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ABB DCS800-EP, Installation And Start-Up Manual

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DCS800-EP
Installation and Start Up Manual

DCS800 Panel Drive (20-1000 Amps)
A supplement to the DCS800 Hardware manual

Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: [email protected]

Summary of Contents for DCS800-EP

Page 1: ...DCS800 EP Installation and Start Up Manual DCS800 Panel Drive 20 1000 Amps A supplement to the DCS800 Hardware manual Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 2: ...njury and or damage to the equipment General warning warns about conditions other than those caused by electricity which can result in physical injury and or damage to the equipment Electrostatic discharge warning warns of electrostatic discharge which can damage the equipment Installation and maintenance work These warnings are intended for all who work on the drive motor cable or motor Ignoring ...

Page 3: ... 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 ...

Page 4: ... carefully to avoid damage and injury DCS800 EP Frames A and B The drives are heavy and may require more than one person to lift Use appropriate lifting techniques Do not lift the unit by the front cover Place the unit only on its back DCS800 EP Frames C and D The drive is heavy Lift the drive by the lifting lugs only Make sure that dust from drilling does not enter the drive when installing Elect...

Page 5: ...ts to open The mains disconnect must be locked in its OPEN position during any installation and maintenance work EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function Pressing the STOP button on the control panel of the thyristor power converter will neither cause an emergency motor stop nor will the drive be disconnected...

Page 6: ...ing and air flow 13 Panel heat dissipation 13 Planning the electrical installation 14 Options for the drive 14 Typical cable sizing and tightening torque 16 Electrical installation 17 Checking the insulation of the assembly 17 IT ungrounded systems 18 Check supply voltages 18 Connecting the power cables 18 Electrical diagrams 20 Connection diagrams 21 Control circuit connections 23 Alternate line ...

Page 7: ...29 Fuses 29 Blower motor starter 30 Other replacement parts 30 Technical Data 31 Electrical and environmental data 31 Accessories 32 Line reactors 32 Diagrams 33 Power 33 Control 36 Index 38 Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 8: ...tion of the DCS800 EP Panel Drive The DCS800 EP The DCS800 EP sizes D1 through D4 are intended as a pre packaged or panelized solution for controlling DC motors Size A 17 104 A Size B 125 205 A Available at a later date Available at a later date Size C 245 405 A Size D 480 950 A Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 9: ... The drive panel is not designed to withstand higher currents Failure to adhere to this warning can result in personal injury and or damage to equipment Non Regenerative 2Q Regenerative 4Q Module Frame Panel Frame HP at 230V HP at 460V Amps AC in DC out DCS800 EP1 0020 05 DCS800 EP2 0025 05 D1 A 5 10 14 17 DCS800 EP1 0045 05 DCS800 EP2 0050 05 D1 A 10 20 29 35 DCS800 EP1 0065 05 DCS800 EP2 0075 05...

Page 10: ...HTC01U EN See the Firmware Manual or Hardware Manual for references to other DCS800 publications Plus Code Option Kit 1 Circuit Breaker All Sizes F278 NA 2 AC Line Reactor DCS800 EP1 0020 05 through DCS800 EP2 0350 05 E213 NA 3 Without AC Line Contactor DCS800 EP1 0020 05 through DCS800 EP2 0680 05 0F250 NA 4 230 Vac supply voltage S235 DCS800 EP 230VAC Supply 5 Fan blower motor starters 1 0 1 6 A...

Page 11: ...e drive to verify that the unit is of the correct size and type A typical label is shown DCS800 PANEL DRIVE 781 775 See Hardware Manual A largest motor Amps Total Model No Input I1n SCCR Output I2n 65 775 950 DCS800 EP1 0020 05 F278 E213 0F250 M602 Adc A KA RMS sym 460V Volts U2 Volts U1 240 500dc 230 460 3 Power Pn Field If Hz 600HP 6 Adc 50 60 450 kW UL File E165086 A B C D E F G A Input current...

Page 12: ...mum clearances When installing the panel in a cabinet minimum clearances from the panel to the cabinet walls top and bottom must be maintained This space is required for proper cabling cooling air flow service and maintenance If one drive is mounted directly above another see DCS800 Hardware Manual Mechanical Installation for additional information See chapter Dimensional drawings Frame X1 side X2...

Page 13: ...1 0020 05 162 182 DCS800 EP2 0025 05 170 190 20 DCS800 EP1 0045 05 228 283 DCS800 EP2 0050 05 246 301 30 DCS800 EP1 0065 05 291 350 DCS800 EP2 0075 05 319 378 40 DCS800 EP1 0090 05 356 426 DCS800 EP2 0100 05 387 457 60 DCS800 EP1 0125 05 483 578 DCS800 EP2 0140 05 530 625 75 DCS800 EP1 0180 05 656 751 100 DCS800 EP2 0200 05 776 903 125 DCS800 EP1 0230 05 882 1017 DCS800 EP2 0260 05 960 1095 150 DC...

