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ABB DCS800, Hardware Manual

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ABB DCS800 Hardware Manual Download Page 21

Mechanical installation

21

3ADW000194R0611 DCS800 Hardware Manual f us

Mechanical installation 

Unpacking the unit

•

open box

•

take out shock dampers 

•

separate manual and accessories

•

do not lift the drive by cover. 

Delivery check

Check that there are no signs of damage. Before attempting installation and 
operation, check the information on the type designation label of the drive to verify 
that the unit is of the correct type. The label includes an IEC rating, 

C

UL

US

 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.   

4

5

3

2

1

Type designation label

Rated input voltage

Rated input current

Rated output current

Rated internal

field exciter  current

Rated fan voltage

Plus code

Summary of Contents for DCS800

Page 1: ...DCS800 Hardware Manual DCS800 Drives 20 to 5200 A ...

Page 2: ...Crane Drive Product note p DCS800 Winder ITC DCS800 Winder Product note PDC2 EN x DCS800 Winder description ITC 3ADW000308 x Winder Questionnaire 3ADW000253z x DCS800 E Panel Solution Flyer DCS800 E Panel solution 3ADW000210 x Hardware Manual DCS800 E 3ADW000224 x DCS800 A Enclosed Converters Flyer DCS800 A 3ADW000213 x Technical Catalogue DCS800 A 3ADW000198 x Installation of DCS800 A 3ADW000091 ...

Page 3: ...3ADW000194R0611 DCS800 Hardware Manual f us DCS800 Drives 20 to 5200 A Hardware Manual 3ADW000194R0611 Rev F EFFECTIVE 15 09 2008 2008 ABB Automation Products GmbH All rights reserved ...

Page 4: ...3ADW000194R0611 DCS800 Hardware Manual f us ...

Page 5: ...s 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 w...

Page 6: ...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 term...

Page 7: ...tances 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 ungr...

Page 8: ...ed for all who install the drive Handle the unit carefully to avoid damage and injury DCS800 Size D4 D7 The drive is heavy Do not lift it alone Do not lift the unit 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 Make sure that dust from drillin...

Page 9: ...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 t...

Page 10: ... instructions 10 3ADW000194R0611 DCS800 Hardware Manual f us Note 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 ...

Page 11: ...t converter DCS800 S0x D1 D4 17 Armature circuit converter DCS800 S0x D5 D7 18 Rebuild system DCS800 R0x 19 Mechanical installation Unpacking the unit 21 Delivery check 21 Before installation 22 Requirements for the installation site 22 Wall 22 Floor 22 Free space around the unit 22 Cabinet installation 22 Preventing cooling air recirculation 22 Unit above another 22 Terminal options converter siz...

Page 12: ...Converters D5 drive configuration using FEX 425 Int field exciter 41 Converters D5 D7 drive configuration using external field exciter DCF803 DCF804 42 Converters D1 D3 3 phase field exciter configuration 43 START STOP and E STOP control 44 Drive configuration with reduced components 46 Fan cooling 47 Thermal overload and short circuit protection 49 Mains cable AC line cable short circuit protecti...

Page 13: ...rminal description 76 Digital and analogue I O connection of the SDCS CON 4 78 Interface Board SDCS COM 8 79 Ch2 SDCS COM 8 Master Follower connections 80 Ch0 Drive Bus connection to Advant Controller star 80 Ch0 Connection to overriding control Nxxx fieldbus adapter 81 Ch3 Ring connection to PC tool DriveWindow 81 Ch3 Star connection to PC tool DriveWindow 82 DDCS Branching unit NDBU 95 83 SDCS D...

Page 14: ...ower section 114 DCS LINK communication 115 Diagnosis 116 RS232 Port 117 FEX425 INTERNAL Fex 425 Int Hardware configuration size D5 117 Dimensions 118 DCF505 DCF506 Overvoltage Protection 119 Fuses and fuse holders IEC 122 Fuses and fuse holders North America 123 Dimensions 123 Line reactors IEC 124 Line reactors type ND 01 ND 17 124 Line reactors type ND 07 ND 12 125 Line reactors type ND 401 ND ...

Page 15: ...is chapter contains 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 Size D1 D4 20 1000 A Size D5 900 2000 A Size D6 1900 3000 A Size D7 2050 5200 ...

Page 16: ...163 with internal field exciter external supplied only D5 25 A Rebuild kit 25 A 16 A without internal field exciter only D1 D4 Fan voltage S171 S172 Size D4 Standard fan voltage 230 V 1 ph 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 600 V 690 V fan voltage 400 500 V 3 ph Current measurement S175 CMA D6 and D7 ...

Page 17: ...3 ISA NDBU95 PCMCIA Master Follower AIMA Slot1 Slot2 Slot3 NDBU95 IOB 2x IOB 3 CON 4 RDIO RAIO X2 X1 X3 X4 X5 X6 X7 DSL X9 X10 X51 24V Panel X33 X34 PC CoDeSys DWL X20 DSL Memory Card RS232 RJ45 X52 X53 Ch3 Ch2 Ch1 Ch0 X19 COM 8 X11 CON 4 short designation of components analogue input output alternative Earth fault monitor optical fibre optical fibre digital input output Legend to field Power supp...

Page 18: ...RAIO X2 X1 X3 X4 X5 X6 X7 DSL X9 X10 X51 24V Panel X33 X34 PC CoDeSys DWL X20 DSL Memory Card RS232 RJ45 X52 X53 Ch3 Ch2 Ch1 Ch0 X19 COM 8 X11 FEX 425 internal three phase D6 and D7 only D5 types CON 4 short designation of components analogue input output alternative Earth fault monitor optical fibre optical fibre digital input output Legend to field Power supply Three phase field supply twisted p...

Page 19: ...1 Slot2 Slot3 NDBU95 IOB 2x IOB 3 CON 4 RDIO RAIO X2 X1 X3 X4 X5 X6 X7 DSL X9 X10 X51 24V Panel X33 X34 PC CoDeSys DWL X20 DSL Memory Card RS232 RJ45 X52 X53 Ch3 Ch2 Ch1 Ch0 X19 COM 8 X11 Existing part CON 4 short designation of components analogue input output alternative Earth fault monitor optical fibre optical fibre digital input output Legend to field Power supply Three phase field supply twi...

Page 20: ...The DCS800 20 3ADW000194R0611 DCS800 Hardware Manual f us ...

Page 21: ...ion on the type designation label of the drive to verify that the unit is of the correct type The label includes an IEC rating CULUS 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 4 5 3 2 1 Type designation lab...

Page 22: ... inhibit the installation Floor The floor material below the installation should be non flammable Free space around the unit Required free space around the drive to enable cooling air flow service and maintenance see chapter Dimensional drawings Cabinet installation The required distance between parallel units is five millimetres 0 2 in in installations without the front cover The cooling air ente...

