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Hardware Manual - Galco Industrial Electronics

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2. o 1 E SDCS FEX 4 Plus code 5164 i F302 v4 M Nili 9 E i w F303 wi 35A FEX425 INTERNAL Supply voltage 5005 motis scr er ect EES 1 or 3 phase for supply 1 at Ha voltages 500 600 V an i 2 Wins 12 autotransormer is mandatory i d LAN 4 i viw i L i 7 1 s T i 5 4h 58 58 4h 58 i UE i i Eum T T i gt 2 i 82 1 58 88 gs Tel 8 fel 8 1 5 5 5 5 5 5 i VV PS ES LI fk 422141 I Ope i 8 i i 4 8 0 4 4 E e i amp HW conf 4 45 2 Lg o7 meme meme me meum Temm mmm mmm mmm meme mmm meme 4 D1 Plus code 164 SDCS FEX 4 i Supply voltage i max 600 V i 35A 425 INTERNAL i i max 500 V t d t 1 2 d a i i ol wl a i i LT i B 8 5 8 i L1 j m eat 5 i sg wu 7 fl gl 3 vel a3 ef gt gt I gt
3. SDCS CON 4 Firmware e N 90 270 V ATACH2 X31 30 90 V 98 gt 2 lm 18 30 V 2 3 s 2 Des d 4 1 Ne 5 82 37 4 55 gt 6 45 3 3 ms o 10V 533 4 55 gt 8 3 3 ms 9 gt 10 5 ms X4 1 gt 2 5 ms 3 GND 4 10 5 10V 6 GND 1004 4757 H 7 AO1 5 5 8 A lt AO 5 5 9 Jj n 10 GND l act 5 1 m y 5 2 121 tone ChA 1 3 ChB 4 ET 45 65 ChB 1 5 Tor ChZ 5 Tot tone 7 pp ChZ 1 7 GND 8 Sense 0 V 9 Sense 5 V POW 4 15 Power _ 111 15V 24V ES uae X6 4k75 47nF F 215 2 10 5 gt 012 3 10 5 gt 4 DIA 5 10 5 gt 05 7 4 6 Homs 016 7 33 5 gt 017 8 3 3 gt DI8 9 24 V lt 125 mA 10 1 7 1 Relay driver lt DO1 2 Relay driver lt DO2 3 Relay driver lt 4 Relay driver lt 004 5 Relay driver lt 005 6 Relay driver lt DO6 7 Relay driver lt DO7 8 IGND Con4 I O b dsf Technical data short circuit protected gain can be varied in 15
4. 18132 ND15 16 c dsf CH 1o 1 th y gi 5 _ T 8 UN SIE 38 y L E di es cic Q4 d e t ND7 to 12 c dsf 10 3 1 C1 E F G H 1 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 8 5 7 X 5 X ND 12 458 250 112 113 424 224 63 100 13 18 554 280 40x6 Line reactors type ND 13 14 Line reactors type ND 15 16 all busbars 40x10 all busbars 60x10 140 2 151 2 8 90 45 45 45 1 q Si 4 UN f g E d 5 Ms 4 2 ai 8 gt 5 5 3 123 2 5 8 8 147 83 gi Sig 15 B 9 9 4 g Y 1 4 4 M dba 15 290 1 ji 15032 40 ND13 14 c dsf 147 Last A A Accessories 000194 0611 DCS800 Hardware Manual f us 126 Accessories Line reactors type ND 17 260 33 495 3 490 53 35 3 80 3 tin plated 147 1 181 55 3 ND17 dsf 8ADW000194R
5. DO7 lt 008 ne cu LI 681 Dix Z gt X6 1 a 11004 681 ak 9 gt DI2 W3 W4 0 0 8 0 04 A gt W5 W6 8 0 0 8 0 0 0 W7 8 DI5 w9 W10 9 0 0 8 0 0 0 gt 06 W11 W12 9 0 0 8 0 04 5 017 W13 W14 ooo 8 RB gt W15 W16 X74 z 2 J m 3 up to revision D from dere revision E on 4 48V conductive support iob2x2_b dsf Technical data Note When the SDCS CON 4 control board with the SDCS IOB 2 I O board is installed terminals X6 and X7 on the SDCS CON 4 must not be used Output value Signal definition by Remarks K1 K5 K8 Firmware potential isolated by relays NO contact element Contact ratings AC lt 250 V lt 3 A DC lt 24 V 3 A or lt 115 230 V lt 0 3 A MOV protected 275 V K6 K7 Firmware potential isolated by optocoupler Switching capacity lt 50 mA external voltage 24 V X4 X5 are screw clamp terminal types for leads up to 4 mm cross sectional area Default values are shown within the software diagrams The ground potential of the digital outputs may vary within 100 V to each other Input value Signal definition by Remarks Channel Firmware potential isolated by optoco
6. DCSLink cable dismantling for shield grounding 2 30 10 mm 40 mm i Screen 10 mm in Q1 1 md F netting tinfoil red nulo Ly black 22 white 7 E EP 2 H F 3 5 rz blue blue 2 Hs Black 21122 24 20 mm two cable pairs 2 m 1 8 pa not twisted pe ved 5 Heat shrink tubing cable Heat shrink tubing x 140 mm 2 DCS link cable dsf 0 54 2 4 10 20 Unscreened cable for SDCS CON 4 SDCS IOB 2 IOB 3 connection 1700 mm Pull tab for cable marking LL IOB2 3 unscreened flat cab dsf Screened cable for SDCS CON 4 SDCS IOB 2 IOB 3 connection 1 4 3 2 4 m screen laid open NC 25 25 85 85 Pull tab Pull tab for cable for cable marking marking SDCS IOB x D 50 5 1 IOB2 3 screened flat cab dsf Accessories 8ADW000194R0611 DCS800 Hardware Manual f us 4 I IP SADWO000194R0611 Rev 09 2008 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 194R0611A8370000
7. 0 n 005 A00S The DCS800 3ADWO00194R0611 DCS800 Hardware Manual f us 3Sp p mao 545 8500 0 1012001 mm esnj 7 2 1ndino 1ndui enBojeue 2 indino ar E sjueuoduioo jo 5 s ox pd sed Gq Auo oi pue eseud eeJui 80l UL wg soa pasim a 28 sss Fs gt amp Eis 5 o OOD c o aad 3 o t o P 9 2 2 4 8r 9t Nld gt gt 5 5 ui 8t 9t Nid 5 5 4 2 t MOd 8 5 8 5 8 5 Ie 05 00852 Jm 2 i ANE n A ddns 5 dn P 0 VSIN 5 B 8 zroad i G c 61 Qa 5 1 i 5 MopuiMeAug lt i o 7 1008 jnej uue3 1911 A0004 18 The DCS800 3ADW000194R0611 DCS800 Hardware Manual f us 19 JSp P mao 545 8504 jeuuojsuea 00 10 989 m easy 1ndino 1ndui enBojeue 2 jndino jep
8. 0e 1 VOL 22 ASI Aver A8v Aver IONS 98 185 0 sjeuueuo 3Su3 A3d 2 298 9 9929 6 9929 4 vdza 9 5 2 2474 uonnquisiq gt L 1929 9 vn 2014 gt 1014 vL An 5 4 zx in 0014 gt v nn 1 0089 00217 108 000 V008 vole 0051 3 27 42 OF OF OF OF sunao Buunseew OG OV ON St WA 1 9 A SeouejsisoJ jueuno eanjgeuu v WOGI Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 94 Power Interface SDCS PIN 46 SDCS PIN 48 SDCS PIN 5x The Power Interface of DCS converter modules
9. ejerpeuuejur Za ve pms ainssalg ZOV LOV AOb ev LA 4 84100 sa Ay i a Z Is dois WS i i 4 9 2 2 94 124 3 Di E FX 8l is vo 5 2 96 t al ERST SS Fi dois 4 40 HR 4 e e 94 lt gt MOEZ an Planning the electrical installation 3ADW000194R0611 DCS800 Hardware Manual f us 42 external field exciter Ion using Converters D5 D7 drive configurat DCF803 DCF804 Wiring the drive according to this diagram gives the most flexibility and offers the highest degree of monitoring functions done by the drive Field converters DCF803 DCF804 are equipped with their own synchronization and can be supplied from an independent net DCF803 0035 can be supplied with 3 phase aux supply jsp ot sue 8504 40 0e0 esn 708504 08504 yun Jayoxe 121 n
10. ee Led D 8 Mechanical installations EET 8 STAM OG ced E 9 Table of contents The DCS800 What this chapter contains css ex Cage s RR ATE RR EAE TTE T 15 065800 15 Type Gode MES cet qu ru sd arie de 16 circuit and control eden de tas 17 Armature circuit converter DCS800 SOx 01 04 17 Armature circuit converter DCS800 SOx D5 D7 18 Rebuild system 5800 fe ede rs ER RE 19 Mechanical installation Uripackirig ilie Unit Pardo 21 Delivery CHECK staan ee eS BRE SUAE d ert 21 Before installation sesso e _______________ 22 Requirements for the installation 22 Wall ct 22 n 22 Free space around the 22 Cabinet aceite Sox ir ordo ORC ES ER eb cibo 22 Preventing cooling air 22 Unit above another
11. Fan D2E 160 GR31M GR31M GR35C 380 500 V 525 690 V 400 690 V Rated voltage V 230 1 400 450 A 400 500 500 690 500 690 A 400 460 450 500 500 600 690 Tolerance 10 10 10 5 10 10 Frequency Hz 50 60 50 60 50 60 50 60 Power consumption W 653 860 800 1340 A 800 1200 29004 3600A 700 2200 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 0A Blocking current A 3 75 45 at450VA at500VA 690 at 500 V A at 400 V Alat 400 VA 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 25A32A 1 26A 1 6A 0 7A 1 65 3 6 41 450V A 500V A 690V A 500V A 400V A 400V A Max ambient temperature C 55 Useful lifetime of grease appr 30000 40 Protection Temperatur detector Uy 230 V In 2 5 A 460 V lt Supply lt 600 V autotransformer strongly recommended energy saving 20000 kWh a Fan connection for DCS800 230 either 230 Vac 115 Vac z or 115 Vac Configuration 1 Configuration 2 Configuration 3 Configuration 4 Configuration 5 D1 D3 D3 D4 D5 D6 D7 Monitoring the DCS800 power section a The size D1 D5 power section is likewise monitored by an electrically isolated PTC thermistor
12. j Line reactor 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 lt 40 Medium voltage network Industrial sone 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 commutating 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 inter ference are complied with provided the measure indi cated is carried out PDS of category C2 formerly restricted distribution in first environment is intended to be installed and commis sioned only by a profes Sional person or organization with necessary skills in installing and or commissioning PDS includ ing their EMC aspects For power converters with out additional components the following warning applies This is a product of cate gory C2 under IEC 61800 3 20
13. L 1929 2014 7 815 5205 1013 94 94 Q4 Ws OG OV 14 9 4 OLNY 10057 VOOcL 108 55 Typical armature circuit thyristor converter diagram with SDCS PIN 4 and SDCS SUB 4 board ISL dd QNO Seouejsise Buunseeui uano tore od Pno Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 100 Galvanic isolation T90 A92 The Galvanic isolation is an option for converters in the current range 2050 5200 A DC and rated voltages 1000 V For converters with a rated AC voltage of 1190 V and 12 pulse serial 2x 500 V the galvanic isolation is a standard equipment It is used to replace the high ohmic resistance voltage measurement and gives the advantage of a total isolation from power part to electronic part The transformer T90 and the DC transducer A92 are located outside the converter module The inter 8601 1 42000D3 745047 nal AC and DC volta
14. Dimensional drawings 112 Size 5 6 Size 7 10 Indicator 15 max 105 epo NI 4xM10 10 deep t E bi UN a _ Ei Size A 7 62 8 90 3 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 assembly mounting kit 3ADT783046 card holder finger protection cover screen clamp IOB 2x IOB 3 not included with universal Phoenix clamp 1202713 it is possible to mount the card holder on standard rail system in horizontally or vertically direction Dimensional drawings S3ADWO00194R0611 DCS800 Hardware Manual f us Accessories DCF803 0035 and FEX 425 internal 113 The field exciter DCF803 0035 and FEX425intern are half controlled three phase field converter Both field converters are based on the same controller board SDCS 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 c
15. eu sjueuoduioo jo Jsp qz sue 8504 poq y 0085020 208 023 029 VN 1 ijo dW Aiddns xny Planning the electrical installation 8ADW000194R0611 DCS800 Hardware Manual f us Fan cooling Fan assignment for DCS800 Converter type Model Configuration Fan type DCS800 S0x 0045 04 05 D1 1 2x CN2B2 DCS800 S0x 00140 05 05 DCS800 S0x 0180 04 05 D2 1 2x CN2B2 DCS800 S0x 0260 04 05 DCS800 S0x 0315 04 05 03 1 2x CN2B2 DCS800 S0x 0350 04 05 DCS800 S0x 0405 04 05 03 2 4 CN2B2 DCS800 S0x 0520 04 05 DCS800 S0x 0610 04 05 04 3 1x W2E200 230 V DCS800 S0x 0820 04 05 DCS800 S0x 0610 04 05 04 3 1x W2E200 115 V DCS800 S0x 0820 04 05 Pluscode E171 DCS800 S0x 0900 04 05 04 3 1x W2E250 230 V DCS800 S0x 1000 04 05 DCS800 S0x 0900 04 05 04 3 1x W2E250 115 V
16. 5800 22 plus code Position X Y Z B Position Plus code Product series DCS800 A Type 0 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 77 Rated voltage 04 400V nominal rating in bold 05 500V 06 600V 07 690 V 08 800 V 10 990 V 12 1200 V Power connection Standard 01 06 L Leftside D7 R Right side D7 Internal field exciter 5164 with internal field exciter external supplied only 05 25 A Rebuild kit 25 16 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 5172 600 V 690 V fan voltage 400 500 V 3 ph Current measurement 5175 CMA D6 and D7 converter Voltage measurement 5186 120 V SDCS SUB 4 for 01 04 converter modules 5180 600 V for D6 and D7 converter modules 5181 690 V for D6 and D7 converter modules 5182 800 V for D6 and D7 converter modules 5183 990 V for D6 and D7 converter modules 5189 galvanic isolation for 06 07 converter modules SDCS DSL board 5199 SDCS DSL board 0 199 SDCS DSL board 4 plug in options Control panel 0J404 no DCS800 control panel J409 Doo
17. 904 80000 04 10 Ave Jeyoxe p1eoq uo 008500 pJeoq i 908490 I I eunjeuue euonippe perddns 1e SI pue peddinbe jou z eunjeuue eq ULI vi 15 4015 Lx Aejap euin ej 1 0 puooes euo dn aye ueo 1 18v OO 0 5 lt 4015 1 gt G py indui se eJnjeuue jo 1SvOO 980 47 SEEK GL pray 0 1 4015 3 1 uop s PIX dwe 4015 3 dois j SDIN 2 2 2 ASH 783 INI l 7662 21 N zu 8ADW000194R0611 DCS800 Hardware Manual f us 44 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
18. 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 Plastic opt fibre max 30m 200 HCS Plastic HCS opt fibre Silicat max 30m max 200 m lt adapter PC 12 02 3ADWO00194R0611 DCS800 Hardware Manual f us grey TxD bus conn a dsf 83 DDCS Branching unit NDBU 95 DDCS Branching Unit DBU is used for DCS 600 DCS800 to implement the star topology of DDCS link This allows a slave unit to fail or become unpowered without disabling the communication The NDBU receives messages from the master PC and sends them to all the slave units simultaneously Each slave unit has an individual address and only the addressed slave unit sends a reply message to the master It is also possible to use NDBU thus enabling peer to peer communication NDBU 95 DDCS Branching Unit has nine output channels where messages from the master are sent The reply message sent by one slave unit is delivered to the master and it can be delivered also to other slaves if necessary Several NDBU 95s can be used in
19. 73 Current ratings North America non regenerative Type code Frame Input RMS An m 5 220 Size Current P le z Issipation TNR E us 45 2Hd current ft min BTU Hr 500 Vdc Di 375 53 1611 30 54 30 54 30 751 19 12 75 1M 60 104 D2 205 125 mers D3 264 150 20 825 200 D4 490 300 25A 795 500 05 979 1105 700 950 600 851 550 25 E maus EE 1632 1904 1100 1480 900 1479 900 Exierna 5 D7 Exierna 600 Vdc 268 200 Ds 734 828 600 665 500 665 500 1224 1428 1000 1325 1000 1325 1000 1479 Exierna 1750 D7 2380 1750 Extemal 3507 2500 700 Vdc 05 620 Exierna 1224 1428 1250 1160 1000 1160 1000 1250 1250 Externa 1750 D7 Exierna 2970 2500 3507 3000 360 800 Vdc line voltage DATA AVAILABLE UPON REQUEST 450 990 Vdc line voltage DATA AVAILABLE UPON REQUEST 540 1200 line voltage 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 8ADW000194R0611 DCS800 Hardware Manual f us 74 Current ratin
20. Temp sensor coding R 57 as a temp sensor for D5 D6 D7 1 53 Os 20 01 Board used as a spare part indicates a removed jumper e default all jumpers Wxx Rxx are condition oxo ensure the correct converter type related settings Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 97 Typical armature circuit thyristor converter diagram with SDCS PIN 48 and SDCS 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 _ 9 9424 yaza 2 2474 T TdZH 990 Xp 80 Yao vo RA ge 2 IS oe Ner MEC sjeuueuo 9711570 _ eo 2265 108 009 1 3 m gt VIT v v gt amp m 0 0 Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 98 Interface Board SDCS SUB 4 General On SDCS PIN 4 and SDCS PIN 51 the line voltage and DC voltage measurement is
21. H uonduosepees 104 900 soa roa 00 423 i 5 i 1e youms einsseijg 204 10 AOL AOL X9 INOO i INI T 2 NI Planning the electrical installation 8ADW000194R0611 DCS800 Hardware Manual f us 43 ing ees Jsp ey sue 8504 NEHHN ey 0 ffers the highest degree of monitor iagram o is d to th 9150 snid 10 1 Aq paqes pe Planning the electrical installation ing ive accord the dr functions done by the drive iring Converters D1 D3 3 phase field exciter configuration L 2 01 E 04 6 H
