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DCS800

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11. 25 Interface board SDCS REB 1 iii 26 xd mee e 27 Funetionality d socrate ai E ctm a c p ila 28 giai 28 ETA LEY 29 Interface board SDOS BEB 9 iei et e bate an 30 time 30 Signal flow and Thyristor 30 DESIGNS ate oec bas fec teni aa 32 Signal handling o e a 32 Plug connectors X1113 and X21 TI seas eterne pesce de 33 Interfacing the Electronics and Thyristors Connection for 2 quadrant application No parallel Thyristors 35 Connection for 4 quadrant application No parallel Thyristors 36 Table of contents 3ADWO000xxxR0101 DCS800 R Sel e a Connection for 4 quadrant application parallel 37 Connection for 2 quadrant application parallel 38 Installation Background for the figures of this 39 Hints f r edo 51 Safety Instructions What this chapter contains rela N ER SETAS GR Apiai 53 To which products this chapter applies 1121 53 Use or warnings and notes 53 Installation and maintenance work ii 54
12. Bunsixe 1 1 1 1 1 _ to motor field 1 Li 1 1 T DCS8 R_sys_ovw dsf Overview of DCS800 R System 3ADW000197R0101 DCS800 R Sel e a Basic Selection 12 Basic Selection 3ADW000197R0101 DCS800 R Sel e a 13 Hardware This chapter gives information about all the components and boards being exclu sively used at the DCS800 ROx kit Components which are used at DCS800 SOx converter modules are just mentioned within that chapter but not described in de tail In case those components need special handling it will be listed here This for example is valid for measuring actual signals at the existing power stack or doing the galvanic isolation for the firing pulse transmission In addition to that environmental conditions dimensions and some hints are listed for better and straighter forward engineering All other components which may come or may had been ordered together with the kit are described in detail either within the DCS800 Hardware Manual or within their dedicated documentation Basic components of the DCS800 R kit The kit is ordered according to the type designation at chapter Basic Selection The delivery can be subdivided into several parts mostly two rebuild kit s main electronics already pre assembled electronic boards and cables to measure signals at the power part and control the existing thyristors this will come as loose parts
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14. 182 5 100 7 SDCS PIN 51 board and holder Hardware 3ADW000197R0101 DCS800 R Sel e a 21 jo 1o1su y ISp ISd gpd 8890 92 z 4 sejoy ben i i 4 ye M M 9 p t Ah 1 344 o T es x N 4 Reino i ee A forle SS SS F E Ss E TT ejqeuns n n mum 3 asnj 2 i E 1 TER 2 TEES a gt n LEON 4 DEC V 18 ONILSIXS Hardware 3ADW000197R0101 DCS800 R Sele Typical rebuild connection with controller board SDCS PIN 48 and SDCS PIN 51 boards 22 Wiring Fastening If the distance between the SDCS PIN 51 terminals C1 D1 U1 V1 W1 and the power terminals of the existing power part exceeds 1 m an additional fuse has to be used per wire see fig before Make sure a jumper is installed connecting fas ton point S1 with S2 This connection is essential for proper grounding of the flat cables x12 and X13 The boards SDCS PIN 48 and SDCS PIN 51 will come with a card holder which ha
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16. SDCS PI N 51 SDCS REB 1 to SDCS CON 4 to SDCS PIN 48 3 2 for Part 2 with REB ion suggest ica Mechan Figure 10 Installation 3ADW000197R0101 DCS800 R Sel e a 49 to SDCS CON 4 50 mm A SDCS PIN 51 4 W26 W25 4 w22 W23 51 w24 w20 21 19 W17 W18 SDCS REB 1 w4 wis wie Wi E 12 W13 VI 3 ws w9 wii W6 H wa w3 wa w5 U1 E wi Se 9 o allo o EI E A 5 BREESE Sees 81555559 2555556 255252 2525526 5 Sasnossa nasess assess Mansano 9 Feed e o 199169 E dates 190709 Dus oJ Sessesy pessoa b e ale 8 224222 2521225 555555 5555286 9 5 Arecaceae g 2e X Q cacece accacala fesccac m leseses eesescin sessec eosecolm 2 e fasta me TISTON E TOOTS 100706
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18. T N 2 quaarant application no parallel connected thyristors Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800 R Sele 36 Connection for 4 quadrant application No parallel Thyristors There are three ways shown on the next three figures how to connect the thyris tors the pulse transformer board s and the measuring board to each other At figure below the flat cables are connected between SDCS PIN 48 X113 and SDCS PIN 48 X213 SDCS PIN 51 X113 to SDCS PIN 51 X213 to which gives the result that one SDCS PIN 48 board transfers all the firing pulses for the thyristors con nected to D1 see figure Arrangement of thyristors in an anti parallel bridge the other SDCS PIN 48 board transfers all the firing pulses for the thyristors connected to C1 see figure Arrangement of thyristors in an anti parallel bridge SDCS PIN 48 25 V12 V23 V16 V21 V14 n I i X22 X122 X23 X24 X25 V24 V11 26 V13 22 V15 a G G G G G e C 1 Cr o 1 Ci 1 Cc 1 Cc 1 8 a Ee 9 aor 5 A B D E F TIR ea 7 SDCS PIN 51 SDCS PIN 48 RI c X13 X13 X513
19. 31 to thyristor SDCS PIN 48 forward amp A to thyristor reverse a V23 amp V22 SR 2ACE SR 1BDF v25 H amp vis SDCS PIN 48 forward 2 forward amp reverse to thyristor to thyristor ga ve reverse to thyristor amp V4 4 SR xBDF m V2 SR xACE amp V1 1 3 amp L V5 3ADW000197R0101 DCS800 R Sele Hardware 32 Design hints The following results from this configuration A thyristor receives firing pulses when it has been addressed by one of the sig nals A to F and by one of the current direction signals SR Xxxx All members of one group have always to be assigned to the same current di rection but not necessarily to the same bridge There are four horizontal groups of rows assigned to the input terminals and eight vertical rows assigned to the output terminals There is one column for the SR 1 and another one for the SR 2 signal and eight pair of rows for the outgoing SR ACE and SR BDF signals Penetrations are located in the intersections of these signals vertical to horizontal If a wire is i
20. Firing pulse assignment At figure below the flat cables are connected between SDCS PIN 51 X413 to SDCS PIN 48 X113 and SDCS PIN 51 X313 to SDCS PIN 48 X113 which gives the result that one SDCS PIN 48 board transfers all the firing pulses for the thyristors con nected to phase L1 and half of the thyristors connected to phase L2 see fig ure Arrangement of thyristors in an anti parallel bridge the other SDCS PIN 48 board transfers all the firing pulses for the rest of the thyristors connected to phase L2 and for the thyristors connected to phase L3 see figure Arrangement of thyristors in an anti parallel bridge SDCS PIN 48 V21 n 16 eo V13 v22 E V12 E v25 V15 G G G G G se c V11 26 22 122 X23 5 X12 SDCS CON 4 X13 x12 X13 X513 X113 B Firing pulse assignment D E E SDCS PIN 48 X213 c4a b dsf Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800 R Sel e a 37 The connection shown below is used normally when the anti parallel bridge is built by connecting two mechanically separate bridges in an anti parallel configuration Then gate wiring is most simple and short when all six thyristors of a bridge are connected to one pulse transformer board
21. Hardware description provides the information about the boards and components Interfacing the Electronics and Thyristors provides the informa tion about the configurations and functions of drives and examples of the whole circuit diagram Installation provides the information about required ambient condi tions space requirements cabling and wiring and how to install a rebuild system Start up gives some general guidelines and cross references how to commission and start up a DC drive system using a Rebuild kit Associated publications Associated publications see inner page of the jacket of that manual Introduction 3ADWO000xxxR0101 DCS800 R Sel e a Introduction 3ADW000197R0101 DCS800 R Sel e a Basic Selection Technical preconditions and limits If an electrical drive is in operation for several years most often discussions will be started about items like better factory automation based on latest technology decrease of standstill time of production availability of spare parts increase of productivity perhaps an enlargement of the whole installation using both types of drives DC and AC drives and other arguments These wishes can be turned into real life by upgrading the drive itself completely upgrading only the converter which had controlled the DC motor upgrading the converter s electronics only upgrading a part of the converter s electronics For a final solution all the benefi
22. Start up 3ADWO00197R0101 DCS800 R Sel e a 61 Mounting the Kit When starting the installation work make sure the equipment is disconnected from the power supply and checked for safe condition The figures within chapter nstal lation show all the components needed for the different configurations possible Use this drawing as a basic guideline which fits the best to the actual power part depending on the number of parallel thyristors and the configuration with without SDCS REB 3 Mounting the boards can be subdivided into 3 steps Select a place for the SDCS PIN 48 board s as close as possible beside the thyristors When fixing the board at the selected place make sure it s conduc tive supports card holder have good metal contact to the cubicle s frame This frame by itself has to be grounded Select a place for the SDCS PIN 51 and all the other components shown within part 2 Take care for the cable length towards the SDCS PIN 48 board s and towards the SDCS CON 4 board All components of this part 2 have to be mounted on a metal plate to ensure good contact between conduc tive supports card holder and the cubicle s frame This frame by itself has to be grounded Make sure the shields of the shielded cables follow the guide lines given in chapter nstallation grounding on large areas by means of clamps Select a place for the electronics housing and mount it Take care for the cable length toward