Page 23: ...ter module In special cases it is beneficial to use the lug bar for easier connection of the DC cables Terminal cover according to VBG 4 regulations For converter modules D1 D4 we provide shrouds for protection against contact DC terminals of D4 module 135 95 71 60 14 7 35 Id No Remark 3ADT631137P0001 D1 D2 3ADV400208P0001 D3 3ADV400207P0001 D4 Bottom view of lug bar mounted on a D4 module Id No R...

Page 24: ... us 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 ...

Page 25: ...he 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 When mounting the right angle busbars...

Page 26: ...S CON 4 Screened cable for hardware interface connection IOB2 IOB3 board is strongly rec ommended Provide sufficient grounding of card holder 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 Use cable straps for fan cable Cooling air outlet To avoid circulating air inside the enclosure it is rec ommende...

Page 27: ... 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 ...

Page 28: ... line reactor The condition described in Configuration A will then likewise be satisfied since the uk is 1 Configuration C1 If 2 or more converters should be supplied by one transformer the final configuration depends on the number of drives in use and their power capability Configuration A or B has to be used which are based on commutation chokes if the drive system consists of any of the convert...

Page 29: ...04 05 DCS800 S02 0260 04 05 ND07 2 ND407 5 DCS800 S01 0290 06 DCS800 S02 0320 06 ND08 2 on request DCS800 S01 0315 04 05 DCS800 S02 0350 04 05 ND09 2 ND408 5 DCS800 S01 0405 04 05 DCS800 S02 0450 04 05 ND10 2 ND409 5 DCS800 S01 0590 06 DCS800 S02 0650 06 ND13 3 on request DCS800 S01 0470 04 05 DCS800 S02 0520 04 05 ND10 2 ND410 5 DCS800 S01 0610 04 05 DCS800 S02 0680 04 05 ND12 2 ND411 5 DCS800 S0...

Page 30: ...LR200BCB 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 KLR...

Page 31: ...f elements in the armature circuit converter You will find further information in publication Technical Guide chapter Aspects for fusing Conclusion for the armature supply In no case standard fusing should be used instead of semi conductor fusing in order to save money on installation In the event of a fault condition the small amount of money saved can cause the semiconductors ot other devices ex...

Page 32: ...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 fi...

Page 33: ...ble 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 Type of converter Size Fuse type Fuse holder Type Fuse Holder 2 Q Converter 4 Q Converter North America DCS800 S01 0020 04 05 DCS800 S02 0025 04 05 D1 170M 1564 OFAX 00 S3L FWP 50B 1BS101 DCS800 S01 0...

Page 34: ...ts each are available Autotransformer data details see chapter Technical Data Field conv Field current F3 1 F3 2 F 3 3 DCF803 0035 IF 6 A 170M 1558 OFAA 00 H10 10 A FEX 425 Int IF 12 A 170M 1559 OFAA 00 H16 16 A DCF803 IF 16 A 170M 1561 OFAA 00 H25 25 A DCF804 IF 25 A 170M 1564 OFAA 00 H25 35 A DCF803 IF 35 A 170M 1564 OFAA 00 H50 50 A DCF804 DCF803 IF 50 A 170M 1565 OFAA 00 H63 63 A DCF804 Type o...

Page 35: ...uires 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 ...

Page 36: ...run with 500 V and more Filter only available on request Type of converter Constr type Filter type f y 4 Filter type f y 5 2 Q Converter IDC A 4 Q Converter IDC A DCS800 S01 0020 0y 20A DCS800 S02 0025 0y 25A D1 NF3 440 25 NF3 500 25 DCS800 S01 0045 0y 45A DCS800 S02 0050 0y 50A D1 NF3 440 50 NF3 500 50 DCS800 S01 0065 0y 65A DCS800 S02 0075 0y 75A D1 NF3 440 64 NF3 500 64 DCS800 S01 0090 0y 90A D...

Page 37: ...y 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 single phase operation Converter type of field supply unit dc current A Filter type Umax 250 V DCF803 0016 DCF803 0035 FEX 425 Int 8 NF1 250 8 16 NF1 250 20 DCF803 0050 50 NF1 250 55 DCF804 0050 50 NF1 250 55 furth...

Page 38: ...icable satisfied satisfied M M Mains filter Converter Line reactor Supply transformer for a residential area rating normally 1 2 MVA Earthed public 400 V network with neutral conductor Medium voltage network Earthed neutral To other loads e g drive systems An isolating transformer with an earthed screen and earthed iron core renders mains filter and line reactor superfluous Operation at public low...

Page 39: ... 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 prod...

Page 40: ... AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 _ _ _ _ _ T T M 0V 0V 0V 0V 0V X3 1 2 3 4 5 6 7 8 9 10 X4 1 2 3 4 5 6 7 8 9 10 X6 1 2 3 4 5 6 7 8 9 10 X7 1 2 3 4 5 6 7 8 1 10 X5 _ _ K1 K20 K21 K6 K8 1 2 S1 K10 S1 5 6 2 4 6 1 3 5 K6 F5 1 2 F8 1 2 F7 1 2 2 1 4 3 6 5 F6 I I I 13 14 U V W M 3 K1 1 3 5 2 4 6 L1 1 2 3 4 K8 13 14 X10 F F 2 1 L1 L2 L1 L2 L3 DCS8_ans_1_1d dsf ...

Page 41: ...K15 K15 S1 1 2 K6 K8 X2 4 X2 5 K11 K10 K21 500V 460V 415V 400V 365V 350V 265V 250V 90V 60V 30V X33 C 1 D 1 AITAC AI1 AI2 AI3 AI4 10V 10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 _ _ _ _ _ T T M 0V 0V 0V 0V 0V X3 1 2 3 4 5 6 7 8 9 10 X4 1 2 3 4 5 6 7 8 9 10 X6 1 2 3 4 5 6 7 8 9 10 X7 1 2 3 4 5 6 7 8 1 10 X5 _ _ K1 K20 K21 K6 K8 1 2 S1 K11 K10 S1 5 6 2 4 6 1 3 5 K...

Page 42: ...230V K15 K15 S1 1 2 K6 K8 X2 4 X2 5 K11 K10 K21 500V 460V 415V 400V 365V 350V 265V 250V 90V 60V 30V X33 C 1 D 1 AITAC AI1 AI2 AI3 AI4 10V 10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 _ _ _ _ _ T T M 0V 0V 0V 0V 0V X3 1 2 3 4 5 6 7 8 9 10 X4 1 2 3 4 5 6 7 8 9 10 X6 1 2 3 4 5 6 7 8 9 10 X7 1 2 3 4 5 6 7 8 1 10 X5 _ _ K1 K20 K21 K6 K8 1 2 S1 K11 K10 S1 5 6 2 4 6 1 ...

Page 43: ... 1 10 X5 _ K1 1 2 S1 S1 5 6 F5 1 2 F8 1 2 F7 1 2 K1 1 3 5 2 4 6 L1 1 2 3 4 K8 X10 F F 2 1 L1 L2 DCS8_ans_1_4a dsf DCS800 PIN 4 DCF506 X11 X12 X14 1 2 Communication board COM 8x Control board CON 4 Power supply Converter module EMER STOP on board field exciter depending on the unit type an other configuration is possible Voltage levels see description control from armature converter Overvoltage pro...