22. 2 y 4018 A Yana an 2 94 D ied T 2 96 hom premens om 1 A 4015 3 0 bd mu e e ASH lt 94 7062 Planning the electrical installation 8ADW000194R0611 DCS800 Hardware Manual f us 41 FEX 425 Int field exciter Wiring the drive according to this diagram gives the most flexibility and offers the Ion using Converters D5 drive configurat 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 3sp oz sue 8500 Ge 9 vl 2 9 ye ees 11 92 3 INS 9 z V 05 4 Sj 94 aan 4 008520 H N uonduosepees 8 21 Sje o 90a oa ioa sid
23. 49 Cross sectional areas Tightening 50 Typical Cable Sizing and Tightening Torque North 51 Selecting the control cables 2 24 52 DCS800 panel cable E ax PAA 52 Connection of a motor temperature sensor to the drive I O 53 Electrical installation What this chapter contains 44 E tt LR 55 Checking the insulation of the 55 IT ungrounded systems 56 SUPP 48 161120 rta teda EER 56 Connecting the power cables 2 os Rede REOS ede ede qe 56 Location R Extension and Interface 57 O Board GonfIgurallor meme ek eee SAE PRU ER 58 Pulse encoder connection arae 59 P lse encoder receiver serena RD ROT oe 60 Connecting the signal and control 5 62 Routing The Cables uua rpg 62 DOS Link oues oy ogo exer ux pee a t eeu x Tbe E Te 63 Installation checklist Table
24. Y 1 i 5 3 t SDCS PIN 4 AJ X5 x22 amp x12 XA i x3 S1 12 automatic x x2 X7 X31 23 290 V ix din mm 8 1 o N eo eo i i i K400 X10 F400 F300 LAc L em w dox X9 X9 X24 X21 X25 X23 20 9 conducting point __ 1 21 1 2 e D Relay Input m output Aux DOS8 supply Output field layout b dsf current Different functional areas on SDCS PIN 4 Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 91 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 1 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 560 W Inrush current 20A 20ms 10A 20 ms recommended fus 6 AT 6 AT ing Mains buffering min
25. reactor data L3 Weight Pow er L loss uH A ko ND30 2x 5500 16 16 11 1 8 Accessories 3ADWO00194R0611 DCS800 Hardware Manual f us 131 Supply transformer T2 for electronics and fan The supply transformer T2 has been re designed The new power and current rating allows to supply then 2 phase fans and the electronics by one transformer only in case D5 converters are used in a 12 pulse configuration Input voltage 230 380 690 1 10 F2 Frequency 50 60 Hz Output voltage 115 230 V 1 282536453886 12 19 1060 Power Weight Fuse F2 Isec Power loss Je t VA kg A W T2 1400 15 16 6 0 230 V 100 12 0 115 V 230 V 115 T2 a dsf 6 3 mm Faston gis SSS 2 E eleleleleielelelelelelelele ojojo 2 ie elelel e e E k 106 128 k 125 148 T2 dim dsf 100 5 Application hint 230 V The transformer is designed to work as a 230 V 230 V transformer to open 2 avoid ground loops This is done via the 380 V and 600
26. 5 4 75 Memory 57 225854 eM mar MM ME ec 75 Watchdog ui pee Sed RR ente fms 75 Seven segment dIsDIay iae pl rhon Oa A Sola id 76 Terminal d scripllionm suu cur em ey Toe eR Ba d eR ee E Xe 76 Digital and analogue I O connection of the SDCS CON 4 78 Interface 50 5 8 1 ERA RN Ee RH re ede 79 Ch2 SDCS COM 8 Master Follower connections 80 Drive Bus connection to Advant Controller star 80 Connection to overriding control Nxxx fieldbus 81 Ch3 Ring connection to PC tool 81 Ch3 Star connection to PC tool DriveWindow 82 DDCS Branching unit NDBU 95 PE UR EE 83 SDCS DSL BOSri c bone erbe ec Rau evene Hie QE edes 84 Digital board 5 5 2 85 Analogue and encoder I O board 5 5 3 87 Power Supply Board 5 5 4 89 Interface Board SDOS PINSA sz vue Da EE da Eu ex reed ace RR es dev ken Rd PSOE 90 90 ce Ex or Duc e
27. 8 rae 9 8 9 V 8 4x45 180 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 25kg 2 7 58 di E 98 55 8 r 2E EE 2 8 2 5 5 5 8 Signal terminals 359 TEREN o 0 5 29 Field and power supply terminals Power connection 8 E 2 88 o 9 inf 2 i 8 55 1 S EE T 5 55 gg 88 a ES eee T 8 22 D1toD3 dim b dsf Dimensional drawings S3ADWO00194R0611 DCS800 Hardware Manual f us 106 Module D4 5 5 DCS800 S01 0610 20 10 mm for size 04 DCS800 S01 0740 DCS800 S01 0900 270 2 225 DCS800 S02 0680 48 5 r fan terminal f 6 DCS800 S02 0820 2 DCS800 S02 1000 luo 600 V types DCS800 S01 0590 DCS800 S02 0650 Weight appr 38 kg 644 625 40 _ 80 12 L 52 80 80 Power terminal Busbar 40 5 mm Weight appr 38 kg
28. OFF2 switches off DC current as 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 000194 0611 DCS800 Hardware Manual f us 45 E STOP i K16 ELEC DISCONN Speed Timer K15 EMER STOP Timer K16 Block current control K1 main contactor CON 4 ________________ 014 X6 9 Block E Stop ramp Coast command Stop Mode dsf Anschl special a dsf E Stop reaction d DC contactor US DC contactor US K1 1 is a special designed contactor with 2x NO con
29. m Lg m 9q ov 2 i 4 gt 9 4 0 7 WE wr OM Wr eM Wi Wi Em 5 H 1 1 1 gt A S om 2 A f i y Y 5 15 5 15 5 5 5 5 18 OV 2 lo foo 111 e Uz Us Us 5 Ajddns xne l 4 amp Ue De He ye 61 5 i 4 S L L LS L quewainseew jueuno eanjeuuv ells i m EUS US oor LS NId SOAS QHVO8 4 1 H3MOd Pr rrr NET ML LM LA LA ees puq y VW 5 eq 54015152 31 e p 72 Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 102 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 1 POWER SUPPLY 230 2 15V Data Selectable voltage gains 675 810 945 1080 1
30. 300 mA min 25 A FEX425 internal 35 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 3 phase or single phase operation Control unit The control includes the following main blocks Micro controller H8 for current control synchronization and fault handling Two channel actual field current measurement of DC circuit e H8 controller for serial communication based on CAN standard Driver circuit for firing of half control bridge The software is stored in the flash PROM memory This software contains PI current control for field circuit Fault and reset logic Synchronization and PLL function setting of current measurement channel The setting and updating of all control parameters are set from armature converter via DCS link serial communication Actual field current reference current control and status bits are cyclic sent via DCS link serial communication The field exciter is equipped with an autoscaling function of burden resistor based on nominal field current of motor Power section The power section is a three phase half controlled bridge with free wheeling diode The external field exciter DCF803 0035 is the three phase half controlled bridge including snubbers based on SDCS FEX 4 board Line fuses and the line reactor and transformer must be located outside the housing The
31. Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 90 Interface Board SDCS PIN 4 General The SDCS PIN 4 board is designed for DCS800 Converter modules sizes D1 up to size D4 20 A 1000 A the board has three different functions 1 Power supply of CON 4 board and the connected plug in modules 2 Control of armature bridge and measurement 3 Control of on board field exciter and field current measurement The board is mounted conducting ground at points inside the module The board is used for supply voltages from 230 V up to 525 V 600 V The converter identification is made by TYPECODE 97 01 and not by hardware The converter identification manages the burden resistor setting and 2 Q or 4 Q bridges operation Field current measurement Armature firing Power supply is 5 i i T100 5 i i L i oi i Y i i 6A 4x i i EE 25A 1 als t i i 1 i 1 1 i e 1 1 al i i wir 27 i i 1 2 a i al 1
32. Weight appr 315 kg 109 230 530 4 i6 350 for M10 N P 3 e N N N e N N e N Pressure switch 1 M ee for M10 E A7 dim a dsf 90 180 80 80 80 93 gt 8ADW000194R0611 DCS800 Hardware Manual f us 422 Busbars in mm AC and DC 100 x 10 Dimensional drawings 110 Module D7 right hand for M10 DCS800 S0x 2050 xxR 8 8 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 appr 315 kg 4 Pressure switch 8 ERA for M10 000 A7 dim a dsf Ac and DC 10 0 i AC and DC 100 10 Dimensional drawings 8ADW000194R0611 DCS800 Hardware Manual f us Fuses installed inside the converter Converter type Model Fuse F1 Size Type 400 V 500 V DCS800 S0x 1200 04 05 D5 800A 660V UR 5 170M 6162 DCS800 S0x 1500 04 05 D5 1250A 660V UR 5 170M 6166 DCS800 S0x 2000 04 05 D5 1600A 660V UR 5 170M 6169 DCS800 S0x 2050 51 D6 1500A 660V UR 5 170M 6168 DCS800 S0x 2500 04 05 06 900A 660V UR D 5 170M 6163 DCS800 801 3000 04 05 D6 1250A 660V UR D 5 170M 6166 DCS800 S02 3000 04 05 D6 1250A 660V UR D
33. 10 V Firmware 320 V OOOO 15 sign 10 0 10 Firmware 20 V 009 15 sign 10 0 10 V Firmware 40 V 02340 15 sign 10 0 10 V Firmware 540 V 00086 15 sign 10 0 10 V Firmware 540 V 009 Power 11 sign 10 0 10 V Firmware lt 5 mA 11 sign 10 0 10 V Firmware lt 5 mA analogue 10 0 10 V R110 lt 5 gain 0 5 5 30 lt 5 forexternal use lt je g 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 4250 Sense lines for GND and supply to 12V 24V 200 correct voltage drops on cable only if 5V 12V encoder is in use Residual current detection is selected as default The jumpers 1 11 12 and 51 13 14 are set inputs X3 9 and X3 10 and jumper 1 9 10 must not be used and inputs 11 and X3 12 serve as input for the current signal taken from a current transformer This detection is based on a sum current transformer where the secondary is connected through a diode bridge to 100 Ohm resistor Voltage will appear across the resistor if the sum of the 3 phase current is not zero In case AI4 should be used for a different purpose use the inputs jumpers accordingly and take the block diagram as a help Restrictions using jumper S1 S2 or S3 The selection for the burden resistor across the input terminals can
34. 121 Ohm and C 100 nF activated EHE 12 Encoder mode single ended or if IOB 3 5 11 connected Pull up resistors 10 activated 3 12 Encoder supply 5 V sense X5 8 9 are active 2 A SDCS POW 4 see section 1 10 Power supply board SDCS POW 4 3 Encoder supply 24 V uncontrolled 2 10 Supplied from CON 4 Park position 3 12 When connecting an encoder to IOB 3 2 10 Setjumper 54 CON 4 board to park position 65283 Step 1 Preparation for Firmware download operation Step 2 Text download normal program execution default value 250 Ohm x 20 mA 5 V 100 Memory circuit 75 230 X17 E x2 i Jumpers shown in default position E i X34 SE X8 SUAE 8 ps 1 1 1 X3 X4 xs xe x 19 3 45678 910123 45678 91012 3 45678910123 45678910123 45 678 SDCS PIN 4 VA SDCS CON 4 SDCS POW 4 SDCS CON 4 10 1112 24 10 1112 24V 5V gt T e 12V 15V 24V X5 10 X5 10 encoder supply encoder supply The 24 V encoder supply can be selected either directly from CON 4 board S4 11 12 or from POW 4 board S4 10 11 54 is located on the CON 4 board Con4_layout_c dsf SDCS CON 4 board is equipped with FlashPROM which contain
35. 73 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 3 and S801 1 Selection of communication speed is set by 1100 51100 6 51100 5 51100 4 Baudrate Selection of armature kBaud converter param 94 02 OFF OFF OFF 20 0 OFF OFF ON 50 1 OFF ON OFF 125 2 OFF ON ON 250 3 ON OFF OFF 500 4 ON OFF ON 800 5 ON ON OFF 888 6 ON ON ON 1000 7 see Parameter 94 08 94 09 8ADW000194R0611 DCS800 Hardware Manual f us S800 S801 Switch 0 9 dsf Accessories 116 Accessories Diagnosis All messages are sent to armature converter and displayed by armature converter control panel If communication is broken or node numbers are mixed up a simple fault display on SDCS FEX 4 board can be used Therefore the unit is equipped with two small LED U730 Green U731 Yellow Following messages are displayed both OFF green and yellow continues green blinking green continues yellow blinking yellow continues green and yellow toggling X times yellow times green 1 Y 1 Y 2 X 2 Y 1 Y 2 Y 3 Y 5 Y 6 Y 9 Y 12 Y 14 Y 15 no 24V supply No firmware 25 A 35 A output active waiting for DCSLINK communication 25 A 35 A output active DCSLINK communication OK 5A output active X100
36. 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 08 2 on request DCS800 S01 0315 04 05 DCS800 S02 0350 04 05 ND09 2 408 5 DCS800 S01 0405 04 05 DCS800 S02 0450 04 05 ND10 2 ND409 5 DCS800 S01 0590 06 DCS800 S02 0650 06 ND13 3 on request DCS800 S01 0470 04 05 DCS800 S02 0520 04 05 ND10 2 ND410 5 DCS800 S01 0610 04 05 DCS800 S02 0680 04 05 ND12 2 ND411 5 DCS800 S01 0740 04 05 DCS800 S02 0820 04 05 ND13 3 ND412 5 DCS800 S01 0900 04 05 DCS800 S02 1000 04 05 ND13 3 ND413 5 DCS800 S01 0900 06 07 DCS800 S02 0900 06 07 ND13 3 on request DCS800 S01 1200 04 05 DCS800 S02 1200 04 05 ND14 3 on request DCS800 S01 1500 04 05 06 07 DCS800 S02 1500 04 05 06 07 ND15 3 on request DCS800 S01 2000 04 05 DCS800 S02 2000 04 05 ND16 3 on request DCS800 S01 2000 06 07 ND16 3 on request with forced cooling 1m s Fig 1 Fig 4 Fig 2 3ADWO00194R0611 DCS800 Hardware Manual f us Planning the electrical installation 30 Line reactors L 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 0 5800 501 1200 05 KLR1100CCB DCS800 S01 1500 05 DCS800 S02 1500 05 KLR1250CCB 600 Vdc DCS800 S01 1500
37. DCS800 S0x 1000 04 05 Pluscode E171 DCS800 S0x 0900 0y D5 4 D2E 160 DCS800 S0x 2000 0y DCS800 S0x 1900 04 05 08 D6 5 GR31M DCS800 S0x 3000 04 05 08 400 500 V 5800 50 1900 06 07 D6 5 GR31M DCS800 S0x 3000 06 07 500 690 V DCS800 S0x 3300 yy D7 5 GR35C DCS800 S0x 5200 yy 400 V 690 V y voltage class Fan Data for DCS800 Fan CN2B2 W2E200 W2E 200 W2E 250 W2E 250 Rated voltage V 115 1 230 1 115 1 115 1 230 1 Tolerance 10 6 10 6 10 10 6 10 Frequency Hz 50 60 50 60 50 60 50 60 50 60 Power consumption W 16 13 64 80 64 80 120 165 135 185 Current consumpt A 0 2 0 17 0 29 0 35 0 6 0 7 1 06 1 44 0 59 0 82 Blocking current lt 0 3 lt 0 26 lt 0 7 lt 0 8 1 5 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 m3 h at working point Max ambient temperature C 60 75 75 60 60 Useful lifetime of grease appr appr appr 45000h 60 appr appr 40000 h 60 45000 h 60 40000 h 40000 h Protection Impedance Temperature detector internal connected 9 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 47 Planning the electrical installation 8ADW000194R0611 DCS800 Hardware Manual f us 48
38. 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 shared with armature bridge e Fuses F100 F101 F102 for cable and motor field protection e 600 V converter are always without Onboard field exciter Ratings AC voltage range 110 500 V 525 V AC insulation voltage 500 V Frequency 50 Hz 60Hz AC input current field current Minimum Current 300 mA Size D1 D2 03 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 8ADW000194R0611 DCS800 Hardware Manual f us 93 Typical armature circuit thyristor converter diagram with SDCS PIN 4 board vh 22 ee lt 0 Jo eseo ui juo gt 92 9 ji ve eoepelul
39. single ended open collector lt X57 5 or 12V or 24V 5 1 2 tera 190 510 AKT O 5 TA 52 2 5 424N 8 Lo 4k7 8 OV GND P X510 SDCS IOB 3 ENCODER INPUT A push pull lt X57 lt lt 5 or 12V or 24V r m 5 1 10078 10 1k0 4 7 ex 3 X 8 HH 52 10k 2 2 5 gt L To do 4k7 2 4 4 5 ul GND X5 10 SDCS IOB 3 ENCODER INPUT A terminal X5 2 X5 4 X5 6 must be connected via a resistor R to GND differential 4 5 lt X5 7 5 1 z IL 4k7 z lt 5 tr ui 8 U AKT 8 258 GND 5 10 SDCS IOB 3 ENCODER INPUT CON 4 IOB 3 5V 12 24 V 5V 12 24 V differential S4 S4 510 510 voltage source 1 2 2 3 4 5 4 5 6 park 8 9 10 11 7 8 9 park 14 15 16 17 differential S10 current source 1 2 5 7 8 5 13 14 In any case if SDCS IOB 3 is used see required settings of SDCS CON 4 board Electrical installation 3ADWO00194R0611 DCS800 Hardware Manual f us 61 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 regul