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24. IX 4 3 a 9 8 o 5 9 ed uojsej jeduunf Elo lt lo lt lo lt lo lt lo lt lo ZS pue 1 0 DV a S a 8b Nid SOGS 8 1 834 soasO 2 IX 3 a 9 8 Alo slo slo slo slo lt 8 8 8 8 Y 5 5 E E 9 e d go lt is O z Ypreog pue sejqeo 2 s p1eoq asind 2 C E vex udde ejqeo udde ejqeo SJeuuojsueJ jueun ped Jamod gt we ajqeo ug 1 thyristor stage Electrical drawing Figure 2 Installation 3ADW000197R0101 DCS800 R Sel e a 41 5005 Ie ejeid LX uojse e pepnpur jou pepierus You ejqeo puens uonoeuuoo punoJ5 uu you elj ejqeo pepjerus ejqeo sees 104 Jou pues ninuyejBuis LS Nid sods RB SELX SZLX 10198uuo9 0 Das peo d eie 3SP 103735 8524 Bd um ce m em mm
25. ejqeo f lle 5 lle 5 lo silo 5 lo SJeuuojsuen JUONI 85 8 8 s eij E SFININO 1 57 ist O z ere Asp dare I 1euuojsuej asind OV A OEZISLL 0 7 10161 udde ejqeo ped amod ug 4 Thyristor stages in parallel Electrical drawing Figure 5 Installation 3ADWO00197R0101 DCS800 R Sele 44 to SDCS CON 4 50 mm _ SDCS REB 1 e Elda SDCS PIN 51 hx i 1 C h x w22 w233 W24 W25 6 DI 11 Mit ie ie E i 1 3135 138 ed 1 Le ce I Wi2 Wis w4 w5 wie WI m w i nai We Wo Wi Vi SOR Two PTC 4 13 S3 i 4 woo gt oS EE e D e X613 713 e 1 2 ITI N NNNNNN S amp pesoeso EG EE XI 3 X22 x X41 LNGO UNG X42 Sos to SDCS PIN 48 Figure 6 Mechanical suggesti
26. Safety Instructions 3ADW000197R0101 DCS800 R Sel e a 55 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 Use grounding strip TM A ABB order no 3ADV050035P0001 Grounding These instructions are intended for all who are responsible for the grounding of the drive Incorrect grounding can cause physical injury death or equipment malfunction and increase electromagnetic interfer ence e Ground the drive motor and adjoining equipment to ensure per sonnel safety in all circumstances and to reduce electromagnetic emission and pick up e sure that grounding conductors are adequately sized as re quired by safety regulations e Ina multiple drive installation connect each drive separately to protective earth PE lt Minimize EMC emission and make a 360 high frequency ground ing of screened cable entries at the cabinet lead through e Do not install a drive with EMC filter on an ungrounded power sys tem or a high resistance grounded over 30 ohms power system Note e Power cable shields are suitable for equipment grounding conduc tors only when adequately sized to meet safety regulations e 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 co
27. The interface towards the PLC can be done via inputs outputs In this case op tional parts may be added Housing for main electronics 5 b DES aD DCS800 ROx kit s main electronics named DCS800 R00 0000 00 Hardware 3ADW000197R0101 DCS800 R Sel e a 14 Pre assembled part This part is pre assembled and consists of Housing for electronics as shown on figure before Control board SDCS CON 4 built in Electronic power supply SDCS POW 4 built in including flat cable to SDCS CON 4 This board needs to be feed by a 2 phase AC line voltage either 115 V or 230 V Drive to drive interfacevia SDCS DSL 4 board Control panel DCS800 CP Flat cable interconnection board SDCS CCB4 Hint The older version of the electronic power supply SDCS POW 1 can be used as a Spare part for the actual one SDCS POW 4 As shown at the end of chapter Basic Selection some options can be ordered us ing aso called plus code Such options most often can only be used together with the controller board sometimes they need to be plugged on the controller board to get their function Those options will be put at their correct place during production Loose parts and therefore will come within the housing Plug in modules e g Prfibus I O extensions and the field supply FEX 425 Inter nal are parts handled by plus codes The kit is available
28. V AC SDCS REB 2 1 gt 48V gt 24V 4 100uF 0V support X2 1 Power o k 2 NP t gt 200pF PE SDCS CON 4 DCS800 R0x Quint_conn dsf QUINT PS connection and dimensions Mounting and wiring of the external power supply the device is cooled by convection because of that mounting direction is impor tant the device needs to be connected to ground e g because of the metal housing etc care must be taken for correct wiring and protection of the feeding lines for more details see description which comes with the device Monitoring of the external power supply by the SDCS REB 2 448 V and 24 V are monitored if 48 V is below 41 V and 24 V below 19 5 V then firing pulses are sup pressed the green led V58 is not lit and the transistor switch connected to X2 is open Normally V58 should be lit and the transistor switch is closed the transistor output rating is 60 V DC max 50 mA the output is isolated see figure above Hardware 3ADW000197R0101 DCS800 R Sel e a 28 Functionality Fastening Hint The above mentioned monitoring signal should be read by the PLC programmable logic controller or connected to an input one of the 2 inputs which have a fast update time of the DCS800 ROx electronics as indicated above to handle the COASTING function of the
29. avoid to get EMF at the DC circuit disable field current or block the motor if the drive will be released and will generate current e Switch on the drive using the ON OFF command The RUN command has to remain in logic O level This action causes the pulse firing logic to work and to generate single firing pulses at inverter limit position No current should flow Record the thyristor voltage connection U1 C1 and the firing pulse e g by means of a current probe and check the firing pulse position being at 150 el e Switch off the drive e Connect the gate leads to thyristor V14 16 and 12 e Switch on the drive using the ON OFF command e Nocurrent should flow Record the thyristor voltage and the firing pulse as be fore e Switch off the drive e Switch on the drive using the ON OFF command Set the RUN command to logic 1 level Generate small current references within zero and limit discon tinuous continuous current Everything is o k if the current can be varied and does not hit the limit set by the parameter above or inverter limit position De pending on the value of the minimum firing angle perhaps higher than 120 perhaps close to 150 it may happen that there is either no current at all or a very small one In this case change the settings step by step until a value around 100 reached e Switch off the drive e Incase of trouble check the wiring for open loop or wrong connections Do the check once ag
30. coding Use the settings given by the next table Depending on the line voltage applied to the existing power stack the jumpers need to be removed accordingly lower line voltage scaling on request Note At existing power parts with high supply voltage the option galvanic isolation should be taken into consideration because of personal and functional safety rea sons Voltage applied appr to the power stack 200 500 V 501 600 V 601 700 V 701 800 V 801 990 V Value for 1000 ConvScalevolt 97 03 209 W3 8 14 19 24 0 0 W4 9 15 20 25 0 0 G xo WS 11 16 21 26 gt lt 6 indicates removed jumper Nominal current coding At first make sure that the current transformers are mounted and wired according to the figure before In addition to that two other definitions are important the nominal current is equivalent to 1 5 V across the nominal current burden resistors the current measurement is designed to handle peak currents up to two times of Most often the current is the thermal current of the existing power part thyristor stack the peak current may be the highest current running through the motor e Ifthe peak current is higher than two times the nominal current needs to be redefined The value 0 5 T has to be used instead of at all the next equations peak e The scal
31. 00 Service Manual e a 54 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 AC Never work on the drive motor cable or motor when main power is applied Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 Voltage between drive input phases U1 V1 and W1 and the frame is close to 0 V 2 Voltage between terminals C and D and the frame is close to 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 C and D cables are connected with the proper terminal Note The motor cable terminals on the drive are at a dangerously high voltage when the input power is on regardless of whether the mo tor 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 and RDIO DCS800 with enclosure extension Before working on the drive isolate the whole drive from the supply
32. 00197 R0101 Rev A 3 2007 197R0101A7110000
33. 1 Vibration class Site elevation 1000 m above M S L gt 1000 m above M S L 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 40 to 70 C 2 D1 D4 1 05 07 100 without current duction with curr reduct see Fig below Size Sound pressure level LP 1 m dis Vibration Shock Transport in Short circuit withstand rating tance original pack The DCS800 is suitable for use in a age circuit capable of delivering not more than as module enclosed conv as module D1 55 dBA 54 dBA 1 2m 65 kA rms symmetrical amps at D2 55 dBA 55 dBA 1 5 2 9 79 22 ms maximum 600 VAC D3 60 dBA 73 dBA 0 5 g 9 200 Hz 10m D4 66 70 dBA 77 dBA depending on fan D5 73 dBA 78 dBA 0 25 m 100 kA rms symmetrical amps at D6 75 dBA 73 dBA 0 3 mm 2 9 2 4 g 22 ms Shock monitor maximum 600 VAC D7 82 dBA 80 dBA LIL ilo Effect of the site elevation above sea level on the con verter s load capacity 100 90 80 70 60 50 1000 2000 3000 Current reduction to 4000 5000m Effect of the ambient temperature on the converter module load capacity 110 100 90 80 70 30 35 1 40 45 50 55 C Current reduction to for co