Page 44: ...g to perform stop category 1 This function should be connected to the E STOP button without any time delay In case of ramp stop selection the K 15 timer relay must be set longer than EStopRamp 22 04 For COAST selection the drive opens the main contactor immediately OFF2 switches off DC current as fast as possible and prepares the drive for opening main contactor or drop down mains supply For a nor...

Page 45: ...ignal 6 03 Bit 10 The acknowledge can be connected to parameter 10 21 MainContAck 10 23 DCBreakAck E Stop reaction E STOP speed Timer K15 Timer K16 Block current control K1 main contactor Stop Mode dsf E Stop ramp Coast EMER STOP K16 K15 K16 K15 ELEC DISCONN DI4 K15 X6 9 CON 4 S1 1 2 Block current command Anschl_special_a dsf U1 W1 V1 PE C 1 D 1 M _ L1 X10 F F 2 1 DCS800 Converter module on board ...

Page 46: ...ld supply units DCF803 804 or a 3 phase field supply DCS800 D1 D4 On board field exciter PIN 4 D5 FEX 425 Int field exciter supplied external X96 DO8 1 2 X99 1 2 X2 4 5 X2 1 2 3 U1 W1 V1 PE K1 K20 K21 K20 K1 X96 1 X96 2 L1 L2 L3 400V 50Hz F1 M K21 C 1 D 1 AITAC AI1 AI2 AI3 AI4 10V 10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 _ _ _ _ _ T T M 0V 0V 0V 0V 0V X3 1 2...

Page 47: ...05 08 DCS800 S0x 3000 04 05 08 D6 5 GR31M 400 500 V DCS800 S0x 1900 06 07 DCS800 S0x 3000 06 07 D6 5 GR31M 500 690 V DCS800 S0x 3300 yy DCS800 S0x 5200 yy D7 5 GR35C 400 V 690 V 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...

Page 48: ...653 860 800 Δ 700 1340 Δ 800 1200 2900 Δ 2200 3600 Δ 3300 Current consumpt A 2 50 3 4 1 45 Δ 0 91 2 0 Δ 0 9 1 2 6 5 Δ 2 3 4 9 Δ 3 0 Blocking current A 3 75 4 5 at 450 V Δ 8 5 at 500 V Δ 8 5 at 690 V 4 4 at 500 V Δ 8 5 at 400 V Δ 25 at 400 V Δ 30 Air flow m3 h freely blowing Air flow m3 h at working point 800 2 5 A 750 3 2 A 1500 1 26 A 450V Δ 1600 1 6 A 500V Δ 1500 0 7 A 690V 1600 1 65 A 500V Δ 42...

Page 49: ...e switch compares the pressure inside the unit with the normal atmospheric pressure If the fan has been switched on and the unit door closed and no unit casings have been removed the pressure switch will signal Cooling conditions ok which means the drive may be enabled There is no need to set any specific differential pressure recommendation center setting Thermal overload and short circuit protec...

Page 50: ...0 xx 450 2 x 95 367 2 x 95 1x 50 1 x M10 25 DCS800 S0x 0520 xx 520 2 x 95 424 2 x 95 1x 50 1 x M10 25 DCS800 S0x 0650 xx 650 2 x 120 555 2 x 120 1x120 1 x M12 50 DCS800 S0x 0680 xx 680 2 x 120 555 2 x 120 1x120 1 x M12 50 DCS800 S0x 0820 xx 820 2 x 150 669 2 x 120 1x120 1 x M12 50 DCS800 S0x 0900 6 7 900 4 x 95 3 x 150 734 4 x 70 3 x 95 1x150 2 x M12 50 DCS800 S0x 1000 xx 1000 2 x 185 816 2 x 150 ...

Page 51: ... xx 290 2 x 4 0 AWG 237 500 MCM 4 AWG 1 x M10 18 DCS800 S0x 0315 xx 315 2 x 4 0 AWG 257 500 MCM 2 AWG 1 x M10 18 DCS800 S0x 0320 xx 320 2 x 4 0 AWG 261 500 MCM 2 AWG 1 x M10 18 DCS800 S0x 0350 xx 350 2 x 250 MCM 286 2 x 4 0 AWG 2 AWG 1 x M10 18 DCS800 S0x 0405 xx 405 2 x 350 MCM 330 2 x 250 MCM 2 AWG 1 x M10 18 DCS800 S0x 0450 xx 450 2 x 400 MCM 367 2 x 300 MCM 2 AWG 1 x M10 18 DCS800 S0x 0470 xx ...

Page 52: ...best alternative for low voltage digital signals but single shielded twisted multipair cable Figure b is also usable 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 ...

Page 53: ...uirement 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 dr...

Page 54: ...Planning the electrical installation 54 3ADW000194R0611 DCS800 Hardware Manual f us ...

Page 55: ...l no 3ADW000163 Checking the insulation of the assembly Every drive has been tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests e g hi pot or megger on any part of the drive Check the insulation of the assembly as follows WARNING Check the insulation before connecting...

Page 56: ...y must not be larger than the voltage shift in case on an earth fault Supply voltage Check supply voltages of Aux X99 Fan Terminals AC voltage for field circuit U1 V1 W1 if used AC voltage for armature circuit U1 V1 W1 Connecting the power cables Grounding and screening of power cables see manual Technical Guide see Reference Cross sectional areas and tightening torques of power cable see chapter ...

Page 57: ... as described below Tighten the screws to secure the extension modules Interface connector X2 SDCS IOB 3 X1 SDCS IOB 2 DCS800 Panel connector X33 SLOT 1 R IO Extension module or R Fieldbus module SLOT 2 R IO Extension module SLOT 3 R IO Extension module or R DDCS interface board X34 PCTool DriveWindow Light AP Tool Commissioning assi stant ...

Page 58: ... of optocoupler relay the signal status is indicated by LED I O s via SDCS IOB 2 and SDCS IOB 3 Analogue I O s 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 I O s via SDCS CON 4 and SDCS IOB 3 Analogue I O s Standard one channel for residual current measuremen...

Page 59: ...respond 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 must be exchanged with inverted signals For single ended encoders Tracks A and B must be exchanged Hardware configuration Encoder supply SDCS CO...

Page 60: ...R to GND In any case if SDCS IOB 3 is used see required settings of SDCS CON 4 board 1k0 4k7 1k0 4k7 5V 121 Ω 100 nF 10k 24V 5V 0V GND X5 1 X5 2 X5 10 X5 7 6 5 4 3 2 1 S10 1k0 4k7 1k0 4k7 5V 121 Ω 100 nF 10k 5V 0V 5V or 24V X5 1 X5 2 X5 7 X5 10 3 2 1 S4 R 2k2 1k0 4k7 1k0 4k7 5V 121 Ω 100 nF 10k 24V 5V 0V GND X5 1 X5 2 X5 10 X5 7 S10 6 5 4 3 2 1 2k2 R 2k2 1k0 4k7 1k0 4k7 5V 121 Ω 100 nF 10k 5V 0V 5...