40. 0 2 in in installations without the front cover The cooling air entering the unit must not exceed 40 104 F Preventing cooling air recirculation Unit above another Prevent air recirculation inside and outside the cabinet mm HOT 4 Main air flow out 1 E Air baffle plates ES 4 COOL AREA 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 3ADWO00194R0611 DCS800 Hardware Manual f us 23 Terminal options converter size D1 D4 There are different options for protection and connection the terminals for converter sizes D1 D4 Connection of DC terminals of D4 converter module In special cases it is beneficial to use the lug bar for easier connection of the DC cables DC terminals of Id No Remark 3ADV280706P0001 right ES Y 3ADV280706P0002 left 135 71 60 3914 95 Bottom view of lug bar mounted on a D4 module Terminal cover according to VBG 4 regulations For converter modules D1 D4 we provide shrouds for protection against contact Id No Remark 3ADT631137P0001 D1 D2 3ADV400208P0001 D3 3ADV400207P0001 04 Mechanic
41. 0050 and DCF503B 504B 0050 field power converters it is already installed Converter for field Reactor ND 30 500 V 50 60 Hz current EN lr reactor a dsf IEC US DCF803 0016 16A ND 30 ND 402 DCF803 0035 16 A KLR 45 CTB FEX 425 Int 216A ND 402 3 phase operation or single phase operation Commutating reactor for more information see chapter Accessories Auxiliary transformer T2 for electronic system fan supply The converter unit requires various auxiliary voltages e g the unit s electronics require 115 V 1 ph or 230 V 1 ph the unit fans require 230 V 1 ph or 400 V 690 V 3 ph according to their size The T2 auxiliary transformer is designed to supply the unit s electronic system and all the single phase fans 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 Al4 of the SDCS IOB 3 board has to be activated a current signal of the three phase currents should be supplied to Al4 by a current transformer Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 36 EMC filters Filter in a grounded line earthed TN or TT network The filters are suitable for grounded lines only for example in public European 400 V lines According
42. 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 03 20 DCS800 S02 0520 04 05 520 398 597 385 578 356 712 DCS800 S02 0680 04 05 680 544 816 538 807 492 984 DCS800 S02 0820 04 05 820 664 996 648 972 598 1196 D4 25A DCS800 S02 1000 04 05 1000 766 1149 736 1104 675 1350 DCS800 S02 1200 04 05 1200 888 1332 872 1308 764 1528 DCS800 S02 1500 04 05 1500 1200 1800 1156 1734 1104 2208 D5 i DCS800 S02 2000 04 05 2000 1479 2219 1421 2132 1361 2722 DCS800 S02 2050 05 2050 1550 2325 1480 2220 1450 2900 DCS800 S02 2500 04 05 2500 2000 3000 1930 2895 1790 3580 D6 DCS800 S02 3000 04 05 3000 2330 3495 2250 3375 2080 4160 DCS800 S02 3300 04 05 3300 2416 3624 2300 3450 2277 4554 DCS800 S02 4000 04 05 4000 2977 4466 2855 4283 2795 5590 D7 DCS800 S02 5200 04 05 5200 3800 5700 3669 5504 3733 7466 600 V 690 V DCS800 S02 0320 06 320 256 384 246 369 235 470 03 DCS800 S02 0650 06 650 514 771 508 762 462 924 D4 DCS800 S02 0900 06 07 900 684 1026 670 1005 594 1188 D5 25A DCS800 S02 1500 06 07 1500 1200 1800 1104 1656 1104 2208 48164
43. 2 waiting for DCSLINK communication 5A output active X100 2 DCSLINK communication OK Alarm phase missed Alarm maximum temperature heatsink Fault Fault Fault Fault Fault Fault Fault Fault Fault DCS link serial communication failed Synchronization fault Overcurrent Field AC supply voltage 30V Field AC supply voltage 650V maximum temperature heatsink Auxiliary voltage No RESET No RESET general hardware general software 8ADW000194R0611 DCS800 Hardware Manual f us 117 RS232 Port The RS232 interface is used for download the Field exciter firmware package The default settings of this interface are as X2 Description follows 1 not connected Signal level RS232 2 TxD Data format UART 3 RxD Message format Modbus Protocol 4 not connected Transmission method half duplex 5 SGND Signal ground Baudrate 9 600 Baud 6 9 not connected Number of Data bits 8 Number of Stop bits 1 Parity Bit odd The firmware download is activated by setting S2 1 2 during auxiliary voltage is switched ON Setting for field exciter mode is S2 3 4 default FEX425 INTERNAL Fex 425 Int Hardware configuration size D5
44. 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 600 690 V DCS800 S0x 0900 06 07 D5 630A 1250V UR 6 170M 6144 DCS800 S0x 1500 06 07 D5 1100A 1250V UR 6 170M 6149 5800 501 2000 06 07 D5 1400A 1100V UR 6 170M 6151 DCS800 S0x 2050 06 07 D6 700A 1250V UR 6 170M 6145 DCS800 S0x 2500 06 07 D6 1000A 1250V UR D 6 170M 6148 5800 501 3000 06 07 D6 1100A 1250V UR D 6 170M 6149 DCS800 S02 3000 06 07 06 1100 1250V UR D 6 170M 6149 DCS800 S0x 3300 06 07 D7 2500A 1000V UR 8 170M 7036 DCS800 S0x 4000 06 07 07 3000 1000V UR 8 170M 7156 DCS800 S0x 4800 06 07 07 3000A 1000V UR 8 170M 7156 790 V DCS800 S0x 1900 08 D6 700A 1250V UR D 6 170M 6145 DCS800 S0x 2050 08 D6 700A 1250V UR D 6 170M 6145 DCS800 S0x 2500 08 D6 1000A 1250V UR 6 170M 6148 DCS800 S01 3000 08 06 1100 1250V UR 6 170M 6149 DCS800 S02 3000 08 06 1100A 1250V UR D 6 170M 6149 5800 50 3300 08 07 2500A 1000V UR 8 170M 7036 DCS800 S0x 4000 08 07 3000A 1000V UR 8 170M 7156 DCS800 S0x 4800 08 07 3000A 1000V UR 8 170M 7156 1000 V DCS800 S0x 2050 10 D7 1800A 1250V UR 9 170M 7976 DCS800 S0x 2600 10 07 1800 1250V UR 9 170M 7976 5800 50 3300 10 07 2500 1250V UR 9 170M 7978 DCS800 S0x 4000 10 07 2500 1250V UR 9 170M 7978 12 fuses per bridge 2x per F1x 8ADW000194R0611 DCS800 Hardware Manual f us 111 L1 L2 L3
45. Every drive has been tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests e g hi pot or megger on any part of the drive Check the insulation of the assembly as follows WARNING Check the insulation before connecting the drive to the mains Make sure that the drive is disconnected from the mains input power 1 Check that the motor cable is disconnected from the drive output terminals C1 D1 F and F 2 Measure the insulation resistances of the motor cable and the motor between each circuit C1 D1 or F 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 C PE Electrical installation 3ADWO00194R0611 DCS800 Hardware Manual f us 56 IT ungrounded systems Don t use EMC filters The screen winding of dedicated transformers must be grounded For installation without low voltage switch e g contactor air circuit breaker use overvoltage protection The voltage shift of the isolated supply must not be larger than the voltage shift in case on an earth fault mm U1 nmm NEN V1 Voltage shiftin y gt Earth fault case of earth fault lt earth fault volt shift dsf Supply voltage Check supply voltages of Aux X99 Fan Terminals AC voltage for field circuit
46. V taping according to the left picture gt gt gt gt 0 Q 10 Q 0 0 T2 BO SE SE LO 10 CO CO 230V 115V T2 a dsf Accessories 8ADW000194R0611 DCS800 Hardware Manual f us 132 Optical cables Accessories For the bus communication of the DCS converters there are different optical cables available Kind of cable Connector cable length Fig plastic fibre optic single cable plug 0 5 20 m 693324 1 plastic fibre optic double cable plug 0 5 20 m 693318 2 HCS silica double without plastic jacket plug 30 50 m 693355 3 HCS silica double with plastic jacket plug 50 200 m 693356 4 Figure 1 L blue Figure 2 black Lm cor black Figure 3 L gt orange C 10 black Figure 4 blue blue u red red 8ADW000194R0611 DCS800 Hardware Manual f us for DCS 400 DCS 500 for DCS 600 DCS800 selected channels see manual NDBU 3ADW 000 100 201 DCS 600 DCS800 133 Other cables
47. 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 40 45 50 55 C Current reduction to 96 for converter modules 3ADWO00194R0611 DCS800 Hardware Manual f us Technical data 70 Regulatory Compliance The converter module and enclosed converter components are designed for use in industrial environments In EEA countries the components fulfil the requirements of the EU directives see table below European Union Directive Manufacturer s Assurance Harmonized Standards Converter modue Enclosed converter _ Machinery Directive 98 37 Declaration of Incorporation EN 60204 1 EN 60204 1 93 68 EEC IEC 60204 1 IEC 60204 1 Low Voltage Directive 73 23 Declaration of Conformity EN 61800 1 EN 61800 1 93 68 EEC 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 0 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 fil
48. detector which is installed on the heat sink in an isolated configuration Evaluation of the resistance and the protection effect correspond to max temperature of type code b The size D6 and D7 power section isolated PTC thermistor is used for air entry temperature The detector thus measures the power section s radiated heat and any Planning the electrical installation 3ADW000194R0611 DCS800 Hardware Manual f us 49 changes in the cooling air temperature and volume Since the cooling air volume can only be detected indirectly a differential pressure switch has been additionally installed at the unit s housing always located close to the power terminals The resistance change proportional to the temperature is acquired and evaluated in the unit s software If the temperature rises above the preset value then first an alarm will be signaled and if the temperature continues to rise an error message The value to be set for this parameter must not be more than 5 degrees above the permissible ambient temperature The differential pressure switch compares the pressure inside the unit with the normal atmospheric pressure If the fan has been switched on and the unit door closed and no unit casings have been removed the pressure switch will signal Cooling conditions ok which means the drive may be enabled There is no need to set any specific differential pressure recommendation center setting Thermal overload and short c
49. 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 e DCS800 Size 04 07 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 8ADW000194R0611 DCS800 Hardware Manual f 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 Prog
50. done by high ohmic resistors typical 5 M ohm for 500 V units Voltages below 100 V line voltage must be adapted by smaller resistance and rescaled measurement channel Such rescaling provide improved mains synchronization and DC measurement resolution at small voltage SDCS SUB 4 board provides a different scaling of voltage measurement The default selection is 1 17 Mohm with maximum mains voltage of 120 V The maximum measurement voltage scale is 200 V Adjust voltage scaling parameter according to table below 75 FE 5 8112 y Rue R17 Rize e g Rigs Riz Ris e 21 Riza R Rize H 21 Ris iN RH R117 5115 ve Field current measurement Rip p X12 Field firing g High voltage X8 gt X10 X24 EE Output field current Layout of SDCS SUB 4 and location on SDCS PIN 4 Technical data 109 D 105 w 109 X v X x101 C 107 G sub4 layout dsf Armature firing X15 Q conducting point Ox X17 xx Mains chain Setting Size voltage 97 03 30 120V _ 1 17 MOhm 117 V 01 04
51. e g generated by a PLC and transferred to the terminals of the converter either by relays using galvanic isolation or directly via 24V signals There is no need to use hardwired signals These commands can be as well transferred via serial communication Even a mixed solution can be realized by selecting different possibilities for the one or the other signal see parameter group 11 PC tool or panel ON MCW 7 01 RUN RI USED MCW RUN 704 T d HW use ON EN La Main Control Word RUN RESET local remote 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
52. 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 108 Module D6 5800 50 1900 Hed DCS800 S0x 2050 375 DCS800 S0x 2500 290 4 409 gt Air outlet DCS800 S0x 3000 5 10x20 2 Weight appr 180 kg A E Fw wc a 4 EZ o 55 a 24 o 5 V o 3 8 8 gt W W 10 o 5 ThPressure switch g 9 i 4 i E SO 722100 10 355 AM x Air entry 7 from the front right left and 468 2 back lt 136 gt Dimensional drawings S3ADWO00194R0611 DCS800 Hardware Manual f us Module D7 left hand DCS800 S0x 2050 xxL DCS800 S0x 2600 xxL DCS800 S0x 3300 xxL DCS800 S0x 4000 xxL DCS800 S0x 4800 xxL DCS800 S0x 5200 xxL
53. holders for field 33 Single phase Transformer for field supply to match voltage 34 Single phase Commutating 35 Auxiliary transformer T2 for electronic system fan 35 Residual current detection eee ele ER E Ec wi 35 PENG HTN 2 oie tfe rca 36 Three phiase SEEN ee ee do ee 36 Converters 01 04 drive configuration using board field 40 Converters D5 drive configuration using FEX 425 Int field exciter 41 Converters D5 D7 drive configuration using external field exciter DCF803 DCF804 42 Converters 01 03 3 phase field exciter 43 START STOP and E STOP 44 Drive configuration with reduced components 46 Fart COOUNG i os uade hie ad bhi es qi Ex wee 47 Thermal overload and short circuit protection 49 Mains cable AC line cable short circuit
54. internal field exciter FEX425 is a ready installed field exciter in a D5 armature converter The unit is based on a SCDS FEX 4 board and contains also line fuses The supply must be connected by independant line reactors located outside of the D5 module see drawing in chapter The DCS800 section Armature circuit converter DCS800 S D5 D7 If the unit is used as a single phase supply the terminal U and W must be used For single phase supply an autotransformer for voltage adaptation is recommended Please see comparison of output voltage ripple between single phase and three phase supply 8ADW000194R0611 DCS800 Hardware Manual f us Voltage ripple of Upc voltage depending on operation modes 0 75 4 0 5 Voltage ripple Vsec 0 25 o DCS LINK communication U dc field 115 single phase half controlled three phase half controlled three phase full controlled The field converter is controlled from armature converter via DCS link serial communication based on CAN hardware Fex4 DCSLink dsf 24 V 1200 1 51100 2 51100 3 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 1100 1 2 ON 120 ohm 1 OFF no termination Ground termination 1100 2 ON 200 kOhm R C ground termination
55. 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 SADWO00194R0611 DCS800 Hardware Manual f us 28 Configuration B If special requirements have to be met at the PCC standards like EN 61 800 3 DC and AC drives at the same line etc different criteria must be applied for selecting a line reactor These requirements are often defined as a voltage dip in percent of the nominal supply voltage The combined impedance of Z and Z 4 constitute the total series impedance of the installation The ratio between the line impedance and the line reactor impedance determines the voltage dip at the connecting point In such cases line chokes with an impedance around 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 us
