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Routing the Cables

The cables that are sources of interference have to be separated from the cables
that are sensitive to interference, thus follows:

Distances between different cable types

Route the motor cables (DC) away from all other cables.

It is recommended that the

−

mains cables (AC),

−

motor cables (DC) and

−

control cables

be installed on separate trays.

Motor cables of several drives can be run in parallel on the same tray next to
each other.

Control cables

Mains / motor cables

Routing of mains-, motor- and control cables

Separate 24 VDC and 115 / 230 VAC control cables.

Electrical Installation

3ADW000352R0101 DCS800-A Installation Manual e a

Summary of Contents for DCS800

Page 1: ...DCS800 Installation Manual DCS800 A Enclosed Converters 18 to 9800 A 19600 A ...

Page 2: ...ive Product note PDC5 EN REVA 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 3ADW00...

Page 3: ...ation Products GmbH All rights reserved DCS800 A Enclosed Converters 18 to 9800 A 19600 A Installation Manual Code 3ADW000352R0101 Rev A DCS800 A Installation Manual e a DOC EFFECTIVE January 2nd 2009 SUPERSEDES none ...

Page 4: ... 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 and advise on 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 c...

Page 5: ...cuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off Do not make any insulation resistance or voltage withstand tests on the drive or drive modules Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor When reconnecting the motor cable always check that the C and D cables a...

Page 6: ...ve installation connect each drive separately to protective earth PE Minimize EMC emission and make a 360 high frequency grounding e g conductive sleeves of screened cable entries at the cabinet lead through plate Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable as equipmen...

Page 7: ...ic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Use grounding strip ABB order no 3ADV050035P0001 WARNING Handle the fiber optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt The minimum allowed bend ra...

Page 8: ...y on its back DCS800 sizes D5 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 drilling does not enter the drive when installing Electrically conductive dust inside the unit may cause damage or lead to malfunction Ensure sufficient cooling Do not fasten the drive by riveting or welding ...

Page 9: ...ring 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 drive will neither cause an emergency stop of the motor nor will the drive be disconnected from any dangerous potential To avoid unintentional operating states or to shut th...

Page 10: ... not shown in the status row of the display the stop key on the control panel will not stop the drive To stop the drive using the control panel press the LOC REM key and then the stop key Safety Instructions 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 11: ...ence the following applies EN 50081 1 Specialized basic standard for emissions in light industry can be satisfied with special features mains filters screened power cables in the lower rating range EN 50081 2 Specialized basic standard for emissions in industry For emitted interference the following applies EN 50082 1 Specialized basic standard for interference immunity in residential areas EN 500...

Page 12: ... floating lines IT networks Residual current detection Together filters with internal discharging resistors cables converter and motor have a considerable capacity to ground which can cause an increased capacitive residual current The tripping threshold of an residual current detector which measures this current must be adapted to this higher value High voltage test Because of the capacitors of th...

Page 13: ...7 Cabinet Construction 17 Moving of the Shipping Splits 18 Working Order of the Mechanical Installation 20 Fastening the Shipping Split to the Floor 22 Fastening Clamps 3AFE 64347683 22 Holes inside the cabinet 23 Layout of bottom plates 25 Cable Conduit below the Cabinet 34 Vibration Dampers Marine Versions 35 Joining the Shipping Splits 36 Working order 36 Connecting the AC busbar and the PE bus...

Page 14: ...ions within the Cabinet 54 Motor Cable Connection 55 Conductive Sleeves 55 Cable Entry 55 Control Cable Connection 56 EMC Grounding at the Cable Entry 56 Routing the Cables 59 Finger protection 63 Installation Checklist Installation Checklist 64 Preventive Maintenance Recommended regular maintenance 66 Air Filters 66 Cooling air pressure switch in converter modules type D5 D6 D7 66 Fan 66 Heatsink...

Page 15: ...all mechanical information concerning the installation of the DC enclosed converters is provided In this chapter details such as moving the shipping splits joining the units together joining the busbars and fastening the cabinets to the floor are given Electrical Installation this chapter discusses the electrical installation Installation Checklist this chapter contains the installation checklist ...

