contact problems etc Semiconductor fuse F3 1 super fast acting should be used if conditions similar to those for armature circuit supply 4 Q operation are to apply like for example protection of the field supply unit and the field winding 30 F3 1 built in Em P Configuration for field supplies The F3 2 and 3 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 E E Configurations for field supplies ND30 F3 3 built in F3 1 lt 2 FF ASP b dsf Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 31 Semiconductor type F1 fuses and fuse holders for and DC power lines DCS800 S01 DCS800 S02 The converter units are subdivided into two groups
144. transformer is designed to supply the unit s electronic system and all the single phase fans including the fan of the D5 converter Input voltage 380 690 V 1 ph 50 60 Hz Output voltage 115 230 V 1 ph Power 1400 VA Residual current detection This function detects current to ground If needed the analogue input AI4 of the SDCS IOB 3 board has to be activated a current signal of the three phase currents should be supplied to AI4 by a current transformer Planning the electrical installation 3ADW000194R0511 DCS800 Hardware Manual e us 34 filters Filter in a grounded line earthed TN 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 5
145. ty in indus try If this standard is satisfied then the EN 61000 6 1 standard is automatically satisfied as well 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 satisfied EN 61000 6 2 EN 61000 6 1 PDS category C3 PDS category C4 Classification Medium voltage network Supply transformer for a residential area rating normally x 1 2 MVA Industrial zone neutral Earthed 400 V network with neutral conductor 3 lt 400 i Mains filter i Line reactor j Line E Y i WIE Converter Operation at low voltage network together with other loads of all kinds apart from some kinds of sensitive communication equipment To other loads e g drive systems Commutation notches 40 Medium voltage network Industrial with earthe Converter m transformer iron core and earthed Screen where appropriate 1 400A and or U gt 500 V 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 co
146. uts 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 3ADW000194R0511 DCS800 Hardware Manual e us 85 Analogue and encoder board SDCS IOB 3 As described at the beginning of the chapter there are via SDCS IOB 2x IOB 3 and SDCS CON 4 various options for configuring the inputs outputs The board SDCS IOB 3 consists of the 5 analogue inputs 3 analogue outputs the galvanical isolated pulse encoder interface and a current source for tem perature measuring devices If these boards are in use they have to be mounted outside the DCS module They must be mounted SDCS CON 4 SDCS CON 4 2 xd way that the conductive supports have a good con SDCS IOB 3 SDCS IOB 2 SDCS IOB 3 4 nection to ground of the installation The cable length between X1 X1 and X2 X2 is max 1 7 m and between X1 X3 is max 0 5 m because of EMC reasons Layout and jumper settings of the SDCS IOB 3 board 233 5 gt LA supports SDCS IOB 3 Functionallity of analogue inputs S4 Pulse encoder supply Paralleing of gainz 1 gain 10 Residual Ch
147. xed up a simple fault display on SDCS FEX 4 board can be used Therefore the unit is equipped with two small LED 0730 Green 0731 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 times green 1 Y 1 Y 2 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 DOSLINK 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 30V Field AC supply voltage 650V maximum temperature heatsink Auxiliary voltage No RESET No RESET general hardware general software 3ADW000194R0511 DCS800 Hardware Manual e us 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

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