56. respectively control panel or PC tool Intended use the operating instructions cannot take into consideration every possible system configuration operation or maintenance Thus they mainly give such advice only which is required by qualified personnel for normal operation of the machines and devices in industrial installations If in special cases the electrical machines and devices are intended for use in non industrial installations which may require stricter safety regulations e g protection against contact by children or similar These additional safety measures for the installation must be provided by the customer during assembly Safety instructions 8ADW000194R0611 DCS800 Hardware Manual f 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 3ADWO00194R0611 DCS800 Hardware Manual f us 11 Table of contents DCS800 Drive ot AS ERI RH 2 Safety instructions What his chapter contalliS ette cutis sth Env re Rog CR RR 5 To which products this chapter applies 5 Use of warnings and notes is e MEHR babe POR 5 Installation and maintenance sese 6 CMT 7 Fibr opic Cables
57. steps between 1 and 4 by software para meter 3ADWO00194R0611 DCS800 Hardware Manual f us Resolution Input output Scaling Com Remarks bit values by mon Hardware mode range 90 270 15 sign 30 90 ViFirmware 15 V 8 30 V 15 sign 10 0 410 Firmware x15 V 15 sign 10 0 10 V Firmware x15 V 15 sign 10 0 10 V Firmware x15 V 15 sign 10 0 10 V Firmware 15V Power 10 V lt 5 mA ext use 10V lt mA e g refer pot 11 sign 10 0 10 V Firmware x5 mA 11 sign 10 0 10 V Firmware x5 mA 10 0 10 V Firmware lt 5 mA 8 V gt min of 325 4 Hardw of 99 03 or 230 of 4 05 Encoder supply Remarks Inputs not isolated Impedance 120 Q if selected max frequence x 300 kHz 5V 5250 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 79 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 Channel 0 is used to co
58. temperature range 10 70 Weight 10 70 Weight 2 1 kg Dimensions in mm Remark max 116 The terminals on the primary side of the transformer are in special design lug termi nals Handling hints First turn the screw counter clockwise to the end stop then swing out the e shrowding cover Put in the cable lug swing x in the shrowding cover and fasten the con nection by turning the screw clockwise Cs 52x77 QUE 159 118 120 130 Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 104 Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 105 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 S01 0405 DCS800 S01 0470 DCS800 S02 0350 DCS800 S02 0450 DCS800 S02 0520 600 V types DCS800 S01 0290 DCS800 S02 0320 27 10 WO
59. 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 product s interference immunity share in expanding the electrical equipment involved First environment residential area with light industry with PDS category C2 Not applied since category C1 general distribution sales channel excluded Not applicable satisfied satisfied Medium voltage network Medium voltage network Supply transformer for a 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 Commutaio
60. 0 1200 1800 1104 1656 1104 2208 D5 men DCS800 S01 2000 06 07 2000 1479 2219 1421 2132 1361 2722 DCS800 S01 2050 06 07 2050 1520 2280 1450 2175 1430 2860 DCS800 S01 2500 06 07 2500 1940 2910 1840 2760 1880 3760 D6 DCS800 S01 3000 06 07 3000 2530 3795 2410 3615 2430 4860 DCS800 S01 3300 06 07 3300 2416 3624 2300 3450 2277 4554 DCS800 S01 4000 06 07 4000 3036 4554 2900 4350 2950 5900 D7 DCS800 S01 4800 06 07 4800 3734 5601 3608 5412 3700 7400 800 V DCS800 S01 1900 08 1900 1500 2250 1430 2145 1400 2800 DCS800 S01 2500 08 2500 1920 2880 1820 2730 1860 3720 D6 DCS800 S01 3000 08 3000 2500 3750 2400 3600 2400 4800 DCS800 S01 3300 08 3300 2655 3983 2540 3810 2485 4970 DCS800 S01 4000 08 4000 3036 4554 2889 4334 2933 5866 D7 DCS800 S01 4800 08 4800 3734 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 Note AC current lac 0 82 lpc Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 72 Current ratings IEC regenerative Unit type Ipci lbc u lbc m Ipc iv Size continu 100 150 100 150 100 200 4 Q converters ous 15 min 60s 15 min 120s
61. 0 2 3 50 mA x SDCS COM 82 5 5Mb 10 10 Mb Fieldbus adapter Ch 2 3 50 x modules Nxxx xx Color of optical components 5Mb blue driver current maximum 30 mA Remark Only channels with the same components e g 10 Mb component may be connected to each other Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 80 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 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 a a a a n a 8 8 8 22 B 2 d 8 8 8 8 8 8 8 8 12222208 5 IS ssl e sel e 2 2 lh 5 85 5 35 5 5515 s l LS af L9 k 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 800 CI 858 Drive Bus Module FCI CI 810 Adapter module Technical data 3ADWO00194R0611 DCS800 Hardware Manual f us Connection t
62. 0 725 0 125 0 542 FWP 70B 100B 1 4406 0 947 2 594 3 625 3 563 0 344 0 75 0 125 0 375 FWP 125A 200A 1 5 09 1 5 2 84 4 19 3 5 0 41 1 0 25 0 75 FWP 225A 400A 1 5 09 2 284 428 3 53 0 41 1 5 0 25 0 78 FWP 450A 600A 1 7 09 25 2 84 572 4 19 0 53 2 0 38 1 3 FWP 700A 800A 1 6 63 2 2 844 5 562 5 062 0 625 1 5 0 25 0 875 Dimensions in inches sasi M G p 1 B 3 500 1 Fig 1 5 800 Amp Range Fig 2 900 1000 Amp Range Fig 3 1200 Amp Range Accessories 000194 0611 DCS800 Hardware Manual f us 124 Line reactors IEC Line reactors type ND 01 ND 17 Line reactors 1 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 Weight Power loss recommended L lms Ipeak Voltage Fe Cu for armature uH A A Un kg w 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 8
63. 04 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 8ADW000194R0611 DCS800 Hardware Manual f us 40 on board field exciter Ion using Converters D1 D4 drive configurat Wiring the drive according to this diagram offers the highest degree of monitoring functions done by the drive 3Sp PI I sue gsod 5 9 d iim S ye ees ayun 008520 uonduosepees 1 A 100 90 80000 loa ji 1016 uoyws 5 zOV 10 AOL AOL 8 09 1 S 4 lt 9A 1
64. 06 KLR1250ECB Recommended AC Line Reactors are available directly from TCI For information see their web page www transcoil com Planning the electrical installation 000194 0611 DCS800 Hardware Manual f us 31 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 The figure shows the arrangement of the switch off elements in the armature circuit 2 ji Ed u converter poe You will find further information in publication Technical Guide chapter Aspects for fusing For field supply 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 circui
65. 0611 DCS800 Hardware Manual f us 20 40 8 5 4 014 Al 80 x 15 101 1 1 1412 Al 80 x 15 1U2 1ve 1We 40 20 9 9 913 101 1V1 1W1 1U2 1W2 127 Line reactors type ND 401 ND 413 Line reactors 4 for use in light industrial residential environment high inductive voltage drop reduced commutation notches These reactors are designed for drives which usually operate in speed control mode at 400 V or 500 V networks Because of that a duty cycle has been taken into account The percentage taken into account for that duty cycle is different for 400 V and 500 V networks for Urated supply 400 V DC curr 1 90 of nominal current for Urated supply 500 V DC curr 2 72 of nominal current For easier reading the maximum average DC load current is listed instead of the percentage in the next table Line reactors ND401 ND402 are equipped with terminals The bigger ones ND403 ND413 are equipped with busbars When connecting them to other components please take relevant standards into account in case the materials are different Type reactor rated Weight Power loss Load Load L Irms Voltage Fe Cu DC c
66. 1 MQ resistors cutting out short circuit wires which are represented by low ohmic resistors Layout of the SDCS PIN 51 board Ut 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 Because of that a current of less than 1 mA will flow to earth When galvanically isolated measurement is needed please contact your ABB representative PTC 2 see diagram Conductive Ws line potential power part supports R123 X2342 X24 2 4 X25 2 271 ws ws we wi 1 2 X22 122 tex uem 125 e Pu iet c dee S3 3 4 TwoPTC R21 11 12 OnePTC Fe Te LLALLA V1 wit wo ws w 7 ER GAL W10 wzo W72 Ree o up ssp dE LT W1 wie wis wi4 wi2 i W80 w82 T Be d c c AE ME X18S X313S Ci wig wis wi7 1 Cat GL GG z 51 I 21 er en 2 2 2 Iso
67. 12 50 DCS800 S0x 5200 xx 5200 8x 300 4202 6x 300 3x300 4xM12 50 Reduced ambient temperature 40 C Option for more flexible cable connection available You will find instructions on how to calculate the PE conductor s cross sectional area in VDE 0100 or in equivalent national standards We would remind you that power converters may have a current limiting effect Excitation Size D1 D2 D3 D4 D5 DCF803 0035 DC output current 6A 15A 20A 25A 25A 35A 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 8ADW000194R0611 DCS800 Hardware Manual f us 51 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 ULViWwi PE TighieningToraue impu Ground Terminal Torque tb 20 25 5 37 5 4AWG 41 5 2AWG 55 75 2 DCS800 S0x 0090 0 DCS800 S0x 0230 0 DCS800 S0x 0260 0 212 DCS800 S0x 0290 0 DC5800 S0x 0815 5
68. 15 DCS800 S0x 0320 DCS800 S0x 0850 0 DCS800 S0x 0405 0 DCS800 80x 0450 5800 50 047052 DCS800 S0x 0520 0 DCS800 80x 0580 05800 50 0610 610 DCS800 S0x 0650 DCS800 80x 0680 8800 50 0740 00580 50 0820 00580 50 0900 4 6800 508 1000 1000 816 DC5800 S0x 1200 1200 9 DCS800 S0x 0020 xx DCS800 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 5 00 5 2500 2500 2040 DG8800 S0x 8000 3000 2448 DG8800 S0x 8800 3800 2655 DGS800 S0x 4000 4000 3264 DCSB00 S04800 9X 4800 5817 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 000194 0611 DCS800 Hardware Manual f us 52 Selecting the control cables All control cables except 220 V or 115 V must be shielded Use a double shielded tw
69. 2 500 5 8 10 33 DCS 0075 ND 05 135 82 122 600 6 4 5 30 DCS 0110 ND 06 90 102 153 500 7 6 7 41 DCS 0140 ND 07 50 184 275 500 12 6 45 90 DCS 0250 ND 08 56 3 196 294 600 12 8 45 130 DCS 0270 ND 09 37 5 245 367 500 16 0 50 140 DCS 0350 ND 10 25 0 367 551 500 22 2 80 185 DCS 0520 ND 11 33 8 326 490 600 22 6 80 185 DCS 0450 7 5 5 ND 13 18 2 698 1047 690 46 8 170 160 DCS 0820 5 5 ND 15 10 9 1163 1744 690 84 0 190 680 DCS 1500 ND 16 6 1 1510 2264 500 81 2 210 650 DCS 2000 ND 17 4 0 1800 2700 800 86 0 250 700 DCS 2500 Frequency 50 60 Hz Line reactors type ND 01 ND 06 a al ND1_to_6_a dsf d 1 1 f g A mm o NDOT 120 100 130 48 65 16 4 8 6 ND 02 120 100 130 158 65 116 4 8 10 IND 03 148 125 157 63 80 143 5 10 0 ND 04 148 125 157 78 80 1143 5 10 16 IND 05 148 125 157 78 80 143 5 10 25 05 178 150 180 72 90 170 5 0 35 e sl Accessories 000194 0611 DCS800 Hardware Manual f us 125 Line reactors type ND 07 ND 12
70. 215 1350 1620 V DC Switch position 7 6 5 4 3 2 1 Output voltage 9 84 5 mA Auxiliary power 230 V 15 50 60 Hz 3 06000000000 Clearance in air Auxiliary power to Output gt 13 mm Insulation voltage Insulation test voltage Ambient temperature range Weight Input Output to Auxiliary power gt 14 mm 2000 V 5000 V 10 70 appr 0 4 kg The voltage gain and frequency response is especially designed for DCS800 converters Dimensions in mm Side view 112 0 E Location of terminals Buttom view 76 0 70 0 7 0 Snap on mounting on DIN 46277 rail Technical data lt 50 0 5 60 0 5 0 8ADW000194R0611 DCS800 Hardware Manual f us Gain selector 7 Transformer T90 103 Principle diagram of the transformer T90 1U 2N 206 205 204 203 202 201 1V 246 2V5 2V4 2V3 2V2 2 1 1W 2W6 2W5 2W4 2W3 2W2 2W1 1N pes Data Selectable transfer ratios Uprim 502 601 701 800 1000 1200 V AC rms Output voltage 7 3 V AC rms Insulation voltage 1200 V Isolation test voltage 3500 V Ambient
71. 30 ms min 30 ms Powerfal O5V 185 1 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 4 in output circuit b dsf X99 Input circuit PIN 4 275 V 9 9 EE X99 Ast _ Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 92 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 4 board The hardware structure is a three phase half controlled bridge supplied direct from mains circuit U1
72. 345 298 amp fan terminal Y E T Direction of air flow M 5 o co s 8 Ei Earthing 8 T1 M12 E 147 5 E 195 5 8 240 PIN 4 nos 287 5 CON 4 E dim b dsf Dimensional drawings S3ADWO00194R0611 DCS800 Hardware Manual f us Module D5 DCS800 S0x 0900 DCS800 S0x 1200 DCS800 S0x 1500 DCS800 S0x 2000 Weight appr 110 kg 107 1005 a ts Fo 400 o Eg r 450 g 8 88 1275 125 125 855 gt 17 26 E 5 for M10 1 o 117 e 26 Q 14 n Q TE e NE 9 po LY 727 L J 27 SS gt 510 LL Vv 480 27 227 e 0 o e Y E Y 8 ble tr ri earthing M12 gis ane a0 min of o o o earthing height 39 mm 9 i M12 Ci oO 1 hol D1 N m 17 754 fan terminals e 1 S 1 o fan terminals 65 5 25 50 50 50 ES La 400 SEs ka 461 325 5 ES le 483 2m Busbars in mm DC 80 x 10 60 5 8ADW000194R0611 DCS800 Hardware Manual f us A5 dim a dsf Mounting the converter module D5 inside an enclosure Two supports should be mounted inside the
73. 5 D6 D7 SDCS PIN 46 PIN 48 V25 V12 23 16 V21 V14 AD AD AD zx l X22 X122 X23 X24 X25 v24 26 V13 V22 V15 ER 18 E 4 ej 4 4 iW Ci Cr Cr 8 j 9 gt OO 9 B C D E F x xX XL 9 o o o F Soca EI E 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 transformer 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 8ADW000194R0611 DCS800 Hardware Manual f us Measuring board SDCS PIN 51 95 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
74. 6 ND 406 255 275 155 175 125 95 10 9 09 ND 407 255 275 155 175 125 95 110 9 11 ND 408 285 285 180 210 150 95 10 9 111 gt H O4 tin coated X Y A B 9 60 45 10 2 Line reactors type ND 409 ND 413 Type A D E F G H K ND 409 320 280 180 210 150 95 10 111 111 ND 410 345 350 180 235 150 115 10 13 114 411 345 350 205 270 175 115 12 13 2x11 412 385 350 205 280 175 115 12 13 2 11 413 445 350 205 280 175 115 12 13 2x11 gt lt O 20 6 2 AL 8ADW000194R0611 DCS800 Hardware Manual f us 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 DCS800 801 0020 05 DCS800 S02 0025 05 KLR21
75. 65A DCS800 S02 0075 0y 75A D1 NF3 440 64 NF3 500 64 5800 501 0090 0 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 NF3 500 110 DCS800 S01 0180 0y 180A DCS800 S02 0200 0y 200A D2 NF3 500 320 NF3 500 320 DCS800 S01 0230 0y 230A DCS800 S02 0260 0y 260A D2 NF3 500 320 NF3 500 320 DCS800 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 500 600 NF3 500 600 DCS800 S02 0820 0y 820A 04 NF3 690 1000 690 1000 DCS800 801 0900 0y 900A DCS800 S02 1000 0y 1000A 04 690 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 690 1000 DCS800 801 1500 0y 15004 DCS800 S02 1500 0y 1500A 05 690 1600 690 1600 DCS800 801 2000 0y 20004 DCS800 S02 2000 0y 2000A 05 690 1600 NF3 690 1600 lt 3000 lt 3000 06 NF3 690 2500 NF3 690 2500 Filter only available on request Planning the electrical installation 8ADW000194R0611 DCS