Page 16: ...inquiries about the product please address your local ABB representative quoting type code and serial number of the unit If the local ABB representative is not available inquiries should be addressed to ABB Automation Products GmbH Ladenburg in Germany Introduction to this manual 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 17: ...d strong enough to support the weight of the unit The floor flatness must be checked with a water level before fastening the cabinets into their final position The maximum allowed deviation of the surface level must be 5 mm for every 3 m of length The installation area should be leveled since the cabinet is not equipped with adjustable feet The wall behind the unit should be of non flammable mater...

Page 18: ...but not mandatory once the cabinets are in their final position If the lifting lug is removed the bolts for each lug must be refastened to maintain the degree of protection of the cabinet Note Maximum length of one shipping split is 3 4 m If required the double roofs of all cabinets can be removed while placing the shipping split on its final position see Working order of Mechanical Installation w...

Page 19: ...to be placed on a suitable pallet for transportation by forklift By fork lift Remove the bottom wooden frame which is part of the shipment Place the shipping split on the rollers and move the unit carefully until it is close to its final position Remove the rollers by lifting the shipping split using a crane or fork lift as described above By rollers Not allowed for marine versions Mechanical Inst...

Page 20: ...rst shipping split to the floor with fastening clamps or through the holes inside the cabinet See section Fastening the Shipping Split to the Floor In marine versions fasten the first shipping split to the floor and roof wall as described in section Vibration Dampers Marine Versions Note Any height adjustment of the cabinets must be done before fastening the cabinets together Height adjustment can...

Page 21: ...first shipping split to the next shipping split See section Joining the shipping splits Each shipping split includes a 200 mm joining cabinet Fasten the second shipping split to the floor Connect the AC busbars and the PE busbar See section Connecting the AC Busbar and the PE Busbar Reinstall the roof if they have been removed Attach each roof with 6 screws M6 Working order installation Mechanical...

Page 22: ...nd fasten it with a bolt to the floor Allowed maximum distance between the fastening clamps is 800 mm Fastening hole distances for the common cabinet are given in Fastening clamp hole distances Fastening bolt M10 to M12 3 8 to 1 2 Cabinet Width mm Hole Distance mm 200 400 a 250 600 a 450 800 a 650 1000 a 350 b 150 a 350 1500 a 350 b 150 a 350 b 150 a 350 Fastening clamp Fastening clamp hole distan...

Page 23: ...800 mm 1000 mm and 1500 mm cabinets 25 Fastening holes Gap between cabinets Fastening hole distances for the common cabinet are given in Hole distances Fastening bolt M10 to M12 3 8 to 1 2 Cabinet Width mm Hole Distance mm 200 a 50 400 a 250 600 a 450 800 a 650 1000 a 350 b 150 a 350 1500 a 350 b 150 a 350 b 150 a 350 Hole distances The bottom plate subassemblies frames of most cabinets layout see...

Page 24: ...24 Ø 31 Ø 18 5 Mounting and through holes Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 25: ...25 Layout of bottom plates Cabinet 200 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 26: ...26 Cabinet 400 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 27: ...27 Cabinet and incoming 600 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 28: ...28 Cabinet and incoming 800 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 29: ...29 550 176 5 318 248 145 73 450 596 596 D6 cabinet 600 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 30: ...30 590 377 97 0 0 42 544 586 D6 D7 cabinet 600 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 31: ...31 550 470 73 496 650 796 596 62 5 D6 D7 cabinet 800 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 32: ...32 590 310 168 300 870 1486 500 550 D7 cabinet 1500 mm width 600 mm depth Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 33: ...lates can be fastened over the cutout of the bottom plates See also chapter Cable Connections Note EMC cable entry is only required for DCS800 A when screened cables are used EMC cable entry Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 34: ... of the floor Top and side view Prevent the cooling air flow from the cable conduit to the cabinet by using bottom plates To ensure the degree of protection for the cabinet use the original bottom plates if delivered with the unit User defined cable entries take care of the degree of protection and fire protection Protection Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 35: ...gh room behind the cabinets for installation use the fastening method shown in Mounting with a clamp Fasten of the upper vibration dampers For the positions of the upper vibration dampers see the accompanying dimension drawing of the shipping split Mounting with a clamp Fasten the support arms to the upper vibration dampers and roof wall Use a clamp not included Vibration dampers details Mechanica...