Page 61: ...o the table below the voltage drop caused by the cable can be compensated by the voltage regulator Use twisted pair cable with pair shielding plus overall shielding Cable length parallel wires for power source GND Cable used 0 50 m 1x 0 25 mm 12x 0 25 mm 50 100 m 2x 0 25 mm 12x 0 25 mm 100 150 m 3x 0 25 mm 14x 0 25 mm Cable length parallel wires for power source GND Cable used 0 to 164 ft 1 x 24 A...

Page 62: ...r 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 driv...

Page 63: ...unication 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 pai...

Page 64: ...meters Larger distances on request Baudrate max cable length 50 k 500 m 125 k 500 m 250 k 250 m 500 k 100 m default and recommended setting 800 k 50 m 888 k 35 m 1000 k 25 m CAN_Bus_termination_c dsf FEX 425 Int SDCS DSL X3 X52 X53 GNDB S2 GNDB S1100 1 S1100 3 S1100 2 3 2 1 1 2 3 3 2 1 FEX 425 Int X3 GNDB S1100 1 S1100 3 S1100 2 2 3 1 SDCS DSL X52 X53 GNDB S2 1 2 3 3 2 1 DCS800 D5 Converter DCS800...

Page 65: ... are ready for start See Planning the electrical installation All screen terminals are checked for tightness 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...

Page 66: ...Installation checklist 66 3ADW000194R0611 DCS800 Hardware Manual f us ...

Page 67: ...efore performing any maintenance on the equipment Ignoring the safety instructions can 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 and cleaning Depends on the dustiness of the environm...

Page 68: ...t 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 Fan The cooling fan lifespan of the drive is about 50 000 operating hours The actual lifespan depends on the drive usage and ambient temperature Fan failure can be predicted by the increasing noise from fan bearings and the gradual ...

Page 69: ...of the ambient temp 0 5 C minute Degree of protection Storage temperature 40 to 55 C Converter Module and options line chokes fuse holder Transport temperature Pollution degree IEC 60664 1 IEC 60439 1 40 to 70 C 2 field supply unit etc IP 00 NEMA TYPE OPEN Vibration class 3M3 D1 D4 Enclosed converters IP 20 21 31 41 IEC 60721 3 3 3M1 D5 D7 Paint finish Site elevation Converter module light grey RA...

Page 70: ...89 336 EEC 93 68 EEC Declaration of Conformity Provided that all installation instructions concerning cable selection cabling and EMC filters or dedicated transformer are fol lowed EN 61800 3 IEC 61800 3 EN 61800 3 IEC 61800 3 in accordance with 3ADW 000 032 in accordance with 3ADW 000 032 3ADW 000 091 North American Standards In North America the system components fulfil the requirements of the t...

Page 71: ...5 2000 1479 2219 1421 2132 1361 2722 DCS800 S01 2050 05 2050 1550 2325 1480 2220 1450 2900 D6 DCS800 S01 2500 04 05 2500 1980 2970 1880 2820 1920 3840 DCS800 S01 3000 04 05 3000 2350 3525 2220 3330 2280 4560 DCS800 S01 3300 04 05 3300 2416 3624 2300 3450 2277 4554 D7 DCS800 S01 4000 04 05 4000 2977 4466 2855 4283 2795 5590 DCS800 S01 5200 04 05 5200 3800 5700 3669 5504 3733 7466 600 V 690 V DCS800...

Page 72: ...2219 1421 2132 1361 2722 DCS800 S02 2050 05 2050 1550 2325 1480 2220 1450 2900 D6 DCS800 S02 2500 04 05 2500 2000 3000 1930 2895 1790 3580 DCS800 S02 3000 04 05 3000 2330 3495 2250 3375 2080 4160 DCS800 S02 3300 04 05 3300 2416 3624 2300 3450 2277 4554 D7 DCS800 S02 4000 04 05 4000 2977 4466 2855 4283 2795 5590 DCS800 S02 5200 04 05 5200 3800 5700 3669 5504 3733 7466 600 V 690 V DCS800 S02 0320 06...

Page 73: ...0709 DCS800 S01 3000 05 2448 2820 1750 2416 1500 2416 1500 940 37875 DCS800 S01 3300 05 D7 2693 3178 2000 2416 1500 2416 1500 External 2500 39922 DCS800 S01 4000 05 3264 3690 2250 2890 1750 2897 1750 2500 44358 DCS800 S01 5200 05 4243 4820 3000 3972 2500 3800 2250 2500 64831 600 Vdc DCS800 S01 0290 06 D3 237 280 200 268 200 268 200 External 210 3105 DCS800 S01 0590 06 S171 D4 481 561 400 480 300 4...

Page 74: ...7 DCS800 S02 2500 05 2040 2395 1500 1995 1250 1990 1250 940 30709 DCS800 S02 3000 05 2448 2820 1750 2382 1500 2382 1500 940 37875 DCS800 S02 3300 05 D7 2693 3178 2000 2416 1500 2416 1500 External 2500 39922 DCS800 S02 4000 05 3264 3690 2250 2890 1750 2890 1750 2500 44358 DCS800 S02 5200 05 4243 4820 3000 3972 2500 3800 2250 2500 64831 600 Vdc DCS800 S02 0320 06 D3 261 295 200 268 200 268 200 Exter...

Page 75: ... S5 1 3 4 2 1 3 4 2 1 3 4 2 1 2 3 10 11 12 1 7 8 2 1 3 4 2 1 2 3 7 8 9 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 10 11 12 S4 SDCS CON 4 24V X5 10 SDCS PIN 4 10 11 12 S4 SDCS CON 4 24V X5 10 SDCS POW 4 5V 5V 12V 15V 24V 1 2 3 10 11 12 Jumpers shown in default position Jumper coding default value 250 Ohm x 20 mA 5 V 100 AI1 X3 5 6 RIN 200 kOh...

Page 76: ... 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 cabl...

Page 77: ... Analog I O Extension Hardware extension RDIO Digital I O Extension DCS800 61131 Programming target see chapter SDCS COM 8 board X20 Slot 4 is used for Memory Card see description IEC61131 programming Prepared function of Signal level RS232 12V 12V Data format UART Message format Modbus Protocol Transmission method half duplex Baudrate DriveWindow Light variable CodeSys download 38 4 kBaud FDT fir...

Page 78: ... τ 10 ms τ 3 3 ms τ 3 3 ms ChA ChB ChZ ChA ChB ChZ AO2 5ms POW 4 5V 15V 24V CON 4 24 V short circuit protected gain can be varied in 15 steps between 1 and 4 by software para meter Resolution bit Input output values Hardware Scaling by Com mon mode range Remarks 90 270 V 15 sign 30 90 V Firmware 15 V 8 30 V 15 sign 10 0 10 V Firmware 15 V 15 sign 10 0 10 V Firmware 15 V 15 sign 10 0 10 V Firmware ...