76. 800 Hardware Manual f us 37 Single phase filters for field supply Many field supply units are single phase converters for up to 50 A excitation current They can be supplied by two of the three input phases of the armature supply converter Then a field supply unit does not need its own filter If the phase to neutral voltage shall be taken 230 V in a 400 V line then a separate filter is necessary ABB offers such filters for 250 V and 6 30 A Converter type of dc current Filter type field supply unit A Umax 250 V DCF803 0016 8 NF1 250 8 DCF803 0035 16 250 20 FEX 425 Int DCF803 0050 50 NF1 250 55 DCF804 0050 50 NF1 250 55 The filters can be optimized for the real field cur further filters for 12 NF1 250 12 rents lField 30 NF1 250 30 single phase operation Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 38 EMC filters You will find further infor paragraphs below describe selection of the electri ethe product s actual emissions mation in publication cal components in conformity with the EMC Guideline The EMC Guideline expects EMC to be taken into Technical Guide chapter The aim of the EMC Guideline is as the name implies account when a product is being developed however EMC Compliant Installa achieve electromagnetic compatibility with other EMC cannot be designed in it can only be quantita
77. 95 1 25 1 10 25 DCS800 S0x 0260 xx 260 2x 35 1x 95 204 2x 25 1x 95 1 25 1 10 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 1x 10 25 DCS800 S0x 0520 xx 520 2x 95 5 424 2 95 5 1x 50 1 10 25 DCS800 S0x 0650 xx 650 2x 120 555 2x 120 5 1 120 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 gt 1 150 1 12 50 DCS800 S0x 1200 xx 1200 4x 120 979 4x 95 3 120 1x185 2xM12 50 DCS800 S0x 1500 xx 1500 4x 185 1224 4 150 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 6 2050 8x 120 6 185 1673 6x120 5 150 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 7x185 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 4x M12 50 DCS800 S0x 4800 xx 4800 8x 300 3876 6x 300 3x300 4xM
78. A92 T90 600V 27 4 kOhm OV D1 D4 ND Example chain Ro R109 R110 R111 Power supply X95 x23 8ADW000194R0611 DCS800 Hardware Manual f us x31 X20 S1 Q K301 K400 F400 1 2 automatic 2 3 230 V fix F300 X96 x99 1 2 12 Relay output DO8 Pin4 SUB4 layout dsf Input Aux supply 99 eoeyejur 9 VOL eb 1 H 12 1 o uonnquisia jsp evans 101 81 oz 22 18 ASIE Aver iy A 87 Aver i ioe IONS Toe us 0 Sjeuueuo asind 2 eus i1 edza 6 Sdza PZ 7428 5428
79. BTB 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 S01 0230 05 KLR200BCB KLR200CCB DCS800 S02 0260 05 KLR250BCB KLR250CCB DCS800 S01 0315 05 DCS800 S02 0350 05 KLR300BCB KLR300CCB DCS800 S01 0405 05 KLR360BCB KLR360CCB DCS800 S01 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 801 1200 05 DCS800 S02 1200 05 KLR1100BCB KLR1100CCB DCS800 S01 1500 05 DCS800 S02 1500 05 KLR1250BCB KLR1250CCB 600 DCS800 S01 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 129 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
80. DCS800 Hardware Manual DCS800 Drives 20 to 5200 A EP ED EP IP DCS800 Drive Manuals Language Public number E ES CN RU DCS800 Quick Guide 000191 DCS800 Tools amp Documentation CD 3ADWO0021 1 DCS800 Converter module Flyer DCS800 000190 Technical Catalogue DCS800 000192 Hardware Manual DCS800 3ADWO00194 x p p Hardware Manual DCS800 update DCF503B DCF504B 38ADW000194Z0301 x Firmware Manual DCS800 3ADWO00193 Installation according to EMC 000032 Technical Guide 3ADW000163 Service Manual DCS800 000195 12 Pulse Manual 000196 CMA 2 Board 000136 Flyer Hard Parallel 3ADWO00213 x Drive Tools DriveWindow 2 x User s Manual 64560981 DriveOPC 2 x User s Manual 3BFE00073846 x Optical DDCS Communication Link 63988235 DDCS Branching Units User s Manual 3BFE64285513 DCS800 Applications PLC Programming with CoDeSys CoDeSys_V23 61131 DCS800 target tool description Application Program 3ADW000199 x DCS800 Crane Drive DCS800 Crane Drive Manual suppl 3AST004143 R0101 x DCS800 Crane Drive Product note p DCS800 Winder ITC DCS800 Win
81. DCS800 S02 2050 06 07 2050 1520 2280 1450 2175 1430 2860 DCS800 S02 2500 06 07 2500 1940 2910 1870 2805 1740 3480 D6 DCS800 S02 3000 06 07 3000 2270 3405 2190 3285 2030 4060 DCS800 S02 3300 06 07 3300 2416 3624 2300 3450 2277 4554 DCS800 S02 4000 06 07 4000 3036 4554 2900 4350 2950 5900 D7 DCS800 S02 4800 06 07 4800 3734 5601 3608 5412 3700 7400 800 V DCS800 S02 1900 08 1900 1500 2250 1430 2145 1400 2800 DCS800 S02 2500 08 2500 1910 2865 1850 2775 1710 3420 D6 DCS800 S02 3000 08 3000 2250 3375 2160 3240 2000 4000 DCS800 S02 3300 08 3300 2655 3983 2540 3810 2485 4970 DCS800 S02 4000 08 4000 3036 4554 2889 4334 2933 5866 D7 DCS800 S02 4800 08 4800 3734 5601 3608 5412 3673 7346 990 V DCS800 S02 2050 10 2050 1577 2366 1500 2250 1471 2942 DCS800 S02 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 Note AC current lac 0 82 lpc Sizing Note 1 The ratings apply at ambient temperature of 40 104 F In lower temperatures the 05 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 40 104 F or the drive is loaded cyclically Duty cycle loci Technical data locu 3ADWO00194R0611 DCS800 Hardware Manual f us
82. Line Reactors are available directly from TCI For information see their web page www transcoil com 8ADW000194R0611 DCS800 Hardware Manual f us Accessories 130 Autotransformer T3 Type Field curr Transformer s Weight Power loss Fuse F3 secondary current IF kg 5 30 z T 3 01 lt lt 7 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 63 690 V 50 60Hz T 3 11 lt X A 15 80 10 T 3 12 lt 12 13A 20 125 16 T 3 13 lt 16 A lt 17 A 30 150 20 T 3 14 30A lt 33 60 230 50 T 3 15 SOA 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 Line reactor L3 F3 F3 T3 SEO 9888 8545858 8855588 1111 e 6 T3 01 T 3 11 210 1101121 75 240 10x18 95 3 0271 312 210 135 112 101 240 10 18 95 T 3 03 5 7 x 5 T 3 04 2601150114411231330 10 18 95 5 175 17 5 3 05 3 15 for single phase for DCF503 0035 as well FEX 425 Int Input voltage 500 V Frequency 50 60 Hz
83. 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 UT lt X510 24V 5 E X511 47 5 8 5 3 10k o TR 2 84 a 100 nF o 4k7 2 ul ov X57 SDCS CON 4 ENCODER INPUT A lt 5 10 5 or 24V e 4 5 2 387 cox 3 3 5 8 10k zi o R 2 4 100 nF e 1 1 0 4 7 2 X52 E 4 5 5 7 SDCS CON 4 ENCODER INPUT A In case of a single ended 5 V encoder the jumpers S4 S10 will be set to a neutral position To get a threshold lower than 5 V each
84. MC 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 39 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 EN 61000 6 2 Specialised basic standard for interference immunity in industry If this standard is satisfied then the EN 61000 6 1 standard is automatically satisfied as well 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 Earthed neutral Earthed 400 V network with neutral conductor 3 lt 400 i Mains filter i Line reactor i
85. 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 51 1 9424 V 51 2 90 V GNDB Set bus termination ON S1 1 2 closed Bus termination Cable length DCF803 0035 FEX 4 Set bus termination ON 81100 1 closed The cable length influences the maximum baudrate Baudrate max cable length 500 125 500 250 250m 500 k 100m default and recommended setting 800 k 50m 888 35 1000 k 25m The bus is designed for cable length up to 50 meters Larger distances on request Electrical installation 3ADWO00194R0611 DCS800 Hardware Manual f us 65 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 installat
86. S02 0075 05 DCS800 S02 0100 05 DCS800 S02 0050 05 DCF506 0140 51 DCS800 S02 0200 05 502 0350 05 DCF506 0520 51 DCS800 S02 0450 05 Inductive load supply Overvoltage Protection for other applications 4 Q 500V DCS800 S02 1200 05 DCF506 1200 51 10 5800 502 1500 05 4 Q 690V DCS800 S02 0900 07 DCF506 1500 71 These converter types are released for field supply operation A derating of 1096 is recommended See also dimensioning of installation fuses reactors contactors 8ADW000194R0611 DCS800 Hardware Manual f us Accessories 120 Diagramm x22 grey X1 3 H SDCS FEP 1 500 V SDCS FEP 2 690 V x23 K S t X31 9 1 2 parts not built in at 2 Q unit jumpered i i 1 H B B NE H x2 grey 1 H i 1 H DCF505di d dsf Output X4 1 2 Potential isolated by
87. U1 V1 W1 if used AC voltage for armature circuit U1 V1 W1 Connecting the power cables Grounding and screening of power cables see manual Technical Guide see Reference Cross sectional areas and tightening torques of power cable see chapter Planning the electrical installation Electrical installation 38ADW000194R0611 DCS800 Hardware Manual f us 57 Location R Extension and Interface Modules Connect the signal cables as described below Tighten the screws to secure the extension modules DCS800 Panel connector X33 SLOT 1 R IO Extension module or R Fieldbus module SLOT2 R IO Extension module Interface connector SDCS IOB 3 X1 SDCS IOB 2 8 SLOT 3 R IO Extension module or R DDCS interface board X34 PCTool DriveWindow Light AP Tool Commissioning assi stant Electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 58 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 1 8 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 1 8 Standard one channel for residual current measurement digital I O s not
88. Vdc line voltage DATA AVAILABLE UPON REQUEST 540 1200 line voltage 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 3ADWO00194R0611 DCS800 Hardware Manual f us Control Board SDCS CON 4 Layout of the control board SDCS CON 4 Jumper coding 613 9 Jumper parking position 2 Br No filter Normal DC Tacho 2 9 Filter for AC Tacho with rectifier 2 8 1 7 3 Tacho input X3 4 connected with 0 V GND 2 di 7 3 E Jumper parking position 2 7 no grounding of Tacho input 3 Tacho input 1 at X3 4 and X3 1 2 3 at ttl SDCS cON 4 3 9 reserved Tacho input 2 at X2 23 and X2 24 at 2 SDCS IOB 3 PS5311 62204 Al X3 5 6 Ry 200 kOhm 1 Range 10 0 10 2 3 5 6 250 Ohm 11143 Range 20mA 20mA 53 29 8 2 X3 7 8 Ry 200 kOhm 1 7 Range 10V 0V 10V 2 B AI2 X3 7 8 250 Ohm 1 7 Range In 20mA 20mA 2 Jumper parking position 5 6 2 He Pull up resistor 4 74 kOhm activated at X3 7 1 7 for PTC temperature sensor S43 19 Encoder mode differential RC load with 2 EHE R
89. a oe Rex e de eee ate Ree Reese t 91 Technical data Lice eR cR v C RUP S EORR RI 91 Armature circuit interface 92 Field circuitanterfaces X be Xn gb MR ROG RR 92 Power Interface 5 5 46 5 5 48 5 5 5 94 Interface Board SDCS SUB 4 E been AO ERE ae 98 PASM Al sf 98 Galvanic isolation T90 A92 utens PROPRE PR Hic 100 DC DG transducer A92 ok dere Us bu races s on ete o e Re a b Aus 102 Table of contents 000194 0611 DCS800 Hardware Manual f us 14 Tir nstortmerTI90 adr e te e eb e ead eee dd e PES 103 Dimensional drawings MOGUIG DI e e sete at eR TE It ie ADR a pert Poe dle a 105 Module ettet Ben o eee t E oat epe 105 Module ms Dues dcs etur n sie heus a iwi 105 Module D4 cute er Rt ED ehe e ete rude Rx DER 106 Module Dow teed Shu fa Eie cb eui quta suits 107 Module tp o Eee emu dr bid uei E TEE 108 Modul amp D7 left harid 2 e Ea uz et bk Reed waa wale wh DR ES VA acd 109 Module DY ed
90. 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 N pu a N amp M 22 5 7 5 Ny X zd N 3ADWO00194R0611 065800 Hardware Manual f 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 the converter module This results in four layers for the power cables In case the AC or DC connection or perhaps both of them have to be made at the right side of the converter module use the space behind the converter and move the power terminals via a right angle busbar up to that point where the final connection is most suitable In this case the busbars need to be fixed at the cubicle enclosure not at the converter module The figures below give a rough example how a right side connec tion can be made m Tm 1 TI Example right side connection Mechanical installation 26 Mounting the converter module D7 inside an enclosure Cooling air entry The cooling fan takes the air from the backside both sides and from the area underneat
91. al installation 3ADWO00194R0611 DCS800 Hardware Manual f us 24 Mounting the D1 D2 cover by using the excisting lateral pins and than swing downward to snap in at the terminal row D3 and D4 mounting is accordingly without the snap in mechanism Examples for covering the DC main terminals on D3 left and D4 right converter modules Mechanical installation 3ADWO00194R0611 DCS800 Hardware Manual f us 25 Mounting the converter module D6 inside an enclosure Cooling air entry The cooling fan takes the air from the backside both sides and from the area underneath the converter module View from the right side the back the left side 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 step eg 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
92. ator 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 010 164 ft 1x24 AWG 12x 24 AWG 164 to 328 ft 2x24 AWG 12x 24 AWG 328 to 492 ft 3 x 24 AWG 14 x 24 AWG 8ADW000194R0611 DCS800 Hardware Manual f us Electrical installation 62 Connecting the signal and control cables The cables for digital signals which are longer than 3 m and all cables for analogue signals must be screened Each screen must be connected at both ends by metal clamps or comparable means directly on clean metal surfaces if both earthing points belong to the same earth line Otherwise a capacitor must be connected to earth on one end In the converter cubicle this kind of connection must be made directly on the sheet metal as close as possible to the terminals and if the cable comes from outside also on the PE bar At the other end of the cable the screen must be well connected with the housing of the signal emitter or receiver Connection of a cable screen with the aid of metal clamp to the me tal surface of the PCB carrier at DCS con verter Size D6 D7 Screen connection Routing the cables Route the motor cable aw
93. ay from other cable routes Motor cables of several drives can be run in parallel installed next to each other It is recommended that the motor cable input power cable and control cables be installed on separate trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is shown below 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 90 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 3ADWO00194R0611 DCS800 Hardware Manual f us 63 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 Swit
94. be done independent from S2 or 3 settings for inputs AI2 and If the gain is set to 10 by using S2 or S3 and the 500 burden resistor is activated the input signal level is changed to 2 0 42 mA For input there are the following configurations available input range 20m input range 10V or earth fault monitoring by Isum not equal to zero via X3 11 and X3 12 8ADW000194R0611 DCS800 Hardware Manual f us 89 Power Supply Board SDCS POW 4 The SDCS POW 4 board is designed for DCS800 converter modules and is mounted on the electronic support This board is used for all types of modules type D5 D6 07 21000 A and rebuild system DCS800 R The SDCS POW 4 works on a switched mode basis in fly back configuration It generates all necessary DC voltages for the SDCS CON 4 and all other electronic boards The input voltage is automatically detected and set to either 230 V AC or to 115 V AC The following figure shows the instructions for the selection of the encoder supply voltage If SDCS CON 4 input X5 is used for encoder speed measurement the incremental encoder supply voltage for 5V 12 V or 15 V must be selected by jumpers S3 S4 and S5 SDCS POW 4 7 SDCS CON 4 42 RC 101112 Pelay output 2 2 AC supply 12V S4 15V 24V X5 10 encoder supply The 24 V encoder supply can be selected either