Page 14: ...ied Configuration A When using the power converter a minimum of impedance is required to ensure proper performance of the snubber circuit A line reactor can be used to meet this minimum impedance requirement The value must therefore not drop below 1 uk relative impedance voltage It should not exceed 10 uk due to considerable voltage drops at converter output Configuration B If special requirements...

Page 15: ...ied by one transformer the final configuration depends on the number of drives in use and their power capability Either configuration A or B which are based on commutation chokes has to be used if the drive system consists of any of the converters D1 D2 D3 D4 With reference to the power converter The line reactors are listed in the table on page 30 They have been sized to the units nominal current...

Page 16: ...0 EP2 0075 05 30 43 6 AWG 53 6 AWG 10 AWG 50 in lb 10 DCS800 EP1 0090 05 40 55 4 AWG 68 4 AWG 8 AWG 50 in lb 10 DCS800 EP2 0100 05 40 55 4 AWG 68 4 AWG 8 AWG 50 in lb 10 DCS800 EP1 0125 05 60 85 2 AWG 104 1 AWG 6 AWG 50 in lb 10 DCS800 EP2 0140 05 60 85 2 AWG 104 1 AWG 6 AWG 50 in lb 10 DCS800 EP1 0180 05 75 102 1 AWG 125 2 0 AWG 6 AWG 23 23 31 PE DCS800 EP2 0200 05 100 134 3 0 MCM 164 4 0 AWG 6 A...

Page 17: ...of the assembly Each drive is factory tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second DO NOT make any voltage tolerance or insulation resistance tests e g hi pot or megger on any part of the drive or drive damage will occur Check the insulation of the assembly as follows WARNING Check the insulation before connecting the drive to the mains Make sure tha...

Page 18: ...The voltage shift of isolated supply must be limited of a range of an earth fault Check supply voltages Aux X99 Fan Terminals 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 Buy www ValinOn...

Page 19: ...DCS800 EP Installation and Start Up Manual 19 Power control connections Typical location for input and output terminals Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 20: ...P2 0100 05 A 40 CON 1 P1 C1 DCS800 EP1 0125 05 DCS800 EP2 0140 05 A 60 CON 1 P1 C1 DCS800 EP1 0180 05 B 75 CON 1 P1 C1 DCS800 EP2 0200 05 B 100 CON 1 P1 C1 DCS800 EP1 0230 05 DCS800 EP2 0260 05 B 125 CON 1 P1 C1 DCS800 EP1 0315 05 DCS800 EP2 0350 05 B 150 CON 1 P1 C1 DCS800 EP1 0405 05 DCS800 EP2 0450 05 C 200 CON 1 P2 C1 DCS800 EP1 0470 05 DCS800 EP2 0520 05 C 250 CON 1 P2 C1 DCS800 EP1 0610 05 D...

Page 21: ... DI7 DI8 _ _ _ M 0V 0V X3 X4 X6 1 2 3 4 5 6 7 8 9 X7 C2 D2 _ _ T S1 5 6 F6 the polarities are shown for motoring if there are intermediate terminals Voltage levels see description set by 50 12 50 13 F5 F4 F2 F3 L1 L2 L3 F10 F11 F9 Reactor Customer connection Optional drive feature Legend T Fan Acknowledge E Stop Reset On Off Start Stop DO1 DO2 DO3 DO4 DO5 DO6DO7 0V 1 2 3 4 5 6 7 8 1 10 10 1 2 4 5 ...

Page 22: ..._ _ M 0V 0V X3 X4 X6 1 2 3 4 5 6 7 8 9 X7 _ T S1 5 6 F6 the polarities are shown for motoring if there are intermediate terminals Voltage levels see description set by 50 12 50 13 F5 F4 F2 F3 L1 L2 L3 F10 F11 F9 Reactor Customer connection Optional drive feature Legend T Fan Acknowledge E Stop Reset On Off Start Stop DO1 DO2 DO3 DO4 DO5 DO6DO7 0V 1 2 3 4 5 6 7 8 1 10 10 1 2 4 5 6 7 8 9 3 0V 0V 10 ...

Page 23: ...uts Input Function Parameter Setting Notes 1 Unused 10 20 NOT USED 2 Fan Acknowledge 10 06 DI2 Change to not used if optional blower motor starter is not selected 3 Unused 10 21 NOT USED 4 Unused 10 08 NOT USED 5 E Stop 10 09 DI5 6 Reset 10 03 DI6 7 On Off 10 15 DI7 8 Start Stop 10 16 DI8 Input Function Parameter Setting Notes AI1 Speed Reference 11 03 13 01 13 02 13 03 Dependent on type of refere...

Page 24: ...e B transformer is located below line fuses 3 Remove the jumper between H2 and H3 4 Reconnect new jumpers between H1 and H3 and between H2 and H4 Remount and reconnect the drive frame A 5 Remove and replace the primary fuses F4 and F5 with fuses shown in the table above Live Test Procedure 1 Open the F6 fuse holder to disconnect control power to the drive and blower motor starter if present 2 Conn...