Page 79: ...P 312 panel as well as interface board NDPI Explanation of LEDs on SDCS COM 8 Color of optical components 5 Mb blue driver current maximum 30 mA Remark Only channels with the same components e g 10 Mb component may be connected to each other 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 dri...

Page 80: ...H 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD 30 m SDCS COM 8 Rev D and higher com8_bus conn_a dsf plastic optic fibre TxD RxD TxD RxD TxD RxD NDBU 95 0 1 2 8 TxD RxD TxD RxD D200 SDCS COM 81 grey grey grey grey dark grey dark grey d a rk g re y blue CH 0 TxD RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD com8_bus conn_a dsf D200 SDCS COM 81 grey grey grey grey dark grey dark grey d a rk g re y blue CH 0 TxD ...

Page 81: ...RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD com8_bus conn_a dsf Fieldbus plastic optic fibre TxD RxD PCI PCMCIA adapter PC NDPC 12 NDPA 02 D200 SDCS COM 8x grey grey grey grey dark grey dark grey d ar k g re y bl u e blue CH 0 TxD RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD D200 SDCS COM 8x grey grey grey grey dark grey dark grey d ar k g re y b lu e blue CH 0 TxD RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 ...

Page 82: ...xD RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD com8_bus conn_a dsf D200 SDCS COM 8x grey grey grey grey dark grey dark grey d ar k g re y b lu e blue CH 0 TxD RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD D200 SDCS COM 8x grey grey grey grey dark grey dark grey d ar k g re y b lu e blue CH 0 TxD RxD CH 1 TxD RxD CH 2 TxD RxD CH 3 TxD RxD 30 m SDCS COM 8 Rev D and higher Internet Ethernet NETA Plastic ...

Page 83: ...he NDBU 95 branching unit Optical links Master channels 1 DDCS input and 1 DDCS output Slave channels 9 DDCS inputs and 9 DDCS out puts Data rate 1 4 MBd programmable Driving current 20 mA 30 mA 50 mA channel disabling programmable Monitoring a green LED for each channel switched on when NDBU is receiv ing messages Transmission device 10 Mb component for each channel Power supply Input voltage 24 ...

Page 84: ...3 1 2 3 1 2 3 S2 S1 2 4 3 1 1 2 3 30 1 2 3 120 Ohm 1 2 3 1 2 4 3 0 Ohm direct ground termination Jumper coding default value Bus termination Ground termination 200 kOhm R C ground termination no termination park position no termination park position X51 1 2 X8 SDCS DSL 4 CON 4 DSL 4_dia_a dsf X52 1 2 3 X53 1 2 3 24 V 200 mA S1 2 1 3 CANL CANH S2 3 1 2 4 Termination 200 kOhm X54 1 2 3 TxD RxD Softw...

Page 85: ...ed outside the DCS module They must be mounted in a way that the conductive supports have a good con nection to ground of the installation I O via SDCS IOB 2x IOB 3 and SDCS CON 4 The cable length between X1 X1 and X2 X2 is max 1 7 m D1 D4 converters is max 4 m screened required for D7 converters between X1 X3 is max 0 5 m because of EMC rea sons See chapter Other cables X3 X4 X5 X2 X1 SDCS CON 4 ...

Page 86: ... 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 ...

Page 87: ...X2 SDCS IOB 3 X2 SDCS CON 4 X1 SDCS IOB 2 X1 X1 X3 X1 X2 SDCS IOB 3 X6 X7 X2 X1 SDCS CON 4 T1 X3 X4 X5 X1 X2 S2 S3 S1 S10 SDCS IOB 3 AITAC AI1 AI2 S1 1 2 S1 3 4 S1 5 6 S2 AI3 S1 7 8 Ch AI4 S1 9 10 1 13 14 2 1 2 22 23 S4 12 2 1 11 R110 S5 1 2 4 3 3 24 V17 1 1 1 12 10 12 S1 11 12 S1 13 14 PTC 1 5 mA PT100 5 mA 12 V S4 S5 S1 S2 S3 24 V 5 V 85 233 5 5 4 70 S10 S2 S3 S3 5 V 12 24 V 13 mA 2 3 1 23 24 22...

Page 88: ...input range 20mA or input range 10V or earth fault monitoring by Isum not equal to zero via X3 11 and X3 12 X2 10V 0V 10V AO1 AITAC AO2 I act AI4 10 ms GND 0V 8 V 325 99 03 max 230 4 05 100k 1n 1n 100k 100k 100k Power Source Sense GND Sense Power 0V AI2 3 3 ms AI1 3 3 ms 500 S1 1 2 3 4 7 8 9 10 12 14 13 11 100 S1 x R110 0V 0V 1 5 mA 5 mA 1 2 3 4 S5 S4 V17 4 5 7 X5 1 2 3 6 8 9 10 3 4 5 6 7 8 9 10 X...

Page 89: ...n 120 VA 120 VA Power loss 60 W 60 W Inrush current 20 A 20 ms 10 A 20 ms recommended fusing 6 AT 6 AT Mains buffering min 30 ms min 300 ms Powerfail 95 V 95 V Output X96 DO8 Potential isolated by relay NO contact MOV element 275 V Contact rating AC 250 V 3 A DC 24 V 3 A or 115 230 V 0 3 A Backup supply X95 These two terminals are used to add addi tional capacitance to the existing ones to increas...

Page 90: ...ard 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 Different functional areas on SDCS PIN 4 1 2 3 S1 X37 T100 X13 X12 X12 X8 X9 X10 X24 X21 X25 X23 V1 X20 W1 D1 X96 X99 K400 K301 X18 X16 X15 X17 X1 X2 X7 X31 F102 F101...

Page 91: ...oltage range default 2 3 230 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 Supply voltage 115 V AC 230 V AC Tolerance 15 10 15 10 Frequency 45 Hz 65 Hz 45 Hz 65 Hz Power consump tion 120 VA 120 VA Power loss 60 W 60 W Inrush current 20 A 20 ms 10 A 20 ms recommended fus ing 6 AT 6 AT Mains buffering min 30 ms min 30 ms Powerfail...

Page 92: ...uit L1 L2 L3 and SDCS CON 4 board The pulses are amplified on PIN4 board The hardware structure is a three phase half controlled bridge supplied direct from mains circuit U1 V1 W1 via fuses F100 F101 F102 If the On board field exciter is not needed it can be switched OFF by firmware The function of field circuit interface consists of Firing the field bridge three phase half controlled bridge Measu...

Page 93: ... S2 S1 S2 PE 1 2 3 4 5 6 T100 K G 1 4 2 4 2 2 2 6 2 1 2 5 2 3 1 2 1 6 1 1 1 5 HWCDD5 7 HWCOD3 5 NC NC 1 3 F100 F101 F102 16A C1 W1 V1 U1 D1 1 2 7 8 13 14 1 2 3 4 5 6 1 3 P2 P1 T52 N 1 S1 S2 X5 X21 X23 X20 X24 X30 X31 R1 X1 X2 X7 X13 F F V100 X8 X9 X12 1 16 15 13 12 X99 1 2 X96 1 2 24 V X37 48 V 24 V 15 V 15 V GND 2 4 6 8 12 24 22 20 18 10 X10 1 2 Pin4_d dsf X18 X15 K G K G K G K G K G V13 V15 V11 ...