95. ched OFF nodes can remain in the bus and do not disturb the serial communication The function of the interface is predefined 1 Mailbox function for peer to peer communication 2 Communication to field exciter DCF 804 DCF803 and three phase field supply of DCS800 3 Communication for 12 pulse operation DCS800 to DCS800 Cabling Every bus node requires the setting of Node number The bus termination of twisted pair cable is performed with a pre designed termination resistor 120 Ohm inside Drive field exciter The termination resistance of 120 Ohm is selected for typical twisted pair cable It must be located in both ends and activated by jumper or switch Preferred cable type DEVICENET Supplier Helu Kabel Germany type 81910PUR Belden USA type 3084A 120 ohm 1 1 4 W 120 ohm 196 1 4 W asf CAN Bus termination Electrical installation 8ADW000194R0611 DCS800 Hardware Manual f us 64 The bus ground GNDB is isolated It can be ground terminated at one point only Example of two DCS800 D5 converters with FEX 425 Int internal field supply DCS800 D5 Converter CAN Bus termination c def DCS800 D5 Converter SDCS DSL FEX 425 Int 1100 2 Set bus Termination OFF termination ON 51100 1 closed Bus termination Termination OFF SDCS DSL FEX 425 Int 3 1 3 21 X53 next drive next converter Set bus termination
96. citer units short circuit protected X523 250 mA 2 5 T CANL 9 V4 DSL communication Remarks 82 Bus termination 4 314 Termination 200 kOhm S1 1 2 120 ohm 2 2 3 no termination park position 3 Ground termination X541 A S2 2 4 200 kOhm R C ground termination 2 1 3 0 Ohm ground termination 3 RxD J 44 park poston RS 485 communication Remarks DSL 4 dia a dsf no isolation Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 85 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 The cable length between X1 X1 and X2 X2 outside the DCS module They must be mounted in a is max 1 7 m D1 D4 converters way that the conductive supports have a good con is max 4 m screened required for D7 converters nection to ground of the installation betwee
97. ctive earth To fulfill this requirement the connection of a thermistor and other similar components to the inputs of the drive can be implemented by three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analogue inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 54 Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 55 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 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
98. der 7 55 170 1559 21 20A 660 UR 0 OFAX 00 531 isis 170M 1561 15 25A 660V UR 0 OFAX 00 531 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 00 531 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 1 5 rst 170M 5810 0 30 500A 660V UR 2 OFAX 2 S3 170M 6811 0 22 700A 660V UR 3 OFAX 3 S3 170M 6813 0 15 900A 660V UR 3 OFAX 3 S3 170M 6163 0 15 900A 660V UR 4 170H 3006 170M 6166 0 09 1250A 660V UR 4 170H 3006 Dimensions mm Size 0 4 Size c d e 0 78 5 35 21 15 1135 89 45 5 0 2 150 69 55 55 6 8 150 668 76 ye 83 o o Size 4 E 139 7 E olders 250 174 123 250 214 133 265 246 160 m 110 64 17043006 8ADW000194R0611 DCS800 Hardware Manual f us 123 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 a
99. der Product note PDC2 EN x DCS800 Winder description ITC 000308 x Winder Questionnaire 0002532 DCS800 E Panel Solution Flyer DCS800 E Panel solution 3ADW000210 x Hardware Manual DCS800 E 3ADWO00224 DCS800 A Enclosed Converters Flyer DCS800 A 38ADW000213 x Technical Catalogue DCS800 A 000198 x Installation of DCS800 A 3ADW000091 p DCS800 R Rebuild System Flyer DCS800 R 38ADW000007 DCS800 R Manual 3ADWO00197 x DCS500 DCS600 Size A5 A7 C2b and C4 Upgrade Kits 000256 Extension Modules RAIO 01 Analogue IO Extension 64484567 RDIO 01 Digital lO Extension 64485733 AIMA R slot extension 3AFE64661442 x Serial Communication Drive specific serial communication NETA Remote diagnostic interface SAFE64605062 Fieldbus Adapter with DC Drives RPBA PROFIBUS 64504215 Fieldbus Adapter with DC Drives RCAN 02 CANopen Fieldbus Adapter with DC Drives RCNA 01 ControlNet 64506005 Fieldbus Adapter with DC Drives RDNA DeviceNet 64504223 Fieldbus Adapter with DC Drives RMBA MODBUS 64498851 Fieldbus Adapter with DC Drives RETA Ethernet 3AFE64539736 x x gt existing p gt planned Status 10 2008 DCS800 Drive Manuals List_h doc DCS800 Drives 20 to 5200 A Hardware Manual 3ADWO000194R0611 Rev F EFFECTIVE 15 09 2008 2008 ABB Automation Products GmbH All rights reserved 8ADW000194R0611 DCS800 Ha
100. directly from CON 4 board S4 11 12 or from POW 4 board S4 10 11 4 is located on the CON 4 board Jumper coding X3 Encoder supply selection X4 X5 fron X5 15vH B HB 5V 12v 1 24v gt B bad Hiv A 9 X37 and X137 are connected in 24N w parallel a Ba x137 X14 is used for SDCS PAR 1 hard parallel converters default value Pow4a dsf Auxiliary supply voltage X99 Input circuit POW 4 Supply voltage 115 V AC 230 V AC NIC ay Tolerance 15 10 15 10 0 Frequency 45 Hz 65 Hz 45 2 65 Hz xm gt RUN Power consumption 120 VA 120 VA OON E Power loss 60 W lt 60 W 1 Inrush current 20A 20ms 10A 20 ms n SAT recommended fusing 6 AT 6 Mains buffering min 30 ms min 300 ms T Ez Powerfail 95 V 95 V 40202 Frequently switching ON and OFF increases inrush current 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 lt 24 V detailed data is available on request via your or 115 230 V 40 3 A ABB representative
101. e 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 D3 04 05 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 current must be considered You will find further information in publication Technical Guide chapter Line reactors Planning the electrical installation 8ADW000194R0611 DCS800 Hardware Manual f us Line reactors 29 DCS Type Line choke Design J Line choke Design 400V 690V type for Fig type for Fig 50 60 Hz configur A configur B 2 Q Converter 4 Q Converter DCS800 S01 0020 04 05 DCS800 S02 0025 04 05 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
102. e reactors type ND 401 0413 127 Line reactors North 129 AutoitramstorftYieled ende E seta 130 line r actor s esr wien Divi du e egeo ERO ae EN 130 Supply transformer T2 for electronics fan 131 Optical cables sin Cr 132 Other cables aoa mere Vete aso dete Eier 133 Table of contents 000194 0611 DCS800 Hardware Manual f 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 1 2 Size 01 04 20 1000 Size 05 900 2000 Size 06 1900 3000 Size 07 2050 5200 The DCS800 3ADWO00194R0611 DCS800 Hardware Manual f us 16 Type code The type code contains information on the specifications and configuration of the drive The first digits from left express the basic configuration e g DCS800 S01 2005 The optional selections are given thereafter on the name plate by plus code The main selections are described below Not all selections are available for all types
103. etween current 5 12V input terminal 10 10 1V 41V measure for 0 4 20 mA ment X311 X312 1 R lt SS mo Temperature sensor supply 0 TC PT10 1 5 5mA ERE 3 4 3 4 51 9 10 65111 12 51 13 14 10 Characteristics for pulse encoder inputs single ended push pull 5V 12V 24V single ended open collector 24 24 23 23 22 22 12 2AV 24 23 22 default value When using SDCS IOB 3 encoder input the following S4 jumper setting S4 on 50 5 4 5 on SDCS CON 4 has to be made 1 There is a card holder available as option for fastening the SDCS IOB 3 board For more information see chapter Dimensional drawings Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 88 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 mu
104. f 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 3ADWO00194R0611 DCS800 Hardware Manual f us Technical data What this chapter contains 69 This chapter contains the technical specifications of the drive e g the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings and warranty policy 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 95 60 Hz 2 95 Dynamic frequency range df dt 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 Change of the ambient temp Relative humidit
105. ge measurement channels are 42001D3 opened and connected to the T90 and A92 units Technical data Hard and software settings Voltage coding on measuring board 05706707 Conv nom voltage V Y 4 400V 6 600V Y 7 690V 8 800 9 990 Y 1 1200V 5 500 Rated mains voltage V AC 220 500 270 600 300 690 350 800 450 990 530 1200 Value f conv nom volt at 1200 SET TINGS block board SDCS 51 51 e gt all resistors are 0 Q Galvanic isolation Resistors Rx on PIN51 27 4 27 4 27 4 27 4 27 4 27 4 DC DC transducer A92 8680A1 Switch position 7 675V 6 810 5 945V 4 1080 V 2 1350 V 1 1620 V DC DC transducer A92 42000D3 DC DC transducer A92 42001D3 Transformer T90 745047 2V1 2W1 12 pulse serial and sequential have a different selection between SConvScaleVolt 97 03 and the scaling of measurement channel See 12 pulse manual for DCS 800 8ADW000194R0611 DCS800 Hardware Manual f us 101 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
106. gs North America regenerative Type code Input RMS Normall Duty Standard Duty Heavy Duty Internal Size Arms Adc HP current 500 Vdc 4 5 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 Ds 99 1105 700 950 600 851 500 25 5800 802 1500 05 8164 1224 1450 900 1320 800 1280 DCS800 802 2000 05 8164 1632 1885 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 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 3000 3972 2500 3800 2550 600 Vdc UIT HERMES M OCC CONDE MA CO EN CONCERN E E 1224 1428 1000 1325 1000 1325 1000 DCS800 S02 3000 06 D7 External DCS800 902400006 E E TU S02 4800 06 700 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
107. h the converter module View from front left side right side air flow ir flow al View from bottom Free space around the converter module Do not place the converter module in a corner In case the fan cannot take the air through the bottom plate of the enclosure none of the remaining entries can be NN gt 20 XN IN 1 50 Ea Air entry through bottom plate Make sure the converter module gets clean air because there is no air filter in front of the fan at the converter Cooling air outlet To avoid circulating air inside the enclosure it is rec ommended to make sure the exhaust air leaves the enclosure Mechanical installation Cable entries The cable entries are existing symmetrically on both sides Nevertheless only the entries on the left side should be used for cables going to the electronics power supply SDCS POW 1 or the controller board SDCS CON 4 OL c 8 Screened cable for IMR hardware interface connection 2 board is strongly rec ommended Provide sufficient grounding of card 1 holder electronics power supply 2 Screened cables converter control cables pressure switch A7 re air inlet b dsf A7 re air inlet b dsf Internal cable d
108. i PS PS TT ta i I E IL pls i i x S S 4 4 8 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 000194 0611 DCS800 Hardware Manual f us 118 Dimensions 170 6 kg 105 o 8 Qu H d see D1 Ut V1 Wi Terminal X100 X101 earthing M6 MORE cross section AWG 7 DCF803 0035 3 67 36 5 LJ oo 28 DD for mounting on mounting plate provide hole with diameter of min 5 mm for thermal sensor 90 N N 9 N see see Ho S ROM 16A 5A D1 Ui V1 Wi N DCF803 0016 dsf DCF803 0016 Accessories S3ADWO00194R0611 DCS800 Hardware Manual f us 300 DCF505 DCF506 Overvoltage Protection 119 The three phase converter can be used as motor field supply This operation needs a separate active Overvoltage Protection unit DCF 505 or DCF 506 to protect the power part against inadmissibly high voltages The protection unit activates a free wheeling circuit between the and F connectors if an
109. ion 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 fuses and disconnector are installed The motor connections at C1 D1 and 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 3ADWO00194R0611 DCS800 Hardware Manual f us 66 Installation checklist 8ADW000194R0611 DCS800 Hardware Manual f us 67 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 page
110. ircuit protection The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive Mains cable AC line cable short circuit protection Always protect the input cable with fuses Size the fuses according to local safety regulations appropriate input voltage and the rated current of the drive see chapter Technical Data High speed semiconductor fuses provide short circuit protection but don t provide thermal overload protection Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 50 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 wire temperature is the same as recommended in the following tables Armature Converter type D1 1 01 V1 W1 AK1 5 PE 1 2 1 2 A 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 5 61 1x 25 2 1 16 1x 6 5800 50 0100 100 1 25 5 82 1x 25 5 1x 16 1x 6 DCS800 S0x 0140 xx 140 1x 35 114 1x 35 1x 16 1x M6 6 DCS800 S0x 0200 xx 200 2x 35 1x 95 163 2x 25 1x
111. 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 1 8 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 10 5 via SDCS IOB 2 and SDCS IOB 3 Analogue 1 8 Standard one channel for residual current measurement digital I O s all isolated by means of optocoupler relay the signal status is indicated by LED current source for PT100 PTC element 38ADW000194R0611 DCS800 Hardware Manual f us Pulse encoder connection 59 Connecting a pulse encoder to the DCS800 converter The connection diagram for a pulse encoder to the electronics of a DCS converter is quite similar if the SDCS CON 4 or the SDCS IOB 3 is used The basic difference between these 2 boards is the galvanically isolated circuit and pulse receivers via opto coupler on the SDCS IOB 3 board Power supply for incremental encoder SDCS CON 4 and SDCS IOB 3 board have jumpers to select a supply voltage V17 LED on SDCS IOB 3 indicates supply is OK 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 co
112. isted pair cable Figure a e g JAMAK by NK Cables Finland or BELDEN type USA for analogue signals This type of cable is recommended for the pulse encoder signals also Employ one individually shielded pair for each signal Do not use common return for different analogue signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable Figure b is also usable 9 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 3ADWO00194R0611 DCS800 Hardware Manual f us 53 Connection of a motor temperature sensor to the drive WARNING IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non conductive or conductive but not connected to the prote
113. label of the drive to verify that the unit is of the correct type The label includes an IEC rating 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 3ADWO00194R0611 DCS800 Hardware Manual f 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 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