Page 36: ...cial distance bolts M6 for fastening the cabinets together are enclosed in a plastic bag inside a cabinet of the shipping split The blind rivet nuts are already installed in the post Detailed view Working order Overview Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 37: ...ng section Partitioning plate Busbar joining cabinet Intermediate plate Back posts accessible 3 Fasten the back post of the joining cabinet with five screws below the horizontal busbar joining part to the post of the next cabinet 4 Remount the intermediate plate and the partitioning plate s in the upper part after connecting the AC busbars Mechanical Installation 3ADW000352R0101 DCS800 A Installat...

Page 38: ...ove the intermediate plate located in the busbar joining cabinet 2 Unscrew the bolts of the joint pieces 3 Connect the busbars with the joint pieces see AC busbar 4 Remount the intermediate plate into its original position due to safety of personnel AC busbar connection M10 Joint pieces Tightening torque 35 37 Nm 25 27 ft lbs AC busbar PE busbar connection PE busbar Mechanical Installation 3ADW000...

Page 39: ...ed filter Replacement filters and brass screens can be ordered from ABB Cabinet width mm Filter Air Tex G 150 Brass screen 400 3AFE 1003 3616 3AFE 6152 5718 600 3AFE 1003 3721 3AFE 6152 5726 800 3ADV 262 037 P0001 3ADV 400 109 P0001 1000 3ADV 262 037 P0005 3AFE 6152 5734 1500 3AFE 1003 3730 3AFE 6152 5742 Order numbers for filters and screens Mechanical Installation 3ADW000352R0101 DCS800 A Instal...

Page 40: ...s no air duct the option Air Ventilation Hood is required to meet protection class IP 21 Air option Cabinet with D6 D7 module This option can also be used for connection to an existing air duct outlet solution indicated by dashed lines Wall Air baffle plates To keep the converter module as cool as possible cooling air re circulation outside and inside the cabinet has to be prevented To prevent out...

Page 41: ...ates D4 air baffle plate D7 air baffle plate Attention Before starting the air baffle plates of the converter modules have to be mounted properly Mechanical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 42: ...be performed before connecting the DCS800 A to the mains Before proceeding with the insulation resistance measurements make sure that the DCS800 A is disconnected from the mains 1 Check that the motor cable is disconnected from the DCS800 A output terminals C1 and D1 2 Measure the insulation resistances of motor cable and the motor between each phase and Protective Earth PE using a measuring volta...

Page 43: ...e connected at both ends by metal clamps see Connection of a cable screen with the aid of metal clamp to the metal surface or comparable means directly on clean metal surfaces if both earthing points belong to the same earth line Otherwise a capacitor e g 3 3 nF 3000 V must be connected to earth on one end In the converter cabinet this kind of connection must be made directly on the sheet metal cl...

Page 44: ...for low voltage digital signals but single shielded twisted multi pair cable see Twisted pair cables b is also usable a b A double shielded twisted pair cable A single shielded twisted multi pair cable Twisted pair cables Pairs should be twisted as close to terminals as possible The analogue and digital signals should be run in separate screened cables Relay controlled signals providing their volt...

Page 45: ...able type tested and approved by ABB is included in the DCS800 Control Panel option kits Optical Cables The max cable length for optical cables depends on the type of optical cable selected plastic fiber optic or HCS for details please refer to the corresponding manual DCS800 Hardware Manual 3ADW000194 Moreover follow the instructions concerning the use of optical cables given by the cable supplie...

Page 46: ...t Hint The armature current cable must contain a third wire for a PE connection if the copper cross section of the screen cannot fulfil the PE safety demands terminals on the CON x board Mounting plate with PE busbar and terminals terminals on the CON x board intermediate terminals prefered solution PE bar to filter choke directly to lower edge of the PCB carrier Tacho Encoder analogue I O and dig...

Page 47: ...g recommendation and it cannot respect all conditions of a plant Therefore each drive must be considered separately and with respect to the special application Additionally the general installation and safety rules must be taken into account Electrical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 48: ... 0680 04 05 D 492 2 150 2 M12 4 DCS800 A01 0740 04 05 D 558 2 185 2 M12 4 DCS800 A02 0820 04 05 D 615 2 185 2 M12 4 DCS800 A01 0900 04 05 D 664 2 240 2 M12 4 DCS800 A02 1000 04 05 D 738 2 240 2 M12 4 D3 Size D1 D4 D5 D2 Unit type AC connection U V W PE o n r e q u e s t DCS800 A0x 1200 04 05 D 935 4 150 4 M12 DCS800 A0x 1200T 04 05 D 935 4 150 4 M12 DCS800 A0x 1500 04 05 D 1169 4 185 4 M12 DCS800 ...