Page 94: ...on no parallel thyristors Construction type D5 D6 D7 Pulse transformer board SDCS PIN 46 PIN 48 Layout of the SDCS PIN 46 PIN 48 pulse transformer board The board consists of six pulse transformers with amplifiers V14 SDCS PIN 46 PIN 48 U1 SDCS PIN 5x SDCS CON x V1 W1 C1 D1 X22 X122 X23 X24 X25 X12 S X13 S X413 S X313 S X13 X513 X113 X213 X413 X313 S2 S1 B C D E F X113 C G C G C G C G C G C G V11 ...

Page 95: ...of AC and DC voltage is done by activating 1 MΩ resistors cutting out short circuit wires which are represented by low ohmic resistors The voltage measurement uses 5 resistor U1 W1 to W5 V1 W6 to W11 W1 W12 to W16 C1 W17 to W21 D1 W22 to W26 If there is a need for voltage adaptation all 5 chains must be han dled in the same way Note Actual voltage signals U1 V1 W1 C1 and D1 of the main circuit are...

Page 96: ...1 18 Ω R12 18 Ω R13 18 Ω R14 18 Ω R15 18 Ω R16 18 Ω R17 33 Ω R18 68 Ω R19 120 Ω R20 270 Ω R21 560 Ω R22 47 Ω R23 47 Ω R24 47 Ω R25 47 Ω R26 100 Ω 4800 5200 2500 1 D7 code_tab_PIN1_PIN20_PIN51_e dsf Current coding Construction type Current transf ratio Rated current A DC Rated current scaling Zero current detection D5 D6 D7 Y 4 400V Y 5 500V Y 6 600V Y 4 400V Y 5 500V Y 6 600V Y 7 690V Y 8 800V Y 9...

Page 97: ... 1M D1 C1 W1 V1 U1 R57 R1 1 X25 2 X24 2 1 X23 2 1 GD W70 W81 HWCDD5 HWCIN4 1 7 ACOD1 ACOD2 HWCOD3 15 X12 5 13 B8 B5 W10 X12 B6 B1 NC B2 W80 7 BZP4 48 V1 SR1 GNDI SR2 BZP5 BZP6 8 6 10 11 12 14 4 2 9 BZP2 BZP3 BZP1 X13 3 5 1 4 B5 0 V FWD 48 V1 A5 A6 A4 A7 A8 A2 A3 B4 B3 5 6 B7 B6 X13 B8 2 3 1 W82 W71 W83 W72 0V A7 B7 A1 B1 A2 A8 B8 A6 B6 A4 B4 A3 B3 X113 A5 B5 A9 B9 A10 B10 A7 B7 A1 B1 A2 A6 B6 A4 B...

Page 98: ...120 V The maximum measurement voltage scale is 200 V Adjust voltage scaling parameter according to table below Layout of SDCS SUB 4 and location on SDCS PIN 4 1 2 3 S1 X12 X12 X8 X9 X10 X24 X21 X25 X23 V1 X20 W1 D1 X96 X99 K400 K301 X15 X17 X1 X2 X7 X31 F102 F101 F100 X22 X5 X4 X3 F300 F400 X95 C1 U1 SDCS PIN 4 Pin4_SUB4 layout dsf 1 2 automatic 2 3 230 V fix SDCS SUB 4 X112 D W V U C GND Armature...

Page 99: ... S1 S2 S1 S2 PE 1 2 3 4 5 6 T100 HWCDD5 7 HWCOD3 5 NC NC F100 F101 F102 16A C1 W1 V1 U1 D1 1 3 P2 P1 T52 N 1 S1 S2 X5 X21 X23 X20 X24 X30 X31 R1 X1 X2 X7 X13 F F V100 X8 X9 X12 1 13 15 16 12 X99 1 2 X96 1 2 24 V X37 48 V 24 V 15 V 15 V GND 2 4 6 8 12 24 22 20 18 10 X10 1 2 Pin4_SUB4a dsf SDCS SUB 4 X25 X112 X12 5M K G 1 4 2 4 2 2 2 6 2 1 2 5 2 3 1 2 1 6 1 1 1 5 1 3 1 2 7 8 13 14 1 2 3 4 5 6 X18 X1...

Page 100: ...tion type D5 D6 D7 Conv nom voltage V Y 4 400V Y 5 500V Y 6 600V Y 7 690V Y 8 800V Y 9 990V Y 1 1200V Rated mains voltage V AC 220 500 270 600 300 690 350 800 450 990 530 1200 Value f conv nom volt at SET TINGS block 500 600 690 800 990 1200 Measuring board SDCS PIN 51 PIN 51 PIN 51 PIN 51 PIN 51 PIN 51 Resistors W1 W26 all resistors are 0 Ω Galvanic isolation Resistors Rx on PIN51 27 4 kΩ 27 4 kΩ...

Page 101: ... ACOD2 HWCOD3 15 X12 5 13 B8 B5 W10 X12 B6 B1 NC B2 W80 7 BZP4 48 V1 SR1 GNDI SR2 BZP5 BZP6 8 6 10 11 12 14 4 2 9 BZP2 BZP3 BZP1 X13 3 5 1 4 B5 0 V FWD 48 V1 A5 A6 A4 A7 A8 A2 A3 B4 B3 5 6 B7 B6 X13 B8 2 3 1 W82 W71 W83 W72 0V A7 B7 A1 B1 A2 A8 B8 A6 B6 A4 B4 A3 B3 X113 A5 B5 A9 B9 A10 B10 A7 B7 A1 B1 A2 A6 B6 A4 B4 A3 B3 A8 B8 A10 B10 A5 B5 A9 B9 X113 GA 2 4 CB CA GB 1 1 2 6 GC CC 1 5 SDCS PIN 48...

Page 102: ...er 230 V 15 50 60 Hz 3 W Clearance in air Auxiliary power to Output 13 mm Input Output to Auxiliary power 14 mm Insulation voltage 2000 V Insulation test voltage 5000 V Ambient temperature range 10 70 C Weight appr 0 4 kg Dimensions in mm Location of terminals Ω k Ω 6 M 17 20 OPAMP TRANSDUCER 1 1 9 10 10nF 230 V AC 15V 0V 15V 0V 1 2 Ω 6 M RG GAIN 7 STEPS POWER SUPPLY Input voltage Output voltage a...

Page 103: ... 10 70 C Weight 10 70 C Weight 2 1 kg Dimensions in mm Remark 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 shrowding cover Put in the cable lug swing in the shrowding cover and fasten the con nection by turning the screw clockwise 1U 1V 1W 2N S 2U1 2U2 2U3 2U4 2U5 2...

Page 104: ...Technical data 104 3ADW000194R0611 DCS800 Hardware Manual f us ...