114. lating D Ne WA e 84 xU gU 48 SDCS PIN 51 305 8ADW000194R0611 DCS800 Hardware Manual f us 96 Settings of the SDCS PIN 51 board if a DCS converter is equipped with it by ABB Current coding R5 9 180 Rye 180 Ino 180 180 RI R12 802 13 180 Ria 9 5 180 180 680 IRi9 1209 9 Ko Rated current scaling 1 1 Qo ihi oo ojo ojo Zero current detection code tab PIN1 PIN20 PIN51 e dsf Construction type 0 06 07 D7 07 Conv nom voltage V 4 400V 6 600v 7 6907 4 400V 6 600 7 690v 8 8007 9 Yat U1 V AC Y 5 500V Y 5 500V 990v 1000 Voltage measurement scaled by type code 500V 600 V 690 V 500V 600 V 690 V 800 V 1000 V parameter selection PIN 51 PIN 51 PIN 51 PIN 51 PIN 51 see 0x0 C 9 6 isolation the converters can be used at lower line voltage then specified by the y value without hardware modifications if the nominal line voltage applied to the converter is not lower than 45 for y 5 9 and not lower than 55 for y 4
115. lectrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Grounding These instructions are intended for all who are responsible for the grounding of the drive Incorrect grounding can cause physical injury death or equipment malfunction and increase electromagnetic interference Ground the drive motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and pick up Make sure that grounding conductors are adequately sized as required by safety regulations In a multiple drive installation connect each drive separately to protective earth PE Minimize EMC emission and make a 360 high frequency grounding of screened cable entries at the cabinet lead through Do not install a drive with EMC filter on an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC stated by EN 50178 5 2 11 1 a fixed protective earth connection is required Safety instructions 8ADW000194R0611 DCS800 Hardware Manual f 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
116. lso 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 See Note 1 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 DC 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 st Fig A B C D E F G H J FWP 5B 30B 1 287 0563 1 855 2477 2477 0 25 0405 0 063 0 25 FWP 35B 60B 1 4 375 0 813 275 3 708 3 312 0 344
117. method is needed for the other jumpers Wx High frequency grounding is done by 100 nF capacitor 8ADW000194R0611 DCS800 Hardware Manual f us 87 Analogue and encoder board SDCS IOB 3 As described at the beginning of the chapter there are I O via SDCS IOB 2x IOB 3 and SDCS CON 4 various options for configuring the inputs 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 in a 21 way that the conductive supports have a good con J nection to ground of the installation SOUS ee SUES 32 The cable length between X1 X1 and X2 X2 is max 1 7 m 01 04 converters is max 4 m screened required for D7 converters between 1 is max 0 5 m because of EMC rea sons SDCS CON 4 SDCS CON 4 Layout and jumper settings of the SDCS IOB 3 board 233 5 pecans supports SDCS IOB 3 1 Functionallity of analogue inputs 4 Pulse encoder supply Paralleingof gain 1 gain 10 Residual Ch 1500 2 b
118. mmunicate data from the overriding control 2 AC800M adapter modules for fieldbus AC80 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 Connector X19 is used CDP 312 panel as well as interface board NDPI 148 gt SDCS COM 8 a N I V1 9 d E s a a gt gt gt gt gt gt Bio 2 152021 9 o2 59 2 o 2 5 COM 8 layout b dsf conductive support Explanation of LEDs on SDCS COM 8 LED color Meaning V6 green 5 V supply ok V1 red blinking boot procedure permanent SDCS COM 8 fault Type Revision optical components Channel 0 used for max driver current Cunduc tive sup port Cho Chi Ch2 PLC DW SDCS COM 81 D F 10 Mb 5Mb 10 Mb 10 Mbjother interfaces Ch 0 2 3 50 mA SDCS COM 82 D F 5Mb 5Mb 10 10 Mb Fieldbus adapter Ch 2 3 50 modules Nxxx xx SDCS COM 81 10 5Mb 10 Mb 10 Mbjother interfaces Ch
119. model D5 D6 D7 from 900 A up to 5200 A consists of two boards the measuring board SDCS PIN 51 and the pulse transformer board SCDS PIN 48 The following figures show the different connections between the SDCS PIN 48 and SDCS PIN 51 board depending on the application 2 or 4 quadrant and the construction type The firing board SDCS PIN 46 is used for converters DCS800 S02 2500 DCS800 S02 3000 double bridge D6 modules 2 Quadrant application no parallel thyristors Construction type D5 D6 D7 8 X22 X122 X24 X25 Vi4 V16 V13 V12 V15 i G G G G G G i e gt i 1 je Gt 1 Cr jt Lr a0 gt o 0 5 i B C D E F Foe i x x 4 0 5 E 2 SDCS PIN 46 PIN 48 2 o eg 2q c34 b dsf Lo N e ME x 4 Quadrant application no parallel thyristors Construction type D
120. n X1 X3 is max 0 5 m because of EMC rea sons See chapter Other cables SDCS CON 4 SDCS IOB 2 Layout and jumper settings of the SDCS IOB 2x board 2 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 2 this dimension may vary 4 5 mm 57 017 A depending on revision 2 2 S8 W100 as printed circuit default value agf There is card holder available as option for fastening the SDCS IOB 2 board For more information see chapter Dimensional drawings Technical data 8ADW000194R0611 DCS800 Hardware Manual f us 86 SDCS IOB 2x Software a F a lt lt MUN 2 rua 2 DO4 5 1 ne Ed 2 lt DO5 sev i F EM BH 2 NZ
121. n notches lt 20 Line reactor Y capacitor Y power converters HF interference and commutation notches T il Converter g o 2 5 5 E o c c E 5 2 gt o 5 5 To other loads which have to be protected from the system disturbances caused by gt 5 5 8 a S 2 2 2 A gt o 2 5 2 2 a o g o gt 8 m 9 S 9 5 o 2 Operation at public low voltage network Operation at public isolating transformer together with other low voltage network with an earthed screen loads of all kinds together with other earthed iron core loads of all kinds renders mains filter and line reactor superfluous Operation at public 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 SADWO00194R0611 DCS800 Hardware Manual f 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 E
122. ntrolled 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 DIFFERENTIAL Sa ChA 5 1 ChA 5 2 ChB 5 3 ChB X5 ChZ X5 5 2 X5 6 Power source 5 10 Sense power 5 9 Sense GND X5 8 GND 5 7 SINGLE ENDED ChA X51 ChA 5 2 ChB X5 3 ChB 5 4 2 5 5 ChZ X5 6 Power source 5 10 X5 9 X5 8 GND 5 7 IOB3x3 g dsf 8ADW000194R0611 DCS800 Hardware Manual f us Commissioning hint Note If the drive s measured direction of rotation is wrong or does not correspond to measured EMF speed the SPEEDFB fault may appear during start up If necessary correct by exchanging the field connection If with a positive reference the position signal 3 07 or 3 08 signal does not look like the illustration below then tracks A amp A must be exchanged with inverted signals For single ended encoders Tracks A and B must be exchanged 65535 7 Forward 0 Electrical installation 60 Pulse encoder receiver Two different incremental encoder connections are available differential connection pulse encoders generating either voltage or current signals can b single ended push pull connection voltage signals e used Restrictions using jumper S4 CON 4 or 10 IOB 3 depending on the board
123. o 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 8ADW000194R0611 DCS800 Hardware Manual f us Planning the electrical installation 34 Field conv Field 1 F32 F33 current DCF803 0035 lpx8A 170 1558 OFAA 00 H10 10A FEX 425 Int lE 12A 170M 1559 00 H16 16A DCF803 lt 16 170M 1561 OFAA 00 H25 25A DCF804 x25 A 170M 1564 OFAA 00 H25 35A DCF803 x35 170M 1564 00 H50 50A DCF804 DCF803 lE lt 50 170M 1565 OFAA 00 H63 63A DCF804 Type of protection Semiconduct LV HRC type circuit breaker elements type fuse for 690 V fuse for 500 V or fuse holder hold OFAX 00 690 V type OFAX 00 F3 1 Fuse KTK25 included in FEX 425 Int inside D5 converter module Fuses and fuse holders for 2 phase field supply Single phase Transformer T3 for field supply
124. o overriding control Nxxx fieldbus adapter 2 ES 8 8 8 9 E amp E amp amp gt lx gt z slz 5 5 5 5 5 185 5Is 5 ir ETR grey Fieldbus a E x e 8 8 8 8 E amp E amp amp EI gt Jes Jes zl 2 5 5 5 5 813851 5 ssl 51518 o Ch3 Ring connection to PC tool DriveWindow max 20 m instead of DriveWindow NETA internet module can be connected see Manual 3AFE64605062 E 59 grey 5 grey TxD p SDCS COM 8x 2 8 e a a 8 B B B 2 gt ESL s I B plastic optic fibre 81 com8 bus conn a dsf i z l i H o o o 17 25 o o o 222 22 22 ye 8 8 8 2l lee gt gt gt gt le gt gt IN plastic optic fibre PCI PCMCIA adapter PC 3ADWO00194R0611 DCS800 Hardware Manual f us SDCS COM 8 Rev D and higher com8 bus conn a dsf Technical data 82 Ch3 Star connection to PC tool DriveWindow Plastic opt fibre 30 m SDCS COM 8 Rev D and higher
125. of contents 000194 0611 DCS800 Hardware Manual f us 65 What this chaplerceohtals s o FC 67 X M 67 Maintenance intervals 67 Heatsink nc uc Ree eee dis 68 Sur RICE RR E mde RE E WI Nx Or RUE Des 68 Fan replacement D6 D7 68 Technical data What this chapter contains eec ee bee eee ee KR RUNE Xn eed odes 69 Environmental Conditions tos 1 aad Kee wt then tM ee tne ke oe 69 Current ratings IEC non regenerative 71 Current ratings IEC 72 SIZING 3 eer t er eee eee 72 es uscite soe oe oic eo emu eae nee ee 72 Current ratings North America non regenerative 73 Current ratings North America regenerative 74 Control Board SDGS CON 4 cut ad ra PY Ra pom ex p A eia eg ac a D dE es 75 Layout of the control board
126. older 2 Q Converter 4 Q Converter North America 5800 501 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 802 0075 04 05 pi 170M 1568 OFAX 00 S3L FWP 125A 1 5103 5800 501 0090 04 05 DCS800 802 0100 04 05 170M 1568 OFAX 00 S3L FWP 125A 1 5103 DCS800 S01 0125 04 05 DCS800 802 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 04 05 D3 170M 6811 OFAX 3 S3 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 04 170 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 t
127. onverter The field exciter is prepared to operate as three phase as well as single phase converter Single phase operation is provided with terminals U and W measurement channel het SAL e X100 Setting of switchable burden X100 35A resistors by rated field current X101 U1 X101 V1 Field X101 W1 X100 D1 4 1 a dsf Layout of the SDCS FEX 4 board 240 2410 P1 SID al 1 T110 T113 G Field O w Xo alg T112 TUM 2 X R106 V110 5 gin X1 24V supply X3 DSL Link X1 1 24 V DC X3 1 GNDB 1 2 OVDC 2 CAN L X3 3 3ADWO00194R0611 DCS800 Hardware Manual f us D800 OP x 5800 0730 5801 07318 52 e e 000000 1100 3 554 e ao X i 5 Fex4_layout_a dsf Accessories 114 Accessories Electrical data Power circuit AC Field input voltage 110 V 15 500 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 Line fuses KTK25 for FEX425 internal external for DCF803 0035 DC output current
128. 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 1 DCS800 S D1 9 Overvoltage protection DCF 506 Motor field supply with DCS800 S02 and 4 Q Overvolt age Protection DCF 506 Assignment Field supply converter to Overvoltage protection unit for motor fields Field supply converter Overvoltage Protection 2 Q 500 V DCS800 S01 0020 05 DCS800 S01 0065 05 DCS800 S01 0090 05 501 0045 05 DCF506 0140 51 10 5800 501 0180 05 DCS800 S01 0405 05 DCS800 S01 0315 05 DCF506 0520 51 4 Q 500V DCS800 S02 0025 05 DCS800
129. p 222 258 sKsego9 sjueuoduioo jo Qs e are 94 yt 44 1 eo i E i 1 i i ar Qx pasim xul sod H H Y E oo gt 4 222 8 2 558 1 8 o a 558 5 1 o ja _ c o E e 1 e Ez 1 o eo 1 1 6 e 1 1 B 1 22 y E 9 E NOE 4 tc o 1 t MOd E 1 8 S i 1 3 9 8 E H i X0M G Sd LNInO 008520 a i i x SvrH E E 4 A ddns vs 0 VSIN 0 1 5 gt jaued vonod Zk odan gt L gt gt N S v 227 5 4 5 Od a 7 Bunsixg 1008 The DCS800 3ADWO00194R0611 DCS800 Hardware Manual f us 20 The DCS800 8ADW000194R0611 DCS800 Hardware Manual f 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
130. 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 Data rate 1 4 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 1 ing messages ABB 105055 Transmission device 10 Mb component for each channel ES Ole UNT Gr CH RXD Power supply Input voltage 24 VDC 10 em 9 ADDRESS Input current 300 mA et 00 Monitoring green LED switched on when the 9 1 output voltage is normal eo S ci RXD Operating temperature 0 50 PCB dimensions s diagram beside E 9 MBIT S Remark Only channels with the same components e g 9 HHHH 10 Mb component may be connected to each eG other Q m col PXD 9 For further information see Appendix D the DriveWindow 9 User s Manual 264 co RXD lt vios 69 Note 4 Q For addressing and automatic node numbering of the dri
131. r mounting Kit 3 m cable length Fieldbus K454 Profibus RPBA K451 DeviceNet RDNA K466 Ethernet IP Modbus K458 Modbus RMBA 10 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 8ADW000194R0611 DCS800 Hardware Manual f us 17 t and control ircui In C Ma 50 01 04 400 V and 500 V units with Onboard field exciter Armature circuit converter DCS800 600 V units are always without Onboard field exciter 38p p S S 8504 Jeuuojsue1 0 101061 esnj 2 indino sjueuoduioo jo uous 7 2 play 2 1 Qs ve are 1 8OI ary arg xul 600 Xx atu xe r 8 oldu Memory Card Slot 1 4 gt 522 298 gt 2 568 o Bas 5 gt lt 2115 LL e 9 c o o a 2 iddns T S L 1 1911 optical fibre vara 00859 ALL A OEZ Pm vs 0 VSIN ZLE 1 viowoa
132. ram 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 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
133. ration for field supplies F3 2 and F3 3 fuse types serve as line protectors and cannot protect the field supply unit Only pure HRC fuses or miniature circuit breakers may be used Semiconductor fuses would be destroyed for example by the transformer s starting current inrush E E m Configurations for field supplies ND30 F3 3 built in F3 1 lt 2 FF ASP b dsf Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 33 Semiconductor type F1 fuses and fuse holders for AC and DC power lines DCS800 S01 DCS800 S02 The converter units are subdivided into two groups Unit sizes D1 D2 D3 and D4 with rated currents up to 1000 A require external fuses 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 needed The third column of the table below assigns the AC fuse type to the converter type In case the converter should be equipped with DC fuses according to the hints use the same type of fuse as on AC side at DC side C1 D1 Blade type fuses are used for all the converters construction type D1 D4 except the converters 610 A 680 A 740 A 820 A 900 A 1000 A Type of converter Size Fuse type Fuse holder Type Fuse H
134. rdware Manual f us 8ADW000194R0611 DCS800 Hardware Manual f 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 follow or damage may occur to the drive the motor or driven equipment Read the safety instructions before you work on the unit To which products this chapter applies This chapter applies to the DCS800 Size D1 to D7and field exciter units DCF800 Use of warnings and notes There are two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning warns of high voltage which can cause physical injury and or damage to the equipment electricity which can result in physical injury and or damage to the equipment Electrostatic discharge warning warns of electrostatic discharge which General warning warns about conditions other than those caused by 4 can damage the equipment Safety instructions 8ADW000194R0611 DCS800 Hardware Manual f us Installation and maintenance work These warnings are intended for all who work on the dri