34. 119 13 0 Re ERRE RR po aaa ace 55 Mechanical Installation an Cote RE Ub lies 56 8 eL Et 56 Start up What this chapter contains cada seite Diane 59 Salety INSFUCUONS ca aa Queste 59 Points to be observed because of the 59 Maintenance work sara dr las aaa 60 sem 60 Measurements with the old equipment still 60 MO Uniting the ducc 61 WTI GANA Esino ee de i deat date init 61 Commissioning THE Kite he pedes dil ae Odile Deua al 62 Table of contents 3ADW000195R0101 DCS800 Service Manual e a Introduction How to use this manual The purpose of this manual is to provide you with the information necessary to select the right rebuild kit with all the necessary or available options to install it do the start up and operate it as a DC drive system Depending on the kit s configuration different func tionality and different options concerning the user interface are available As long as the hardware needs to be named or cross referenced to in a very general way the term Rebuild kit will be used Contents of this manual Introduction describes how to use this manual and the boundary conditions applying Basic Selection provides the information about the types of the Rebuild kits their type designations and options
35. 22 X122 X23 ES 1 SDCS PIN 51 1 X13 o n e 114 U viti VII 9 V113 VII V115 X413 X313 cc cc X213 Dois 1 X513 618 xira RTS rs A B D E F X213 SDCS PIN 48 Forward bridge pulse transformer boards 2 quaarant application parallel thyristors Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800 R Sel e a 39 Installation The information given within this chapter shall help the installation personnel to se lect a place for the different components of the rebuild kit to mount them and do the interconnections between the boards and the existing hardware Background for the figures of this chapter The figures within this chapter show the different electrical configurations of the kit and give some suggestions for mechanical mounting On the electrical figures a 4 Q version is drawn in case a 2 Q version is in use the SDCS PIN 48 boards plus cables for the reverse bridge will not be delivered with the kit please ignore that part of the figures The drawings Figure 4 to Figure 6 differ from the ones afterwards With the first ones the SDCS REB 3 board is not shown to indicat
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37. DCS800 Selection Installation and Start Up Manual for Rebuild Kits DCS800 Drives DCS800 Single Drive Manuals All the documents available for the drive system DCS800 are listed below Language Public number E D ES F CN DCS800 Quick Guide 3ADW000191 x p p p p DCS800 Tools amp Documentation CD 3ADW000211 x DCS800 Converter module Flyer DCS800 000190 x x p x p p Technical Catalogue DCS800 000192 x x x x p x Hardware Manual DCS800 3ADW000194 x x p p p p Firmware Manual DCS800 000193 Installation according to EMC 3ADW000032 x Technical Guide 3ADW000163 x Service Manual DCS800 3ADW000195 x p Planning and Start up for12 Pulse converters 3ADW000196 p CMA 2 Board 3ADW000136 p Flyer Hard Parallel 3ADW000153 p 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 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
38. E Panel Solution Flyer DCS800 E Panel solution 3ADW000210 x Hardware Manual DCS800 E 3ADW000224 x DCS800 A Enclosed Converters Flyer DCS800 A 3ADW000213 x System description DCS800 A 000198 Installation of DCS800 A 3ADWO000091 p p DCS800 R Rebuild System Flyer DCS800 R 3ADWO00007 p p DCS800 R Manual 3ADW000197 p DCS500 DCS600 upgrade manual Extension Modules RAIO 01 Analogue IO Extension 3AFE64484567 x RDIO 01 Digital IO Extension 3AFE64485733 x AIMA 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 x Fieldbus Adapter with DC Drives RETA Ethernet 3AFE64539736 x gt existing p gt planned Status 01 2007 DCS800 Drive Manuals List c doc DCS800 Drives DCS800 ROx Selection Installation and Start Up Manual for Rebuild Kits SADWO00197R0101 DCS800 R Sel e Table of contents Introduction How to use this 5 Contents of this manual 5 Associated publications 5 Basic Se
39. SDCS PIN 48 24 V21 V26 V23 V22 V25 G an n V14 V11 V16 V13 vi2 V15 i I 22 122 X23 X24 8 5 gt e e Cc Cos cca Cos D 5 B D E F N N x 5 See 2 N ao SDCS PIN 48 X 4q_nopa_a dsf E 5 4 quadrant application no parallel thyristors Connection for 4 quadrant application parallel thyristors With parallel connected thyristors both additional boards SDCS REB 1 and SDCS REB 2 are needed Because of the REB 2 board exter nal 24V and 48V are needed The power supply SDCS POW 4 is not able to give enough power for parallel connected thyristors The figure below shows the configuration for a 4 quadrant bridge with 4 parallel connected thyristors Reverse bridge pulse transformer boards q q amp q S a a gt a gt amp amp amp a 48VEXT 1 S aff 24VEXT H g q
40. Temp 97 04 60 C temperature monitoring 2 Q or 4 Q mode S BlockBridge2 97 07 1 at 2 Q power part at 4 Q power part Hardware 3ADW000197R0101 DCS800 R Sele 26 Interface board SDCS REB 1 Using SDCS REB 1 plugged to SDCS PIN 51 the firing commands are arranged in such a manner that one SDCS PIN 48 gives firing pulses to the six forward bridge thyristors and another one to the six reverse bridge thyristors If the REB 1 is plugged on SDCS PIN 51 board connectors X513 X113 and X213 the board routes the firing pulse so that the pulse transformer board for the forward bridge is connected to X613 and the pulse transformer board for the reverse bridge is connected to X713 Thyristors in old bridges are often differently positioned on the heat sink than in modern converter modules At the bigger standard DCS800 modules firing com mands are arranged on the pulse transformer board SDCS PIN 48 In this way three channels are used for forward bridge and three channels for re verse bridge This solution keeps the gate leads as short as possible see chapter Interfacing the Electronics and Thyristors front side of the board Layout of the SDCS REB 1 board Hardware 3ADW000197R0101 DCS800 R Sel e a 27 Power supply The power supply can be made with two 24 V power supplies wired up in series For this connection suitable power supply is QUINT PS rated 24 V 2 5 A 2x QUINT PS 100 V 240
41. This is done based on the procedure used for DCS800 S0x converters Only the actions and steps which are different are listed here Safety Instructions The rebuilt kit together with the power part and other components being reused will form a converter and a drive system very similar as a new converter module or a new cubicle with a converter module built in Based on that the mechanical and electrical danger installation and commissioning personal is exposed to during the work is similar sometimes even higher There is some work which will only be come necessary together with a rebuild kit like thyristor assignment activation of feedback signals and some tests and measurements not necessary to ready made converters Because of that the Safety Instructions which have been given within the chapter before need to be observed with extreme care When listing the different steps of the start up procedure additional warnings will be given Based on the possible variations caused by the individual projects not all conditions can be covered Please take that procedure as a general guideline and be prepared for individual decisions concerning safety and security Points to be observed because of the situation All relevant safety regulations must be observed in the installation commissioning and maintenance work Because the rebuild kit enclosure class is IPOO it s main and auxiliary connections and other electrical parts can be reached without a
42. agrams at chapter Basic Selection show ing the overall configuration The detailed description of these options is to be found within the Hardware Manual All components belonging to the third part should be mounted close to each other in the existing drive cabinet see di mension drawing Installation 3ADW000197R0101 DCS800 R Sele 40 8t NId SOQS 12 LX 20 290009 0 j9euuoo 9 uo NJ e LS NId S90S yoddns Bn ejqeo uo ind uogoeuuoo punoJo Jey ejqeo ejqeo mee pepjerus ejqeo y pueris ed Jedunf ei 25 pue LS LS Nid Soas ie pJeo SELX SZLX 1019euuoo UOISEH 0 eye d Bununojy uppus siqeo JSp TAS 3noAel pres 8504 s pseog asind Bs 8b NId S00S exp
43. ain e Incase the current can be varied by the reference and the power part consists of a reverse bridge go on with the same procedure used for the forward bridge Keep the value of the parameter for minimum firing angle position Check for correct connections If current is flowing in forward and reverse direction in a controlled manner set the parameter for the minimum firing angle back to default Check for the correct value for the parameter of the bridge changeover time In case the power part consists of parallel bridges do the gate interconnections bridge per bridge and check for correct assignment Do the commissioning of the other parallel bridges once again with the minimum firing angle set to high values because of safety reasons When the gate connections are done and current is flowing in a controlled manner set the minimum firing angle position to default the bridge changeover time to val ues necessary and go on with the other steps necessary to get the drive into op eration Start up 3ADWO00197R0101 DCS800 R Sel e a DCS800 family DCS800 S modules n The versatile drive for any E application E L 20 5 200A O 1 160 Vse E 230 1 000 V E IPOO DCS800 A enclosed E converters E Complete drive solutions E 20 20 000 O 1 500 Vic E 230 1 200 Vo n IP21 IP54 DCS800 E series E Pre assembled drive kits E 20 2 000A E 700 230 600 E IPOO E DCS800 R Rebu