Page 105: ...230 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 S 5 mm S 10 mm S S H A B A B C D E F G H 4x45 180 86 32 5 45 64 5 C1 U1 V1 W1 D1 10 270 225 48 5 D1toD3_dim_b dsf E F G 10 5 T2 T1 C D 43 5 8 7 9 20 Power connection Field and power supply terminals Signal terminal...

Page 106: ...V types DCS800 S01 0590 DCS800 S02 0650 Weight appr 38 kg S 10 mm S S f M6 48 5 270 225 644 625 107 52 40 80 80 80 f M12 45 U1 V1 W1 C1 D1 for size D4 fan terminal Power terminal Busbar 40x5 mm Weight appr 38 kg D4_dim_b dsf 345 298 8 7 250 577 150 9 287 5 CON 4 240 PIN 4 195 5 147 5 25 20 42 fan terminal min Top clearance min Bottom clearance Earthing M12 Direction of air flow ...

Page 107: ...nals fan terminals Mounting the converter module D5 inside an enclosure Two supports should be mounted inside the enclosure in such a way that they can carry the converter s weight when placing the converter later on The minimum distance between the supports should not be less then 480 mm because of electrical clearance DC busbars A L shape support as indicated will allow to place the converter te...

Page 108: ...DCS800 S0x 2050 DCS800 S0x 2500 DCS800 S0x 3000 Weight appr 180 kg Pressure switch 63 458 2 10x20 20 1725 C D U V W 385 445 10x20 1079 5 15 425 375 250 C D U V W A6_dim dsf M12 409 225 200 1750 200 200 62 M10 72 100 759 5 40 50 355 Air entry Air outlet 468 2 136 from the front right left and back ...

Page 109: ...eft hand DCS800 S0x 2050 xxL DCS800 S0x 2600 xxL DCS800 S0x 3300 xxL DCS800 S0x 4000 xxL DCS800 S0x 4800 xxL DCS800 S0x 5200 xxL Weight appr 315 kg 80 80 80 80 93 230 530 350 for M10 200 225 200 200 1725 A7_dim_a dsf 759 5 25 for M10 Pressure switch Busbars in mm AC and DC 100 x 10 ...

Page 110: ...s Module D7 right hand DCS800 S0x 2050 xxR DCS800 S0x 2600 xxR DCS800 S0x 3300 xxR DCS800 S0x 4000 xxR DCS800 S0x 4800 xxR DCS800 S0x 5200 xxR Weight appr 315 kg A7_dim_a dsf 200 225 200 200 1725 759 5 25 for M10 for M10 Pressure switch Busbars in mm AC and DC 100 x 10 ...

Page 111: ... 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 6 170M 6148 DCS800 S01 3000 06 07 D6 1100A 1250V UR 6 170M 6149 DCS800 S02 3000 06 07 D6 1100A 1250V UR 6 170M 6149 DCS800 S0x 3300 06 07 D7 2500A 1000V UR 8 170M 7036 DCS800 S0x 4000 06 07 D7 3000A 1000V UR 8 170M 7156 DCS800 S0x 4800 06 07 D7 3000A 1000V UR 8 170M 7156 790...

Page 112: ... Ø 3 3 25 25 100 67 5 82 5 Ø 11 max 105 Ø 56 A 8 max 105 Size A 7 62 8 90 9 105 10 120 Remark Given dimensions may be exceeded in some cases Please take them only for information IOB assembly mounting kit 3ADT783046 card holder finger protection cover screen clamp IOB 2x IOB 3 not included with universal Phoenix clamp 1202713 it is possible to mount the card holder on standard rail system in horiz...

Page 113: ...ia serial communication from the armature converter The field exciter is prepared to operate as three phase as well as single phase converter Single phase operation is provided with terminals U and W Layout of the SDCS FEX 4 board Fex4x1_a dsf 5 A 35 A IFact X101 U1 Field measurement channel Setting of switchable burden resistors by rated field current X101 V1 X101 W1 X100 5A X100 35A X100 D1 240 ...

Page 114: ... external field exciter DCF803 0035 is the three phase half controlled bridge including snubbers based on SDCS FEX 4 board Line fuses and the line reactor and transformer must be located outside the housing The internal field exciter FEX425 is a ready installed field exciter in a D5 armature converter The unit is based on a SCDS FEX 4 board and contains also line fuses The supply must be connected...

Page 115: ...1100 5 S1100 4 Baudrate kBaud Selection of armature 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 0 0 25 0 5 0 75 1 0 1 0 4 0 7 1 U dc field Voltage ripple Vsec single phase half controlled three phase half controlled three phase full controlled X1 1 2 Fex4_DCSLink dsf X3 1 2 3 24 V 200 mA S1...

Page 116: ...waiting for DCSLINK communication green continues 25 A 35 A output active DCSLINK communication OK yellow blinking 5A output active X100 2 waiting for DCSLINK communication yellow continues 5A output active X100 2 DCSLINK communication OK green and yellow toggling X times yellow Y times green X 1 Y 1 Alarm phase missed Y 2 Alarm maximum temperature heatsink X 2 Y 1 Fault DCS link serial communicat...

Page 117: ...1 V14 1 4 2 1 2 4 1 1 2 6 V26 V13 1 3 2 3 1 6 V23 V16 2 2 V22 V15 1 5 2 5 1 2 V25 V12 K G K G G K G K G K G K G K K G K G G K K G G K V1 W1 C1 D1 R11 C11 C24 F11 R13 C13 C26 F13 C15 C22 R15 F15 C14 C21 F14 R14 F16 C16 C23 R16 F12 C12 C25 R12 R57 R24 R21 R26 R22 R23 R25 PE T51 P2 4000 1 4000 1 P1 T52 P2 P1 S1 S2 S1 S2 U1 HW conf FEX4 dsf D1 U1 V1 W1 SDCS FEX 4 5A 35A F301 F302 F303 U V W L3 K3 Plus...

Page 118: ...5 DCF803 0016 X1 X3 X2 1 2 1 2 3 35A 5A D1 U1 V1 W1 earthing M6 DCF803 0035 dsf 6 kg DCF803 0016 dsf 1 2 3 16A 5A D1 U1 V1 W1 X1 X3 X2 1 2 S800 S801 S1100 1 173 100 320 300 67 3 36 5 300 146 90 for mounting on mounting plate provide hole with diameter of min 5 mm for thermal sensor ...

Page 119: ...s contactors The overvoltage protection unit DCF 505 is suit able for 2 Q converters DCS800 S01 with simple non motoric inductive load Simple load with DCS800 S01 and 2 Q Overvoltage Pro tection DCF 505 For motor field supply via DCS800 S01 2 Q or DCS800 S02 4 Q the overvoltage protection unit DCF 506 is always required Motor field supply with DCS800 S02 and 4 Q Overvolt age Protection DCF 506 Fie...