Page 25: ...tened All cable connections are seated properly and tightened according to specified torque See Typical cable sizing and tightening torque Electrical Installation See Planning the electrical installation Electrical installation The drive is properly grounded The AC input voltage matches the drive nominal input voltage The AC input cables are properly seated and tightened to specified torque See Ty...

Page 26: ...s depth by 19 3 490 mm DSC800 EP Panel Drive HP at 460 Vac Panel Size Height in mm Width in mm Depth in mm 10 A 18 79 477 12 15 309 14 40 366 20 30 40 60 75 B 19 32 491 20 00 508 13 92 354 100 125 150 200 C TBD 250 300 400 D TBD 500 600 Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 27: ...tallation and Start Up Manual 27 Dimensional drawings Panel A Panel B Use M6 or 1 4 in mounting hardware Use M8 or 5 16 in mounting hardware Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 28: ...28 DCS800 EP Installation and Start Up Manual This page intentionally left blank Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 29: ...8 10 FWH 80B DCS800 EP1 0090 05 DCS800 EP2 0100 05 A FWH 125B FNM 2 8 10 FWH 125B DCS800 EP1 0125 05 DCS800 EP2 0140 05 A FWH 125B FNM 2 8 10 FWH 125B DCS800 EP1 0180 05 B FWH 200B FNM 2 8 10 FWH 200B DCS800 EP2 0200 05 B FWH 200B FNM 2 8 10 FWH 200B DCS800 EP1 0230 05 DCS800 EP2 0260 05 B FWH 250A FNM 2 8 10 FWH 250A DCS800 EP1 0315 05 DCS800 EP2 0350 05 B FWH 300A FNM 2 8 10 FWH 300A DCS800 EP1 ...

Page 30: ...0 11 84 NA 1B250BTZ13RBF T2H060E5W KLR35BTB DCS800 EP1 0065 05 DCS800 EP2 0075 05 A A40 30 11 84 NA 1B250BTZ13RBF T2H060E5W KLR45BTB DCS800 EP1 0090 05 DCS800 EP2 0100 05 A A50 30 11 84 NA 1B250BTZ13RBF T2H100E5W KLR55BCB DCS800 EP1 0125 05 DCS800 EP2 0140 05 A A75 30 11 84 NA 1B250BTZ13RBF T2HQ100BW KLR110BCB DCS800 EP1 0180 05 B A95 30 11 84 NA 1B250BTZ13RBF T4H150E5W KLR110BCB DCS800 EP2 0200 0...

Page 31: ... with input impedance of 1 5 pct min 4 to 10 pct max depending on system configuration See Line Reactors in DCS800 Hardware Manual for details Fuse Protection AC input line fuses 3 DC output armature fuses regen only 2 Specification Permitted Value Electrical Input Voltage 3 Phase 230 460 Vac Input volage deviation 10 continuous 15 short time Note Special consideration must be given to voltage dev...

Page 32: ...ated current Control transformer 10 150 HP 250 VA 230 460 Vac primary 120 Vac secondary Available for customer use zero Amps AC or DC Contactor 10 300 HP AC line contactor with 1 aux N O contact for customer use 6 Amps 24 127 Vac or 24 Vdc 400 600 HP DC armature DB contactor 3 pole 2 N O 1 N C main contacts with 1 aux contact for customer use 10 Amps 600 Vac or 0 2 Amps 600 Vdc Buy www ValinOnline...

Page 33: ...LR110BCB 95 26 KLR110CCB 191 50 DCS800 EP1 0180 05 75 KLR110BCB 95 26 KLR110CCB 191 50 DCS800 EP2 0200 05 100 KLR160BCB 127 47 KLR160CCB 254 84 DCS800 EP1 0230 05 DCS800 EP2 0260 05 125 KLR200BCB 135 53 KLR200CCB 337 110 DCS800 EP1 0315 05 DCS800 EP2 0350 05 150 KLR200BCB 135 53 KLR200CCB 337 110 DCS800 EP1 0405 05 DCS800 EP2 0450 05 200 KLR300BCB 216 54 KLR300CCB 443 122 DCS800 EP1 0470 05 DCS800...

Page 34: ...34 DCS800 EP Installation and Start Up Manual Diagrams Power Power Diagram P1 Frames A B Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 35: ...DCS800 EP Installation and Start Up Manual 35 Power Diagram P2 Frame C NOT AVAILABLE Power Diagram P3 Frame D NOT AVAILABLE Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 36: ...36 DCS800 EP Installation and Start Up Manual Control Control Diagram C1 Frames A C Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 37: ...DCS800 EP Installation and Start Up Manual 37 Control Diagram C12 Frame D NOT AVAILABLE Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 38: ...ations 31 Environmental specifications 31 F Factory options 10 Fuses 29 G Grounding 3 18 H Heat dissipation 13 I Installation checklist 25 Installation warnings 2 Insulation check 17 I O programming 23 L Line reactors 14 15 26 Low voltage configuration 24 M Mechanical installation 4 11 Mechanical installation warnings 4 N Nameplate 11 O Operation 5 P Panel photographs 8 Parameter settings 23 Plann...

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