44. ange 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 Ap plication Program if dangerous situations can occur When acti vated these functions will reset the drive and resume operation af ter a fault Do not control the motor with the disconnecting device discon necting mains instead use the control panel keys Or commands via the I O board of the drive Safety Instructions 3ADW000197R0101 DCS800 R Sel e a 57 e Mains connection You can use a disconnect switch with fuses in the power supply of the thyristor power converter to disconnect the electrical com ponents of the unit from the power supply for installation and main tenance work The type of disconnect used must be a disconnect switch as per EN 60947 3 Class B so as to comply with EU regu lations or a circuit breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker s main con tacts to open The mains disconnect 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 thy ristor power converter will neither cause an emergency motor stop nor will the drive be disconnect
45. as a 2 Q or 4 Q version Both of them are available for power parts with one up to four thyristors in parallel Because of the different versions some components will be part of the delivery in every case like the SDCS PIN 51 and SDCS REB 1 board others depend on the configuration DCS800 ROf 0000 01 1 bridge 0000 02 2 bridges 0000 03 3 bridges 0000 04 4 bridges 2 Q DCS800 R02 1x PIN 48 0000 01 1 bridge 2x PIN 48 2x QUINT PS 1x REB 2 0000 02 2 bridges 3x PIN 48 2x QUINT PS 1x REB 2 0000 03 3 bridges 4x PIN 48 2x QUINT PS 1x REB 2 0000 04 4 bridges 4 Q 2x PIN 48 4x PIN 48 2x QUINT PS 1x REB 2 6x PIN 48 2x QUINT PS 1x REB 2 8x PIN 48 2x QUINT PS 1x REB 2 Hardware 3ADW000197R0101 DCS800 R Sel e a 15 The boards serve for different purposes SDCS PIN 48 Pulse transformer board is mounted on a card holder For the interconnections 6 firing leads twisted pair system plug on one end and a shielded flat cable round 20 pole will come with the kit For cable length please refer to chapter Installation SDCS PIN 51 Measuring board is mounted on a card holder For the interconnections 5 leads for the AC and DC voltage measurement single core 6 3 mm faston on one end 2 leads for the current measurement twisted pair system plug on one end 2 shielded flat cable round 16 pole and a pluggable resistor for X22 will com
46. cates a removed jumper DCS800 R volt amp curr coding dsf Hint In case a DCS800 ROx will be used to replace a DCR500B or DCR600 keep the coding of the SDCS PIN 51 board as done in the past and set parameter 97 02 exactly to that value the SDCS PIN 51 board was coded The zero current detection is done on the controller board SDCS CON 4 Because of that the resistors available for that function need not to be coded Hardware 3ADW000197R0101 DCS800 R Sel e a 25 If the ratio of the current transformer is different to 2500 1 or 4000 1 Calculate the total burden resistance R R LS DOS with 1 nominal current of power part br di roct ratio of current transformer Calculate the resistors to be cut off within R1 to R21 according to the next formula The resulting resistance R should be as close as possible to the burden resis tance R If the resulting resistance is smaller than R the nominal current R will be higher than the current the calculation was based on keep the coding and use the recalculated current at parameter S ConvScaleCur 97 02 1 1 1 1 1 1 Rl R2 R3 Rn Additional settings The following settings will be done by software parameters Converter Parameter Parameter Settings Remarks no type code TypeCode 97 01 NONE nominal current S ConvScaleCur 97 02 XXXXX A as coded nominal voltage S ConvScaleVolt 97 03 xxx V as coded power stack S MaxBrdg
47. cing and overall control and performance of the drive Ei ther a binary or an analogue signal should be available indicating field supply equipment o k In case this signal is not available galvanic isolated then it should be made potentially free for safety reasons If the drive should also be used in the field weakening range an analogue signal representing the actual field current is highly recommended It will be used for monitoring and fault in dications generated within the Rebuild kit s software Depending on the old control structure an analogue tacho generator can be re used A pulse generator can only be re used if it generates a pulse train as an output signal see Hardware Manual The Rebuild kit expects an armature current feedback signal for the current control loop This signal normally is taken from two current transformers on the a c side of the thyristor bridge The current transformers shall give 0 5 0 85 A which corre sponds to the nominal current of the thyristor bridge other solutions on request A 115V or 230 V AC supply for the Rebuild kit s electronics is needed Conditions caused by the application It has to be checked if the selected Rebuild kit type can handle the application of the existing drive As long as the existing one was used in a 6 pulse bridge configuration there is no limitation If the existing bridge has been used in a configuration different to 6 pulse addi tional engineering is
48. converter If the supply voltage is o k the converter can be released by the PLC If the supply voltage drops below the threshold the signal level changes at X2 1 2 The COASTING function should be activated which will block the controllers of the converter and force the current to zero as fast as possi ble for safety reasons To avoid a blocking and unblocking condition the power ok signal should be latched off The PLC should release the system depending on other starting conditions Electrical characteristics of the SDCS REB 2 Current requirement for 24 V is 100 mA Current requirement for 48 V is 0 4 A for each parallel connected thyristor if there are 4 parallel thyristors the requirement is about 1 6 A The power supply should contain sufficient amount of capacitance so that 10 secondary voltage tolerance is not exceeded due to voltage ripple 0 V terminal of the electronics on SDCS REB 2 is connected to the six mounting holes on the board Therefore it is grounded At the input plug connectors X613 and X713 firing pulse signals 1 to 6 are re ceived and the current direction signals SR1 and SR2 as well The board ampli fies these signals and distributes them to 8 plug connectors named X11 to X42 The current direction signal SR1 is assigned to plug connectors Xx1 and current direction signal SR2 to plug connectors Xx2 The SDCS REB 2 board has six M4 mounting holes All of them must be grounded using metal stand offs
49. d that firing pulses for one complete thyristor bridge will be available at SDCS PIN 48 To get flexible routing of the firing pulses the SDCS REB 3 board comes into use This board enables the firing pulses to be assigned to the pulse transformers and therefore to the thyristors as well If the SDCS REB 3 board is used it must be installed between the SDCS REB 2 and the pulse transformer board SDCS PIN 48 This board represents a matrix which is used for assigning the current direction signals and the firing pulses re ceived at plugs X11 to X 42 to the output plugs X113 to X813 If possible try to avoid connecting thyristors of different bridges to the same SDCS PIN 48 Com missioning and testing will become easier At a power part with parallel thyristors each thyristor gets a three digit number Every digit has the meaning see chapter nterfacing the Electronics and Thyristors figure Arrangement of thyristors in an anti parallel bridge thyristors named 1 2xx 3xx or 4xx belong to the first second third or fourth bridge thyristors named belong to the forward bridge which is activated by the current direction signals 1ACE and SR thyristors named x2x belong to the reverse bridge which is activated by the current direction signals SR 2ACE and SR 2BDF thyristors named xx1 xx2 up to xx6 indicate the normal firing sequence by their number The pulse transformer board SDCS PIN 48 contains 6 channe
50. ditions The next tables describe the technical specifications of the product e g the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings Remark System connection Voltage 3 phase Voltage deviation Rated frequency Static frequency deviation Dynamic frequency range 17 This chapter with exactly the same lay out is used for all subsets of the system DC S800 Because of this only headlines without are applicable to the product DCS800 R df dt 17 s 0 5 to 30 cycles 230 to lt 1000 V acc to IEC 60038 10 continuous 15 short time 50 Hz or 60 Hz 50 Hz 2 60 Hz 2 50 Hz 5 Hz 60 Hz 5 Hz Please note Special consideration must be taken for voltage devia tion in regenerative mode Degree of protection Converter Module and op tions line chokes fuse holder field supply unit etc Enclosed converters Paint finish Converter module Enclosed converter IP 00 NEMA TYPE OPEN IP 20 21 31 41 light grey RAL 9002 light grey RAL 7035 Environmental limit values Permissible cooling air temperat at converter module air inlet with rated DC current w different DC curr acc Fig below Options Relative humidity at 5 40 C Relative humidity at 0 5 C Change of the ambient temp Storage temperature Transport temperature Pollution degree IEC 60664 1 IEC 60439