Page 49: ...q u e s t DCS800 A0x 2050 10 D 1681 6 185 16 M12 DCS800 A0x 2600 10 D 2132 8 185 16 M12 DCS800 A0x 3300 10 D 2706 10 185 16 M12 DCS800 A0x 4000 10 D 3280 10 240 16 M12 D7 D7P o n r e q u e s t o n r e q u e s t DCS800 A0x 5200 10PD 4018 2 x 8 185 DCS800 A0x 6600 10PD 5084 2 x 10 185 DCS800 A0x 8000 10PD 6232 2 x 10 240 1200 V D7 D7P o n r e q u e s t o n r e q u e s t o n r e q u e s t o n r e q u...

Page 50: ... 0820 04 05 D 750 2 185 2 M10 4 M12 4 DCS800 A01 0900 04 05 D 810 2 240 2 M10 4 M12 4 DCS800 A02 1000 04 05 D 900 2 240 2 M10 4 M12 4 DCS800 A0x 1200 04 05 D 1140 4 150 8 M12 8 DCS800 A0x 1200T 04 05 D 1140 4 150 8 M12 8 DCS800 A0x 1500 04 05 D 1425 5 185 8 M12 8 DCS800 A0x 2000 04 05 D 1850 6 185 8 M12 8 o n r e q u e s t D6 Unit type With DC fuses Without DC fuses DC connection U U 2 PE D5 Size ...

Page 51: ...10 D 2050 7 185 16 M12 DCS800 A0x 2600 10 D 2600 9 185 16 M12 DCS800 A0x 3300 10 D 3300 11 185 16 M12 DCS800 A0x 4000 10 D 4000 12 240 16 M12 o n r e q u e s t o n r e q u e s t D7P D7 DCS800 A0x 5200 10PD 4900 2 x 9 185 DCS800 A0x 6600 10PD 6200 2 x 11 185 DCS800 A0x 8000 10PD 7600 2 x 12 240 1190 V o n r e q u e s t o n r e q u e s t o n r e q u e s t o n r e q u e s t D7 D7P DCS800 A0x 2600 12 ...

Page 52: ...of the DCS800 A enclosed converters The N conductor is not usually used although it is visible in the following diagrams Low Power Supply Low current 300 A cable connection when one cable is sufficient see Low current connection Low current connection High Power Supply Busbar connection High current 300 A busbar connection see High current busbar connection High current busbar connection Electrica...

Page 53: ...electrical safety codes In case metallic cable entries e g EMC cable entry are used all three phases L1 L2 L3 have to be routed together through one single drilling hole L1 L2 L3 L1 L2 L3 L1 L2 L3 Bottom_plate EMC_cable entry_a dsf If the phases are routed separately means each phase uses its own drilling hole then the metal will be heated due to circulating currents Single core Cables with Concen...

Page 54: ...able Connections The following sections provide some basic instructions for the routing and mechanical connection of cables The mechanical cable connections are basically the same whether they are for a incoming cabinet or a DC thyristor power converter module what changes between the various types are the cabinet dimension and the location of the terminals for the cables The cabling direction may...

Page 55: ...ound terminal or PE busbar 5 Peel off 3 to 5 cm of the outer cover of the cable above the entry plate for the 360 high frequency grounding 6 Fasten the conductive sleeve to the cable shield with cable ties 7 Tie up the unused conductive sleeves with cable ties Cable Entry Conductive sleeves shows a bottom cable entry for power cables of DCS800 A Tighten the conductive sleeve on the stripped part o...

Page 56: ...p view Conductive cushions Special for Top Entry When each cable has its own rubber grommet sufficient IP and EMC protection can be achieved However if lots of control cables are connected to one cabinet plan the installation beforehand as follows 1 Make a list of the cables to be connected to the cabinet 2 Sort the cables connected to the left into one group and the cables connected to the right ...