135. relay NO contact Contacts no protected Contact rating AC 60 V 550 mA DC lt 60 550 mA line potential SDCS FEP 1 FEP 2 1 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 000194 0611 DCS800 Hardware Manual f 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 121 220 SDCS FEP 1 500 V SDCS FEP 2 690 V 8ADW000194R0611 DCS800 Hardware Manual f us lt lt 42 I 145 I 145 MB 520 a dsf E 111 111 MN 1 1 MB 1500 a dsf Accessories 122 Fuses and fuse holders IEC Accessories Type Resistance Fuse F1 Size Fuse hol
136. ription 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 X20 RDIO RAIO x x R Fieldbus adapter x SDCS COM 8 x Second fieldbus RMBA x 8ADW000194R0611 DCS800 Hardware Manual f us Technical data 78 Digital and analogue connection of the SDCS CON 4
137. rs 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 05 740 596 894 578 867 538 1076 04 25 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 es DCS800 S01 2000 04 05 2000 1479 2219 1421 2132 1361 2722 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 600 690 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 07 150
138. s 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 3ADWO00194R0611 DCS800 Hardware Manual f us 68 Heatsink Fan The heatsink fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean In a 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 o
139. s the firmware plus the stored parameters Parameters handled by DCS800 panel or DWL PCtool or by Serial communication parameter service are stored immediately in the FlashPROM Parameters handled by cyclic serial communication dataset table Group 90 92 and pointers group 51 are not stored in the Flash PROM They must be stored by means of ParApplSave 16 6 service The faultlogger entries are stored in the FlashPROM during power down auxiliary power supply OFF Watchdog function The control board has an internal watchdog The watchdog controls the running of the control board program If the watchdog trips it has the following effects Writing to FPROM is disabled e Thyristor firing control is reset and disabled Digital outputs are forced low Programmable analogue outputs are reset to zero OV 8ADW000194R0611 DCS800 Hardware Manual f us Technical data 76 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 5 3 4 7seg DCS8 dsf Terminal description Technical data X37 Connector is used for
140. sss ede texte 22 Terminal options converter size 1 4 23 Connection of DC terminals of D4 converter 23 Terminal cover according to VBG 4 regulations 23 Mounting the converter module D6 inside an enclosure 25 Mounting the converter module D7 inside an enclosure 26 Planning the electrical installation Table of contents 000194 0611 DCS800 Hardware Manual f us 12 What this chapter COMAINS a 27 To which products this chapter 27 Opti ns for 27 secos oh 27 lide rBactors erer Eee tose 29 Line reactors LL1 for North 30 Aspects of fusing for the armature circuit and field supplies of DC drives 31 Generals 3 6 abus o cert 31 Conclusion for the armature supply 31 Conclusion for the field 5 32 Semiconductor type F1 fuses and fuse holders for AC and DC power lines 33 Fuses F3 x and fuse
141. st not be used SDCS IOB 3 SDCS CON Software 51 100 100k X3 inr 2 9 0 50 Hook E1004 gt gt AITAC s 94 4 S2 3 3 ms 3 99 5 5 6 Tro 21 10 E gt 6 Lo 3 3 ms 7 s P lt Ee 10 m b A4 10 12051914 10 ms 11 1107 100 12 1001 475 Xe AO1 2 ov 3 lt AO2 4 100 ov 2405 21 5 c3 lt 100nT 2 fh 8 V 325 99 03 6 1 ov R110 max 230 4 05 7 10V 8 OV 9 E T 10V osr H 15 10 s PCE 5 11 ov 12 S10 S10 X51 456 2441237 Vis ChA 2 9 fd ChA 3 TEER Wt chB gt 4 ep m 71 ChB 5 1461718 ChZ gt 6 roii MUERE 17 7 Power 8 Sense Power Source Sense 99 2 88 10 S4 GND total smoothing time lt 2 ms 20 0 20 by setting S1 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 1 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 g dsf Resolution Input output Scaling Common Remarks bit values by mode Hardware range 15 sign 10 0
142. supply of SDCS CON 4 from SDCS POW 1 SDCS POW 4 SDCS PIN 4 supply voltage can be measured to ground 7 3 48V 7 5 24 7 7 15 37 11 15 X37 13 5V encoder X37 23 5V CPU Supply voltage monitoring 5V CPU is monitored by 4 75 V and forces CPU to reset In parallel the CPU monitors Powerfail signal from power supply SDCS PIN 4 or SDCS POW 4 X12 and X13 connector are used for measurement voltage current and temperature and firing thyristors by SDCS PIN 4 PIN 41 PIN 46 PIN 41 PIN 51 see chapter Technical data X17 and X300 are routine test connectors X1 and X2 are used to connect SDCS IOB 2 and SDCS IOB 3 board see chapter Technical data X33 is used to connect DCS800 Panel It can be connected direct via 40 mm jack or via CAT 1 1 cable 45 X34 is used for download firmware for DWL and IEC61131 programming connection 3ADWO00194R0611 DCS800 Hardware Manual f us 77 The RS232 interface is normally used for setting parameter in the drive via the DWL PC Tool The default settings of this interface are as follows Signal level RS232 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 Desc
143. t 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 8ADW000194R0611 DCS800 Hardware Manual f us 32 Conclusion for the field supply Basically similar conditions apply for both field supply and armature circuit supply Depending on the power converter used half controlled bridge fully controlled 4 quadrant bridge some of the fault sources may not always be applicable Due to special system conditions such as supply via an 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 P Configu
144. tacts for C1 and D1 connection and 1x NC contact for connection of Dynamic Brake resistor The contactor should be controlled by signal 6 03 Bit 10 The acknowledge can be connected to parameter 10 21 MainContAck 10 23 DCBreakAck H Main contactor 6 03 b 7 DCS800 Converter board field exciter Dyn Brake 6 0368 module DC Contact US 6 03 b 10 DC cont us dsf Planning the electrical installation SADWO00194R0611 DCS800 Hardware Manual f us 46 th reduced components ion wi Drive configurat on board field exciters Int field exciter but externally supplied using D4 400 500 V Converters D1 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 Converters D5 using FEX 5 194 pjey eseud e 10 v09 6084OQ SHUN Ajddns eui esn SPUNI 104 v 92 02 91 perddns 1u GZy X34 Gd pjey UO 9 dn sjuauno pue A 0 dn eui ye pasn eq ued 4 Jeioxe UO A 006 gt pue A 4 5 1919Au09 008520 10
145. ters 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 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 on request 2600 V to 990 V IEC see table EN types on request above for details see table Available for converter above modules including field exciter units Technical data 3ADWO00194R0611 DCS800 Hardware Manual f us 71 Current ratings IEC non regenerative The current ratings for the DCS800 with 50 Hz and 60 Hz supplies are given below The symbols are described below the table Power converter module currents with corresponding load cycles The characteristics are based on an ambient temperature of max 40 C and an elevation of max 1000 m a s l Unit type Ipci lbc Ipc m Ipc iv Size T field curr continu 100 150 100 6 150 100 200 2 Q converte
146. to EN 61800 3 filters are not needed in insulated industrial networks with own supply transformers Furthermore they could cause safety risks in such floating lines IT networks According to EN 61800 3 filters are not needed in industrial zone Second Environment for DCS800 drives above 100 A rated current For rated currents below 100 A the filter requirement is identical to Light Industry First Environment Three phase filters EMC filters are necessary to fulfil the standard for emitted interference if a converter shall be run at a public low voltage line in Europe for example with 400 V Such lines have a grounded neutral conductor ABB offers suitable three phase filters for 400 V and 25 A 600 A and 500 V filters for 440 V lines outside Europe The filters can be optimized for the real motor currents 0 8 IMOT 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 QConverter _ 4QOonvrter IDC A 1 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
147. 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 lE type 50 60 Hz external supply Uprim 500 V DCF803 0035 2 e FEX 425 Int lt 12 13 98 lt 16 3 03 DCF803 4 0050 30 A T 3 04 DCF803 4 0050 SOA T 3 05 Uprim 3600 V DCF803 0035 5 Ux FEX 425 Int SIE A Tee lt 16 3 13 Uprim 2690 V 6A 3 11 autotransformer lt 12 A 3 12 DCF803 4 0050 T 3 13 DCF803 4 0050 2303 T334 SOA 3 15 Autotransformer data details see chapter Technical Data Planning the electrical installation 000194 0611 DCS800 Hardware Manual f us 35 Single phase Commutating reactor For DCF803 0016 DCF803 0035 and FEX 425 Int field power converter with external supply must be connected via additionally commutating reactor because of EMC considerations if the supply has a separate mains With DCF803 804
148. u aH RENE iE 110 Fuses installed inside the converter 111 Accessories DCF803 0035 and FEX 425 113 ED ERR OE ete Seded 114 bits eacus Pei uS ei das euge Oud 114 POWer SeClIOnu eR mU LR _ ER A E 114 DCS LINK 115 pea aes Cede Shaw Hone eee 116 232 d Ui ah an se Re get ha 117 FEX425 INTERNAL Fex 425 Int Hardware configuration size 05 117 DirrierisiOns s aree fee Drews Beh son ar oak efe NM ta Ee aret 118 DCF505 DCF506 Overvoltage 119 Fuses and t se holders EG sx ERI a re RD HEY 122 Fuses and fuse holders North 123 DINES ONS dc E Ese He ER 123 bine reactors Eus Dubia IS bce 124 Line reactors type 01 ND 17 124 Line reactors type ND 07 ND 12 125 Lin
149. ucts 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 3ADWO00194R0611 DCS800 Hardware Manual f us 27 Planning the electrical installation What this chapter contains This chapter contains the instructions that you must follow when selecting the motor cables protections cable routing and way of operation for the drive system Always follow local regulations Note If the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Reference Technical Guide publ no 3ADW000163 To which products this chapter applies This chapter applies to the DCS800 S Size D1 D7 Options for the drive Line reactors for armature DCS800 and field DCF800 supply When thyristor power converters operate the line voltage is short circuited during commutation from one thyristor to the next This operation causes voltage dips in the mains PCC point of common coupling For the connection of a power converter system to the mains one of the following configurations can be applied Configuration A Line 9 When using the power converter minimum of impedance is 4 required to ensure proper performance of the snubber circuit A line reactor can be used to meet this minimum impedance requirement 1 The value
150. upler 1 8 24 48 1 8 4 7 IOB 21 gt 0 signal 0 8 V gt 1 signal 18 60 V 115V R1 R8 22 IOB 22 gt 0 signal 0 20 V gt 1 signal 60 130 V 230 V R1 R8 47 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 50 not galv isolated from the DCS electronics only available at SDCS IOB 21 If the inputs are supplied from the internal 48 V X7 3 and or X7 4 a connection must be done from either X7 1 and or X7 2 to ground of the DCS800 module In default condition ground is identical to the converter s frame If the inputs are supplied by any external source 48 V DC 115 V AC or 230 V AC the neutral line line must be connected to either X7 1 or X7 2 If the inputs should be controlled with the same voltage level but from two different voltage sources having probably two different ground levels the first neutral line should be connected to X7 1 and the second to X7 2 In this case the jumpers Wx connecting the inputs to X7 2 but controlled by the source connected to X7 1 must be cut off The same
151. urr 1 DC curr 2 uH Line AC A Un kg IW IW f Usuppty 400V f Usuppty 500V ND 401 1000 18 5 27 400 3 5 13 35 22 6 18 402 600 37 68 400 7 5 13 50 45 36 403 450 55 82 400 11 42 90 67 54 404 350 74 111 400 13 78 105 90 72 405 250 104 156 400 19 91 105 127 101 406 160 148 220 400 22 104 130 179 143 407 120 192 288 400 23 117 130 234 187 408 90 252 387 400 29 137 160 315 252 409 70 332 498 400 33 170 215 405 324 410 60 406 609 400 51 260 225 495 396 411 50 502 753 400 56 260 300 612 490 5 5 5 7 5 ND 413 35 740 1105 400 75 312 410 900 720 Frequency 50 60 Hz Line reactors type ND 401 ND 402 Type A C D EF ND 401 160 190 75 80 51 175 7 9 5 115 175 7 Terminals WAGO Type 202 4 170 UL File E45172 BY CZ H OT tin coated H 4 77 Y 2 4 gt A34 A B gt 8 G G 5 Es B gt Accessories 8ADW000194R0611 DCS800 Hardware Manual f us 128 Accessories Line reactors type ND 403 ND 408 C D IND 403 220 230 120 135 100 77 5 7 9 6 6 404 220 225 120 140 100 77 5 7 9 6 6 IND 405 235 250 155 170 125 85 10 9 6
152. ve motor cable or motor Ignoring the instructions can cause physical injury or death Only qualified electricians are allowed to install and maintain the drive Never work on the drive motor cable or motor when main power is applied Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 Voltage between drive input phases U1 V1 and W1 and the frame is close to 0 V 2 Voltage between terminals C1 and D1 and the frame is close to 0 V Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off Do not make any insulation or voltage withstand tests on the drive or drive modules When reconnecting the motor cable always check that the C1 and D1 terminal is correct Note The motor cable terminals on the drive are at a dangerously high voltage when the input power is on regardless of whether the motor is running or not Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the terminals of relay outputs SDCS IOB 2 RDIO DCS800 with enclosure extension Before working on the drive isolate the whole drive from the supply Safety instructions 8ADW000194R0611 DCS800 Hardware Manual f us WARNING printed circuit boards contain components sensitive to e
153. ves and branching units see DriveWindow documenta ny SETTING tion 5 xt G4 LONG co Eo G9 el o o Technical data 3ADWO00194R0611 DCS800 Hardware Manual f us 84 SDCS DSL Board The SDCS DSL board provides a drive to drive communication The communication hardware and protocol is based on CAN bus This communication will be used for 12 pulse operation communication to field exciter either single phase or three phase field exciter The communication hardware is equipped with an isolated supply and isolated transmitter The terminator can be set by Jumper S2 and S1selection of termination see section DCS Link Wiring SDCS DSL 4 drw b dsf Jumper coding 1 Bus termination 3 1 120 Ohm 3 termination park position S2 Ground termination 2 4 0 Ohm direct ground termination 224 200 kOhm R C ground 1 3 termination H termination park position default value SDCS DSL 4 Software Supply Remarks x8 CON 4 24 5200 24 V grounded supply for 425 internal and DCF803 0035 field 2 a ex
154. y at 5 40 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 70 Pollution degree IEC 60664 1 IEC 60439 1 Vibration class IEC 60721 3 3 Site elevation 1000 m above M S L gt 1000 m above M S L 2 D1 D4 3M1 05 07 100 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 79 22 ms 600 VAC D3 60 dBA 73 dBA 0 5 9 9 200 Hz 1 0m 04 66 70 77 dBA depending on fan D5 73 dBA 78 dBA 0 25 100 kA rms symmetrical amps at maxi D6 75 dBA 03 mMm 2 9 4 Shock monitor mum 600 VAC D7 82

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