51. ds one of them is Start up 3ADWO00197R0101 DCS800 R Sel e a 62 the auxiliary cathode and check them for electrical contact to C1 power part terminal by means of an Q meter look for the other thyristors and mark them if there are parallel connected thyristor bridges do the same marking as for the first do the electrical connections according to the drawing for the flat cable connections within and between the 3 parts the 3 AC and the 2 DC voltage measurements the 2 current transformers for the power part monitoring klixon fan monitoring others the auxiliary voltage make sure a 2 2 kohm resistor or something similar is plugged on terminal X22 at SDCS PIN 51 board sure the jumper is placed on 1 and S2 on the SDCS PIN 51 board make sure all cable shields are correctly connected don t connect any of the gate leads Commissioning the Kit The complete commissioning of a DC drive consisting of the motor and the thyris torized power part equipped with a rebuild kit is based on the manuals used for the converter type DCS800 S0x Only few additional steps are recommended and will be listed afterwards Start with the commissioning steps used for complete converter modules Safety Instructions local safety regulations etc Check the engineering e g make sure the selected voltage levels are correct and selector switches if existing are in the correct position Make s
52. e that this board does not need to be used in every case as long as the mechanics allow gate cable length lower than 1m Parts which are common for the different configurations are always drawn at the same position So the parts not needed or not used in the one or the other situa tion can easily be recognised The installation of the kit can be subdivided into 3 parts Figure 3 is taken as an example and will have these 3 parts marked read the other pictures in a similar way e Part 1 consists of the SDCS PIN 48 boards which have to be mounted as close as possible to the thyristors e Part 2 covers the SDCS PIN 51 and the SDCS REB 2 boards with their acces sories The components within this part may be different depending on the final configuration needed for the existing power part The cable connections within these boards are quite short so the boards have to be mounted close to each other but can be mounted quite far away from the boards used for part 1 or 3 Figure 6 gives a suggestion how the components can be mounted on a metal plate In case the configuration according to Figure 8 or Figure 9 is used Figure 10 and the following ones will show the mechanical possibilities e Part 3 shows the main DCS800 ROx electronics with the electronic power sup ply SDCS POW 4 and the microprocessor system SDCS CON 4 All other op tions which can be connected to the controller boards are left out for easier reading They are indicated on the di
53. e with the kit For cable length please refer to chapter nstallation SDCS REB 1 Interface board QUINT PS Power supply SDCS REB 2 Pulse amplification board for more than one bridge in parallel is mounted on a card holder For the interconnections 2 flat cables 20 pole will come with the kit For cable length please refer to chapter nstallation Optional parts The options available differ in their usage Some of them are related to the rebuild kit some to the drive itself or to the application the drive is used for Subassembly SDCS REB 3 This board is used together with the SDCS REB 2 and SDCS PIN 48 With the help of this board the firing pulse assignment can be changed and adapted to the needs given by the existing power part construction The board will come mounted on a card holder For the interconnections 4 flat cables 20 pole will come with the kit For cable length please refer to chapter nstallation Plus code 5164 FEX 425 Internal This field supply can be build into the electronic housing When ordered using the plus code it will be mounted inside the housing during production The board can be connected to any 2 or 3 phase power supply with up to 500V Power rating with 2 phase supply 16A max with 3 phase supply 25A max When doing the engineering please make sure all conditions for the power sup ply configuration are taken into consideration Subassembly SDCS IOB 2x IOB 3 This subassembly is a par
54. ed 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 e Intended use The operating instructions cannot take into consideration every possible case of configuration operation or maintenance Thus they mainly give such advice only which is required by qualified personnel for normal operation of the machines and devices in in dustrial installations If in special cases the electrical machines and devices are in tended for use in non industrial installations which may require stricter safety regulations e g protection against contact by chil dren or similar these additional safety measures for the installa tion must be provided by the customer during assembly Note e When the control location is not set to Local L not shown the status row of the display the stop key on the control panel will not stop the drive To stop the drive using the control panel press the LOC REM key and then the stop key QD Safety Instructions 3ADW000195R0101 DCS800 Service Manual e a 58 Safety Instructions 3ADW000197R0101 DCS800 R Sel e a 59 Start up What this chapter contains This chapter describes the commissioning procedure for a DCR kit
55. erter can be done with this DCR kit too as long as the components necessary for that application can be used for both systems Engineering help is given within the DCS800 converter module s documentation see inner page of the jacket of this manual This manual just focuses on items related to the engineering of the Rebuild kit Door Overriding DriveWindow control I NDPA 02 Panel NDPC 12 P MCIA CDP 312 NISA 03 ISA RJ45 NDBU95 DCS800 R00 0000 00 Slot 1 Fieldbus CON 4 adapter Rxxx or RDIO RAIO jeondo tdo SIS SCt X33 4 i 1 i DCSLink twisted pair 1 30 8 7 i Advant i controller i os o 1 gn gn is 4 Figure 1 Overview of DCS800 R System Basic Selection 3ADWO00197R0101 DCS800 R Sel e a Ordering code 11 DCS800 RO 0000 01 0000 DC Drives Product family DCS800 converter Rebuild kit Bridge type 1 7 single 2Q 2 anti 40 Number of parallel antiparallel thyristors 01 7 1 bridge 02 2 bridges in parallel 03 3 bridges in parallel 04 4 bridges in parallel Options XXXX codes according list for add on options selectable option taorb 9200 208 490 J9312xo
56. g connector demanded by the thyristor type in use Hardware 3ADW000197R0101 DCS800 R Sele 20 Measurement board SDCS PIN 51 This board is always required with the rebuild kit One SDCS PIN 51 board per kit The SDCS PIN 51 board contains following functions Connection to pulse transformer board boards Interface for heat sink temperature measurement with a PTC resistor Measurement and scaling of AC and DC voltage via high ohmic resistors Measurement of the armature current and scaling with burden resistors to 1 5 V for rated current burden resistors for zero current detection e Card holder for SDCS PIN 51 5 y 2 1 A 8 331 e 347 q o 2 f L W5 see diagram Conductive R123 7 power supports 168 5 line potential PTA F LE 1 Xen2 1 xa 2 Wi n X22 X12 LSU 155 d kc ob od 4 T S3 3 Two PTC R1 1 rare Vi wit wo we w we P eas co d E GE d Ie 4 F E WA W71 W72 8 Wi wie wis wi wis wie x IF Ge ere Wr i wei wo wig wis WI7 da Isolating supports Di W26 w235 w24 W23 W22 A de El 5
57. g of SDCS REB 3 e Check the configuration A firing pulse amplifier of the SDCS REB 2 via plug connectors X11 X21 X32 and X42 may operate only one firing pulse transformer per current di rection There is only one connecting point allowed per column at a 2 Q system There are only two connecting points allowed per column at a 4 Q system There is only one connection allowed per row Precisely one matrix field with six connections should be assigned per out going plug connector X113 X813 SR ACE or SR BDF outputs of plug connectors X113 to X813 must always be assigned to only one current direction signal either to SR1 or to SR2 e Assign SDCS PIN 48 to SDCS REB 3 board connections e Configure the SDCS REB 3 board complying with the information given by the example e Inspect visually for clean solder points and remove undesired tin bridges e Check firing pulses Plug connectors X1113 and X2113 These plug connectors are only used in simple applications aiming solely at a re distribution of the firing pulses as compared to and deviating from the standard dis tribution in modular design In this variant REB 1 and REB 2 are dispensed with with the result that only two anti parallel thyristor bridges can be controlled Hardware 3ADW000197R0101 DCS800 R Sele 34 Fastening The SDCS REB 3 has nine fixing holes All of them must be grounded 170 80 pit RAT 5 X121