Page 57: ...rommet but ensure that each cable has a proper contact to the cushions on both sides 3 Strip off the cable plastic sheath above the base plate just enough to ensure proper connection of the bare screen and the conductive cushions 4 Earth the screen by means of the conductive cushions a If the outer surface of the screen is conductive Push the two parts of the lead through plate together so that th...

Page 58: ...il to keep the shielding continuous Note The ground wire if present must not be cut Push the two parts of the lead through plate together so that the conductive cushions press tightly round the foil covered screen 5 Lock the two parts of the lead through plate by tightening the positioning screws 6 Top entry If more than one cable go through a single grommet the grommet must be sealed by Loctite 5...

Page 59: ...y from all other cables 2 It is recommended that the mains cables AC motor cables DC and control cables be installed on separate trays 3 Motor cables of several drives can be run in parallel on the same tray next to each other Control cables Mains motor cables Routing of mains motor and control cables 4 Separate 24 VDC and 115 230 VAC control cables Electrical Installation 3ADW000352R0101 DCS800 A...

Page 60: ... 230 VDC control cables in separate ducts inside the cabinet 5 The cable screen grounding must be as near to the terminals as possible Connection of a cable screen with the aid of metal clamp to the metal surface of the PCB carrier at a DCS converter Size D6 D7 Screen connection Grounding of cable screens Electrical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 61: ...y plateEMV Conductive sleeve short pigtail Unpainted bottom plate Mains and motor cables Twist the pairs up to the terminals Short pigtail PE Cable Remove the outer insulation of the cable Unpainted gland plate Conductive cushion Continuity of Faraday Cage Control cables Electrical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 62: ...ng of control and mains or motor cables at 90 degrees 9 Route control and other sensitive cables between different cubicles as close to the grounding busbar as possible Control cables Routing of control cables at PE busbar 10 Do not run extra cables through the drive 11 The cable trays must have good electrical connection with each other and to ground PE 12 Aluminum tray systems can be used to imp...

Page 63: ...om touching high voltage parts of the drives by mistake Finger protection DCS800 A module size D7 finger protection WARNING Before starting the finger protection covers of the DCS800 A enclosed converter have to be mounted properly Electrical Installation 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 64: ...ted properly o the D6 D7 modules if used air outlet is connected properly o the air baffle plates of the converter modules are mounted properly ELECTRICAL INSTALLATION see chapter Electrical Installation Joining of the shipping splits o the AC busbars and PE busbars are properly connected see chapter Mechanical Installation o the internal control cables are properly connected The converter units a...

Page 65: ...e that both ends of the cables are connected and the cables do not cause any damage or danger when power is being switched on Cleanliness of the cabinets and surroundings e g o there are no tools or other foreign objects inside the cabinets or waste left from installation e g cable trimmings o there is no garbage under the cabinets the cooling air fan will draw the garbage inside the cabinets o us...

Page 66: ...sscheck this result with the module s door closed Attention Do not reach into the fan Negligence to this warning can cause injury Fan The lifetime of the cooling fan is about 20 000 to 40 000 hours depending on the converter type The actual lifetime depends on the usage of the DCS and the ambient temperature Fan failure can be predicted by means of increasing noise from its bearings and a gradual ...

Page 67: ... for the electronic power part SDCS POW 4 respectively SDCS POW 1 for the converter fan and for other auxiliaries Open the cabinet s and module s door if needed secure them Set a latching torque spanner to 25 Nm 18 lb ft a 17 mm nut is needed too Check the torque of the screws marked within Power part of a converter module type D7 Apply the torque spanner to the screw and turn right until the righ...

Page 68: ... be checked Screws to be checked Screws to be checked Screws to be checked located behind the busbar Power part of a converter module type D7 Preventive Maintenance 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 69: ...69 Preventive Maintenance 3ADW000352R0101 DCS800 A Installation Manual e a ...

Page 70: ...A ႀ Proven long life components are re used such as power stacks main contactors cabinets and cabling busbars cooling systems ႀ Use of up to date communication facilities ႀ Increase of production and quality ႀ Very cost effective solution ႀ Open Rebuild Kits for nearly all existing DC drives ႀ tailor made solutions for ႀ BBC PxD ႀ BBC SZxD ႀ ASEA TYRAK ႀ other manufacturers DCS800 S modules The ve...

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