Page 120: ...or systems used at line voltages up to 690 V this board is equipped with a 1800 V trigger diode F A1 X2 3 X1 1 G1 A K1 X2 2 X1 3 X2 1 G2 K2 X3 1 X3 2 X4 1 X4 2 K R3 F X11 X12 1 2 AK 1 2 1 2 1 2 R1 R4 R2 V1 X1 2 SDCS FEP 1 500 V SDCS FEP 2 690 V DCF505di_d dsf parts not built in at 2 Q unit R3 jumpered red grey red grey X3 X4 X2 X1 line potential SDCS FEP 1 FEP 2 Fep1_2 dsf Output X4 1 2 Potential ...

Page 121: ...voltage Protection DCF 505 0140 0520 51 DCF 505 1200 51 DCF 506 0140 0520 51 Dimensions in mm Weight appr 8 kg X3 X1 X4 X2 1 2 SDCS FEP 1 500 V SDCS FEP 2 690 V MB_1500_a dsf 42 145 8 5 355 145 f M6 M8 40 32 35 8 5 482 20 135 X11 X12 Overvoltage Protection DCF 506 1200 51 DCF 506 1500 51 DCF 506 1500 71 Dimensions in mm Weight appr 20 kg ...

Page 122: ... 3817 0 47 315A 660V UR 1 OFAX 1 S3 170M 3819 0 37 400A 660V UR 1 OFAX 1 S3 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 Size a b c d e 0 78 5 50 35 21 15 1 135 69 45 45 20 2 150 69 55 55 26 3 150 68 76 76 33 Fuse holder HxWxD mm Protec tion OF...

Page 123: ... 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 059...

Page 124: ...00 37 68 600 3 8 9 20 DCS 0050 ND 04 168 55 82 500 5 8 10 33 DCS 0075 ND 05 135 82 122 600 6 4 5 30 DCS 0110 ND 06 90 102 153 500 7 6 7 41 DCS 0140 ND 07 50 184 275 500 12 6 45 90 DCS 0250 ND 08 56 3 196 294 600 12 8 45 130 DCS 0270 ND 09 37 5 245 367 500 16 0 50 140 DCS 0350 ND 10 25 0 367 551 500 22 2 80 185 DCS 0520 ND 11 33 8 326 490 600 22 6 80 185 DCS 0450 ND 12 18 8 490 734 500 36 0 95 290 ...

Page 125: ...tors type ND 15 16 all busbars 60x10 C 1 B 1 F 0 3 H 2 15 3AST47 822 3 D5 3AFE 10014603 0 018 8 mH 49 0 A I max 73 4 A 15 K I 6x G 4 A 2 E 2 A A E 2 7 0 3 F A A C1 L ND7_to_12_c dsf min 30 without varnish for conduction to the mounting plate A A A A 18x13 3x 100 2 140 45 45 4 154 2 342 2 150 40 50 2 123 10 1 290 100 30 0 3 224 15 40 ø13 ND13_14_c dsf min 30 without varnish for conduction to the mo...

Page 126: ...Accessories 126 3ADW000194R0611 DCS800 Hardware Manual f us Line reactors type ND 17 ø14 40 20 20 40 20 80 verzinnt ND17 dsf tin plated ...

Page 127: ...them to other components please take relevant standards into account in case the materials are different Frequency 50 60 Hz Line reactors type ND 401 ND 402 Type reactor rated Weight Power loss Load Load L Irms Ipeak Voltage Fe Cu DC curr 1 DC curr 2 μH Line AC A A UN kg W W f Usupply 400V f Usupply 500V ND 401 1000 18 5 27 400 3 5 13 35 22 6 18 ND 402 600 37 68 400 7 5 13 50 45 36 ND 403 450 55 8...

Page 128: ...D 406 255 275 155 175 125 95 10 9 9 ND 407 255 275 155 175 125 95 10 9 11 ND 408 285 285 180 210 150 95 10 9 11 Type A B C D E F Ø G Ø H Ø K ND 409 320 280 180 210 150 95 10 11 11 ND 410 345 350 180 235 150 115 10 13 14 ND 411 345 350 205 270 175 115 12 13 2x11 ND 412 385 350 205 280 175 115 12 13 2x11 ND 413 445 350 205 280 175 115 12 13 2x11 B A F 2 10 45 50 ø H tin coated E 2 C D øG 5 A X B Y C...

Page 129: ...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 DC...

Page 130: ...4 30 A 33 A 36 180 50 T 3 05 50 A 57 A 60 250 63 Uprim 690 V 50 60Hz T 3 11 6 A 7 A 15 80 10 T 3 12 12 A 13 A 20 125 16 T 3 13 16 A 17 A 30 150 20 T 3 14 30 A 33 A 60 230 50 T 3 15 50 A 57 A 60 320 63 e A h C B D G F 3 F 3 T 3 T 3 Type A B C D h e G T 3 01 T 3 11 210 110 112 75 240 10x18 95 T 3 02 T 3 12 T 3 03 210 135 112 101 240 10x18 95 T 3 13 230 150 124 118 270 10x18 95 T 3 04 260 150 144 123...

Page 131: ...pplication hint F2 T2 0 V 115 V 230 V T2_a dsf Input voltage 230 380 690 V 1 10 Frequency 50 60 Hz Output voltage 115 230 V 1 Type Power Weight Fuse F2 Isec Power loss VA kg A A W T2 1400 15 16 6 0 230 V 12 0 115 V 100 150 106 125 128 148 100 5 35 0 115 230 0 380 400 415 450 500 525 575 600 660 690 6 3 mm Faston T2_dim dsf F2 T2 0 V 115 V 230 V T2_a dsf 230 V The transformer is designed to work as...

Page 132: ... 0 5 20 m 3ADT 693324 1 plastic fibre optic double cable plug 0 5 20 m 3ADT 693318 2 HCS silica double without plastic jacket plug 30 50 m 3ADT 693355 3 HCS silica double with plastic jacket plug 50 200 m 3ADT 693356 4 Figure 1 for DCS 400 DCS 500 DCS 600 DCS800 Figure 2 Figure 3 for DCS 600 DCS800 selected channels see manual NDBU 3ADW 000 100 R0201 Figure 4 blue black L blue black black blue L L...

Page 133: ...lue screen black X1 FEX4 DCF503B DCF504B DCS link cable dsf Heat shrink tubing 20 mm 30 mm 10 mm 40 mm 10 mm 140 mm Heat shrink tubing 20 mm 3 2 1 1 2 1 2 3 2 1 X3 FEX4 3 1 2 5 3 4 2 1 3 1 2 1 2 tinfoil wire netting screen two cable pairs not twisted cable cable sheath dismantling for shield grounding Pull tab for cable marking IOB2 3 unscreened flat cab dsf 1 4 3 2 4 m screen laid open Pull tab f...

Page 134: ...W000194R0611_Rev F 09_2008 ABB Automation Products Wallstadter Straße 59 68526 Ladenburg GERMANY Telefon 49 0 6203 71 0 Telefax 49 0 6203 71 7609 www abb com motors drives 194R0611A8370000 194R0611A8370000 ...

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