58. ild Kit E Digital control kit for existing powerstacks E 20 20 000 A E 1160 Voo n 230 1 200 E IPOO E Ak ED ED ABB Automation Products GmbH Wallstadter StraBe 59 68526 Ladenburg GERMANY Tel 49 0 6203 71 0 Fax 49 0 6203 71 7609 www abb com motors amp drives Compact Highest power ability Simple operation Comfortable assistants e g for commissioning or fault tracing Scalable to all applications Free programmable by means of integrated IEC61131 PLC Individually adaptable to customer requirements User defined accessories like external PLC or auto mation systems can be included High power solutions in 6 and 12 pulse up to 20 000 A 1 500 V In accordance to usual standards Individually factory load tested Detailed documentation DCS800 module with all necessary accessories mounted and fully cabled on a panel Very fast installation and commissioning Squeezes shut down times in revamp projects to a minimum Fits into Rittal cabinets Compact version up to 450 A and Vario version up to 2 000 A Proven long life components are re used such as power stacks main contactors cabinets and cabling busbars cooling systems Use of up to date communication facilities Increase of production and quality Very cost effective solution Open Rebuild Kits for nearly all existing DC drives tailor made solutions for BBC PxD BBC SZxD ASEA TYRAK other manufacturers Ident No 3ADW0
59. ing for nominal current will be done by the resistors R1 to R21 which are connected in parallel Hardware 3ADW000197R0101 DCS800 R Sele 24 If the ratio of the current transformer is either 2500 1 or 4000 1 The next table lists some burden resistor settings based on two types of current transformers 2500 1 and 4000 1 and some values for the nominal current As long as the nominal current of the power stack is close to these cur rents and the current transformers are identical as listed below this op tion for coding the current should be used In such a case remove the jumpers on the SDCS PIN 51 board according to the current selected and set parameter S ConvScaleCur 97 02 to exactly that se lected rated current 2500 1 4000 1 Nominal current iw IA 900 1200 1500 2000 2500 3300 4000 4800 5200 IRT RA 180 0 0 0 0 pene e 9 R6 89 9 2 Rs fso 5 Rio x 8 15 G o R2 180 2 65 exo Ria peo G o 15 180 oxo Rie 180 9 R18 680 oxo R19 1209 oxo R20 2709 504 82 R23 479 865 624 70 3 4 gt 6 indi
60. is built up by more than one bridge in parallel If a single bridge cannot give this current a brand new converter is probably the more economical solution The ratio between reverse forward blocking voltage of the thyristors and the nominal line voltage should be factor 3 or higher the blocking voltage has to be measured on a thyristor test stand if the actual blocking voltage gives a lower ratio the thyristor s need to be replaced In such a case please check if a complete new converter may be more economical Basic Selection 3ADW000197R0101 DCS800 R Sel e a Drive s design conditions It is intended to install the kit into the existing drive cabinet The following drive equip ment will be reused and should therefore be in good condition Check all parts in the AC supply like main disconnecting switch with fuses or main contactor or similar for good condition Check the thyristor bridge itself fixing devices press clamps for thyristor mounting etc with cooling equipment for good condition If a Rebuild kit is used for the armature supply the existing field supply can be re used or upgraded too Ifthe field supply will be upgraded one of these can be used SDCS FEX 425 internal built in 1 or 3 phase DCF803 0035 external 1 or 3 phase DCF803 0050 4 0050 external 1 phase DCS800 S0x xxxx 05 external 3 phase If the old field supply will be reused check the overall strategy concerning monitoring fault tra
61. lation 52 Seca Sera QUA ona s l E even 9 o g Il i SU 55 5 To 2 EV 96 LE ELA 95 gt IZLA 5 4 m 4 sen o m 2 a 5 S LE 9 8 een b o 5 Sill vera x g via x PHA x c lt lt peux 3 m T 8 E no d E E 9 Nid SodS pc 19 NId SOdS LS d an E SeLex Ea 5 A SEX 9 a FU sex a 8 perex 2 ELX u m 10 211 2 1 o o o 8 2 S ZIX 4 8 e a a 1 8 8 5 o 5 8 Figure 13 Principles of cabling yout electr cabling dsf DCS8 reb card 1 Installa
62. lection Hardware Technical preconditions and limits 7 Selecting the suitable Rebuild 7 Hardware COnCiIONS PUE D 8 Drives design conditions pena cect RO GET Aaa teeta adu 9 Conditions caused by the Application ee edhe uie teed ote Uta es 9 Type coding ce sienne ep tiet er e nea 10 Basic components of the DCS800 R nnne 13 Housing Tor main cett tones O odio tod mte perda 13 Pre assembledipaltca assalire 14 once adaga Da 14 a ile 15 Dimensions main electronic 16 Environmental Condita dae eco a get cles eren heben ese ba tatg ace 17 Pulse transformer board SDCS PIN 48 sse 19 ULI EUM 19 Measurement board 50 1 20 WIFINO reete ee e cite device dep eter o a Ep dene Hte eee Meena eed 22 EASTONINO M P 22 occ io notai 22 GC OCG RE EP 22 Voltage 23 Nominal current E E 23 Additional settings ete e oe rede acte padece pat
63. ls numbered A to F These are in turn subdivided into 2 groups one with the channels A C E and one with the channels B D F These are controlled by two current direction signals The next figure shows the routing of the firing pulses and the activation of the two groups for three different configurations used with the bigger standard DCS800 SOx modules Signal flow and Thyristor designation Signal flow of firing pulses and doubling of current direction signals are shown based on the relevant figures in chapter nterfacing the Electronics and Thyristors That results in the thristor designation Hardware 3ADW000197R0101 DCS800 R Sel e a SDCS CON 4 4211 X13 SDCS PIN 51 signal routing SR_1BDF SDCS CON 4 1 7 6 SR_2ACE SR_2BDF t Hx413H X213 HX113 t X313 SDCS PIN 51 12 ld ig JL4 Cai m ns signal routing r SR 1ACE SR 1BDF SDCS CON 4 T1 X13 SR_2ACE SR 2BDF t t Hx413H X213 HX1 13 1 X313 SDCS PIN 51 signal routing a SR_1BDF DCS8 R RB_sign dsf SR_2ACE SR_2BDF Hx213HX113 t 413 Hx X318 SDCS REB 1 signal routing Signal flow of firing pulses and thyristor designation X113 X113 SDCS PIN 48 forward
64. needed It should be checked at first if a standard converter DCS800 S0x can be used for such a configuration Most likely DCS800 ROx can be designed similar as with a standard converter There are drives used in the past in a configuration sometimes named MASTER FOLLOWER or MASTER SLAVE or similar In all these applications one drive had generated references or commands for the second third etc The Rebuild kit is basically prepared for those configurations the final wiring may be different For more details please refer to the documentation If the existing converter has been used in a non motor application most often a pre pared solution is not available but most often an engineered solution can be found Please contact your local ABB engineering organization Basic Selection 3ADW000197R0101 DCS800 R Sele 10 Type coding and accessories There is only one mechanical construction for all the different versions of the kit It basically serves as a cover for that part named DCS800 ROx on the next figure Ordering of the kit is done with the ordering code shown on the right page The op tions available for the Rebuild kit are identical as for a DCS800 S0x converter Some options e g K454 adapter module for PROFIBUS DP communication will be build in if ordered some will come within the kits box and others need to be specified seperate and will come in a separate box All applications which can be done with a DCS800 conv
65. nnection is required Safety Instructions 3ADW000195R0101 DCS800 Service Manual e a 56 Fiber optic cables optic cables always grab the connector not the cable itself Do not WARNING Handle the fiber optic cables with care When unplugging touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt The minimum allowed bend radius is 35 mm 1 4 in Mechanical installation These notes are intended for all who install the drive Handle the unit carefully to avoid damage and injury A Operation DCS800 sizes D4 D7 The drive is heavy Do not lift it alone Do not lift the unit by the front cover Place units D4 and D5 only on its back DCS800 sizes D5 D7 The drive is heavy Lift the drive by the lift ing lugs only Do not tilt the unit The unit will overturn from a tilt of about 6 degrees Make sure that dust from drilling does not enter the drive when in stalling Electrically conductive dust inside the unit may cause damage or lead to malfunction Ensure sufficient cooling Do not fasten the drive by riveting or welding 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 AC 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 r
66. nserted in these penetrations and soldered on both sides an input to output connection has thus been established The multilayer construction used for this board enables this method to be em ployed e Name the AC terminals of the existing power part e Name all thyristors according to the list above e Look for a place where the SDCS PIN 48 board can be mounted and make sure that the distance to the gates of the thyristors does not exceed one me ter the best noise immunity can be achieved with the shortest gate leads e Assign the thyristors to a firing channel bearing in mind the group assignments Signal handling The handling of the signals controlling a thyristor is presented by an example Stipulation Thyristor Vx26 is to be controlled via plug X32 to plug X813 and chan nel D of SDCS PIN 48 board e Evaluation Thyristor Vx26 has been assigned to signal 6 Thyristor Vx26 belongs to current direction 2 SR 2 Channel D has been assigned to group SR BDF Channels B and F are then likewise assigned to current direction 2 Hardware 3ADW000197R0101 DCS800 R Sel e a 33 e Implementation Solder in pin row to X813 intersection SR 2 SR BDF Solder in pin field 3 8 intersection 6 D Pins have to be soldered in by inserting the pin solder it on both sides of the board and shorten the pin Signal handlin
67. nstallation 3ADWO00197R0101 DCS800 R Sel e 42 peo 8t NId SOQS d Bununoy 41 LX 10 9eUu09 uonoeuuoo 4 pepierus PUNOI ejqeo uoqqi sees ur pepnpur jou pepjerus you jou puens LS NId S00S ie SE LX SZLX 10 99UUOI uojseJ 0 pJeo eyejd aiqeo Sp postas ynokeT pres esoa 4 jeuuojsuea asind premios a lt lt IX v ebpug iS O z Buissi pue segeo asind esie eH gt puaba 5 0 cm emm mmm mcm g 9 dA uoisej jeduunf BIA 25 pue LS pouuoo 9 9 8 v MOd S2as t OV A 055 511 9r 4 210 1 N q x x 2 x nn ee n
68. nverter modules 3ADW000197R0101 DCS800 R Sel e a Hardware 18 Regulatory Compliance The converter module and enclosed converter components are designed for use in industrial envi ronments In EEA countries the components fulfil the requirements of the EU directives see table below European Union Directive Manufacturer s Assur ance Harmonized Standards Converter module Machinery Directive 98 37 EEC Declaration of Incorpora EN 60204 1 EN 60204 1 93 68 EEC tion IEC 60204 1 60204 1 Low Voltage Directive 73 23 EEC Declaration of Conformity EN 61800 1 EN 60204 1 93 68 EEC IEC 61800 1 IEC 60204 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 installa tion instructions concern ing cable selection ca bling and EMC filters or dedicated transformer are followed in accordance with 3ADW 000 032 in accordance with 091 North American Standards In North America the system components fulfil the requirements of the table below Rated supply voltage Standards Converter module Enclosed converter to 600 V see UL Listingwww ul com certifi cate no E196914 Approval The spacings in the modules were evaluated to table 36 1 of UL 508 C Spacings also com
69. ny protection After the supply voltage is disconnected by the main switch always ensure by measuring that no part of the system has voltage or the system is protected with sufficient touching cover before any work is started There might be live terminals inside the drive cabinet even after the supply voltage has been disconnected by the any main switch e g incoming busbars of the main switch itself or external auxiliary power supplies Avoid unnecessary voltage withstand tests on any part of the unit Start up 3ADWO00197R0101 DCS800 R Sel e a 60 Maintenance work Tools All maintenance must be carried out by a competent electrician who shall also have custody of keys to the doors unless the system is located in switch gear All points within this chapter must be observed before any work is begun In addition to the tools needed to maintain electrical parts some special tools are recommended Oscilloscope either with galvanically isolating transformer or isolating amplifier for safe measurements Clamp on current probe an AC type is sufficient for gate firing pulse measure ments in case the scaling of the DC load current needs to be checked a DC type is needed Voltmeter Make sure all equipment in use is suitable for that voltage level applied to the power part General hint In addition to the work specific for the installation of the pure rebuild kit hardware attention should be paid to features rela
70. on Part 2 without SDCS REB 3 gt suun jddns samod 104 uonoeuip Installation 3ADWO000197R0101 DCS800 R Sel e 45 ed uojsej Uonoeuuco pungit Jeduunf ei 25 pue 6 papjalys you uoqqid 84 pepierus punoJ ejqeo ser SU pepjerus 100 ejqeo 1 52005 ie SELX SZ LX 101090000 UOJSE O pred e pred 8t NId SOQS 18 ejejd d LX 10 0 uojse4 eu you ejqeo JSp tqex pas paes esoa eiae
71. ons If this is not a problem the DRIVE S DESIGN CONDITIONS will give some guidelines for the overall design After that a decision must be made for the functionality of the interface between the kit and the Programmable Logic Controller Depending on that the Rebuild kit s type code can be fixed by using the type designations listed on the next pages Afterwards please check if all conditions are fulfilled as listed in CONDITIONS CAUSED BY THE APPLICATION Hardware conditions If a Rebuild kit is taken into consideration the items listed afterwards will give some help to decide whether a Rebuild kit or a converter module enclosed con verter is the better solution Before an existing DC power part is upgraded by the Rebuild kit it should be checked if a brand new module may be easier to install or may be a more reli able solution tested power stack The existing power bridge should be build up by max 4 thyristors in parallel per current direction solution for more thyristors in parallel on request It doesn t matter whether the bridges have the same number of thyristors in parallel The supply voltage used for the existing thyristor bridge has to be lower than 990 V because of the devices used to interface the electronics to the thyristors higher mains voltages on request The thyristors actually used should be of a disk type One single thyristor bridge should be capable of running around 1000 A or more if the converter
72. oooo once Moooooao oooooo Roca T NORIU see a a a a SRE rr rr o ssssss ssssss w ssssss ssssss 9 9 x amp gt gt gt l 7 20055055 Moooooo 9999995 RAE ooa ARGOS Q He BRs DS O pipa ec w sessss sss2s282 vw s5essss ss9855 o lt lt gt lt gt 8 5 0 x gt 22555553 gt 2 e Moooooo Moooooo Rie GO qo rc CC Rage VON DADA OR EI ovp dur Arp ERE DP 2 openee SSSSSS x gt gt 2 o os5558 22555585
73. ply with table 6 and table 40 of C22 2 No 14 05 or on request UL types on request 2600 V to 990 V EN IEC xxxxx see table above Available for converter modules in cluding field exciter units IEC types on request for details see table above Hardware 3ADW000197R0101 DCS800 R Sel e a Enclosed converter 3ADW 000 032 3ADW 000 19 Pulse transformer board SDCS PIN 48 This board is always required with the rebuild kit Normally one SDCS PIN 48 board per 6 thyristors if the board can be placed close gate wires lt 1 m to all 6 thyristors of one bridge bx A Card holder for SDCS PIN 48 80 05 10 317 E SDCS PIN 48 conductive supports 5 260 Pin48 dsf SDCS PIN 48 board and card holder Wiring The gate cathode wires which are a part of the rebuild kit s delivery have to be handled in this way end is equipped with a coded plug which fits the C pins on the SDCS PIN 48 The cable length in the delivery condition is 2 m The cable routing should be done to end up with a cable length as short as possible the max cable length is 1m The cables have to be shortened and have to be equipped with the plu
74. q S 8 q a OVEXT H q q ovexT 4_ gt e e Gye gt amp amp a gt gt lt gt lt gt gt ens gt eL A B D E F 2 SDCS PIN 48 RB 49 4p a dsf X22 X122 X23 24 555 ae e gt e a gt a e S e P gt gt gt AAAA x E 2 a 85 8 ep ep ep eps SDCS PIN 51 cea e 2 E Pa eS gt sc gt aj gt als 8 L SDCS REB 1 A B D E F 2 SDCS PIN 48 Forward bridge pulse transformer boards 4 quaarant application parallel thyristors Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800 R Sele 38 Connection for 2 quadrant application parallel thyristors With parallel connected thyristors the additional board SDCS REB 2 is needed Because of the REB 2 board external 24V and 48V are needed The power supply SDCS POW 4 is not able to give enough power for parallel connected thy ristors The additional board SDCS REB 1 can be used but must not be used Depending on the final decision the flat cable from X613 SDCS REB 2 has to be connected to either X613 SDCS REB 1 or X513 SDCS PIN 51 with SDCS REB 1 re moved The figure below shows the configuration for a 2 quadrant bridge with 4 parallel connected thyristors X24 X
75. re several ways to connect the firing commands from the measurement board to the pulse transformer board s The assignment of power section mains connection and wiring to the SDCS PIN 51 board is mandatory since the com puter board uses this assignment as the basis for computing the pulse sequence With existing systems we recommend following our configuration when numbering the semiconductor valves so as to preclude any errors The arrangement of the thyristors in an anti parallel bridge is presented in the figure below Thyristors for forward bridge current direction 1 SR1 are numbered V11 V12 V16 and thyris tors for reverse bridge current direction 2 SR2 are numbered V21 V22 V26 In two quadrant applications only the forward bridge is existing L1 U1 L2 V1 L3 W1 N M DCS800 u i meas val dsf actual U actual U gc actual to SDCS PIN 51 Arrangement of thyristors in an anti parallel bridge Connection for 2 quadrant application No parallel Thyristors i 122 X23 X25 vi4 Vi vie Vi2 15 8 G G G G G G gt C Cc Cs Cos 5 o 2 g B x N x g x Lx eee gt D 5 SDCS PIN 51 S Spas nds 5 ol e o o 2q c34 c dsf
76. s got six M4 mounting holes Using this card holder care must be taken to have a good connection to ground When mounting these boards without card holder the figures for the corresponding boards shown before show which of the holes have to be grounded and which have to be isolated 15 to 20 mm long metal stand offs and insulation stand offs have to be used The insulation clearance must be rated for 990 V AC working voltage PTC temperature sensor Normally there is no temperature sensor in existing converters in this case a separate resistor 2 21 kohm 0 5 W 1 delivered with the kit must be connected between terminals X22 1 and X22 3 on SDCS PIN 51 jumper S3 on the same board must be in position 1 2 Because of this the temperature measurement reads a fixed value and is out of operation Some kind of power part monitoring can be designed by using optional devices For more information see chapter Special Accessories HW type coding All jumpers W70 to W72 W80 to W83 and W10 should be kept untouched default condition n case a board should be used which had been in operation or which had been coded why ever reason with the above listed jumpers no additional ac tions need to be done It can be used without further modification just leave the jumpers as they are They will not be read by the converter s software and therefore not taken into calculation Hardware 3ADW000197R0101 DCS800 R Sel e a 23 Voltage
77. s the SDCS PIN 51 Take the same grounding guidelines as be fore Wiring the Kit The system still has to be in a safe condition The drawing used for the mechanical work should now be used for the electrical wiring too For single thyristor bridges take the hints given in chapter Interfacing the Electronics and Thyristors into con sideration Before the wiring work is started do the following preparations Check if there are labels indications on the existing power part naming the thyristors and or phases according to figure Arrangement of thyristors in an anti parallel bridge In case labels are existing check if they are correct and fit to each other If there are no labels existing or they are incorrect start in this way look for the phase U1 L1 and mark it do the same with V1 L2 and W1 L3 look for thyristor V11 and mark it the next statements may be of help in case problems may arise e use the measurements done before e if not follow the busbar U1 the thyristor connected to that busbar is ei ther V11 or V24 e the cathode of V11 or the heatsink has electrical contact to the C1 power part terminal disk type thyristors the orientation can easily be recognised by the smaller distance between cathode and gate compared to the bigger dis tance between gate and anode e if the place of V11 V24 is found but the orientation is not clear and the thyristor is not visible take one pair of pulse firing lea
78. see figure Layout of the SDCS REB 2 board below Hardware 3ADW000197R0101 DCS800 R Sel e a Diagram X1 1 POWER OK X1 2 lt gt 25 X14 we ale 24 Ov ov separated potential range POWER SUPPLY 48V X2 1 2066 X2 2 II I Ji X42 Diagram of the SDCS REB 2 board 285 200 204 gt Card holder for SDCS REB 2 150 15 21 SDCS REB 2 height lt 55 mm without clearance supports are conductive diameter of all supports 4 6 mm Layout of the SDCS REB 2 board 29 3ADW000197R0101 DCS800 R Sele Hardware 30 Interface board SDCS REB 3 Firing pulses This board is not included in the standard kit In case the function described later on gives some advantage it needs to be ordered separately In a single thyristor bridge the distance between the 6 thyristors and the pulse transformer board is often quite short The length of these cables which is limited to 1 meter is sufficiently long In big thyristor stages with parallel thyristors the dis tance can be longer than 1 meter In addition to that there is another reason which becomes more critical at big thy ristor stages The wiring of the SDCS PIN 51 SDCS REB1 and SDCS REB 2 is designe
79. sss u Sessss 5 5 A 3 z 5 5 N 885 5 0 m peered E lu 26 9 Aeree 5 Ae 2 E pere 5 Aesse gessi 45 E F 5522 18 9 5555554555555 5 COTON 2 lu 5 cabra lu lu 5 5 5 SR1 mounting direction for power supply units Ul ws ws gt gt 1 wo ws W6 T t 4 Wi wie 15 Wi4 W13 Wi2 Ci wai w20 wig wis wi7 4 FD fF I Di wo w2 w24 W22 gt FL
80. t of the accessories of the DCS800 SOx converter module In case the inputs or outputs available at the controller board directly do not fulfill the criteria concerning the input or output voltage range or the crite ria of the input output to ground this option may be a solution The subassembly needs to be placed close to the electronic housing Depending on the overall configuration and the needs caused by the application itself it may be necessary to add other options These options should be selected based on the overview of the DCS800 R system shown at the end of chapter Basic Selection Hardware 3ADW000197R0101 DCS800 R Sele 16 Dimensions main electronic housing The electronics housing is just equipped with these components mentioned before There is no cooling fan Nevertheless based on the components build in natural convection is necessary to keep the temperature of the used components within the limits Because of that it is important to mount the housing as shown on the figure before and to make sure the convection is not blocked i 5 b e 8 3 064 9 o u 2 N E o o z EM 22 02 m 10 59 86 Dimensional drawing of DCS800 R Hardware 3ADW000197R0101 DCS800 R Sel e a Environmental con
81. ted to drives in general There is the engi neering and the interface to other components in general the selection of control cables and their routing earthing and grounding screening and other points which need further considerations The manual Technical Guide gives some help within the chapter EMC Compliant Installation and Configuration for a Power Drive Sys tem This chapter gives information specific to fulfill the needs necessary for the CE marking Most often CE marking is not the most important target for a system upgraded by a rebuild kit Nevertheless using some of the ideas will make the complete system safer Measurements with the old equipment still working Some measurements should be carried out before the existing installation is switched off and dismantled They serve to document the existing performance and get the definition of some signals or terminals of the existing hardware record the actual signals of the speed the armature and the field current line armature and field voltage other application related signals record line and armature voltage to determine the name of the single line phase and the position of the and terminal this will be an alternative to disassemble the thyristor stack to check the orientation of the thyristors at power parts with more than one thyristor in parallel record the firing pulse and the thyristor current of each thyristor to be sure all of them are conducting
82. tion 3ADW000197R0101 DCS800 R Sel e a 53 Safety Instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing operating and servicing the drive If ignored physical injury or death may follow or damage may occur to the drive the motor or driven equipment Read the safety instructions before you work on the unit To which products this chapter applies This chapter applies to the whole range of the product DCS800 the converter modules 0 5800 50 size D1 to D7 field exciter units DCF80x etc like the re build kit DCS800 ROx 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 dan ger 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 volt age which can cause physical injury and or damage to the equipment than those caused by electricity which can result in physical injury and or damage to the equip ment Electrostatic discharge warning warns of electro 4 static discharge which can damage the equip ment General warning warns about conditions other Safety Instructions 3ADW000195R0101 DCS8
83. ts described by higher production more accurate control design of state of the others will be compared with the disadvantages of revamping described by standstill time of production hardware cost training etc If this comparison is based on an upgrade of the converter s electronics the Re build kit which is described within this document may be a solution Before the fi nal decision is made to use a Rebuild kit the configuration of the existing drive needs to be checked more in detail to make sure the kit fulfills all demands Selecting the suitable Rebuild kit The basic structure of a converter to control a DC motor looks like this Converter control electronics thyristor with interface to bridge thyristor bridge PLC The electronics of the existing converter indicated by the left box above is splitted into 2 boxes in the kit electronics electronics thyristor interface to interface to bridge PLC thyristor bridge Rebuild kit Existing The Rebuild kit can be used for armature bridges in non regenerative or regenera Basic Selection 3ADW000197R0101 DCS800 R Sele tive mode with maximum 4 thyristors in parallel In case there are more than 4 thy ristors in parallel per current direction there is no standard kit prepared please con tact your local ABB organization To selecting the Rebuild kit first the HARDWARE CONDITIONS must be checked to become aware of critical limitati
84. ure safety equipment is working properly Set basic parameters e g the ones which are presetted by the WIZARD within the PC based tool DriveWindow Light during steps 1 and 2 Set the parameters in group 97 described in chapter Hardware section Measurement board SDCS PIN 51 For setting the values of parameters 97 01 to 97 03 the following procedure needs to be used Select 99 06 and set to SetTypeCode equivalent value 10 Select 97 01 and make sure it s set to None equivalent value 0 Select 97 02 and set the value demanded by the hardware Select 97 03 and set the value demanded by the hardware Select 97 04 and 97 07 and set as recommended necessity Switch OFF the control voltage of the rebuild kit and ON again to apply the settings In contrast with the normal commissioning procedure additional precautions should be made to avoid damage to components of the drive system in case of wrong wir ing or unknown data e Connect the gate leads to thyristor V11 V13 and V15 Set the parameter for the bridge changeover to a remarkable value e Before the drive is released the first time the parameter for the minimum firing Start up 3ADWO00197R0101 DCS800 R Sel e a 63 angle should be set to values higher than 95 degrees Allow the system some moments to adapt to the new value This limits the output voltage of the drive and gives a safe operation even with a fault in the current feedback circuit Precautions should be made do

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