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DCS800

Selection, Installation and Start-Up Manual for Rebuild Kits
DCS800 Drives

Summary of Contents for DCS800

Page 1: ...DCS800 Selection Installation and Start Up Manual for Rebuild Kits DCS800 Drives...

Page 2: ...000199 x Winding with the DCS 800XXXXX 3ADW000058 Winder application description Flyer magnetic application Magnetic application description DCS800 E Panel Solution Flyer DCS800 E Panel solution 3ADW0...

Page 3: ...DCS800 Drives DCS800 R0x Selection Installation and Start Up Manual for Rebuild Kits Code 3ADW000195R0101 Rev A DCS800 Service Manual e a DOC EFFECTIVE June 19th 2006 SUPERSEDES...

Page 4: ...3ADW000195R0101 DCS800 Service Manual e a 3ADW000197R0101 DCS800 R Sel e a...

Page 5: ...g 1 4 H16 Environmental conditions 1 5 H17 Pulse transformer board SDCS PIN 48 1 6 H19 Wiring 1 7 H19 Measurement board SDCS PIN 51 1 8 H20 Wiring 1 9 H22 Fastening 2 0 H22 PTC temperature sensor 2 1...

Page 6: ...apter contains 4 3 H53 To which products this chapter applies 4 4 H53 Use of warnings and notes 4 5 H53 Installation and maintenance work 4 6 H54 Grounding 4 7 H55 Mechanical installation 4 8 H56 Oper...

Page 7: ...describes how to use this manual and the boundary conditions applying Basic Selection provides the information about the types of the Rebuild kits their type designations and options Hardware descript...

Page 8: ...6 Introduction 3ADW000197R0101 DCS800 R Sel e a...

Page 9: ...ccurate control design of state of the art others will be compared with the disadvantages of revamping described by standstill time of production hardware cost training etc If this comparison is based...

Page 10: ...wer part is upgraded by the Rebuild kit it should be checked if a brand new module may be easier to install or may be a more reli able solution tested power stack The existing power bridge should be b...

Page 11: ...ogue tacho generator can be re used A pulse generator can only be re used if it generates a pulse train as an output signal see Hardware Manual The Rebuild kit expects an armature current feedback sig...

Page 12: ...CR kit too as long as the components necessary for that application can be used for both systems Engineering help is given within the DCS800 converter module s documentation see inner page of the jack...

Page 13: ...2 bridges in parallel 03 3 bridges in parallel 04 4 bridges in parallel Options xxxx codes according list for add on options selectable option R0 1 0000 DCS8 R_sys_ovw dsf PIN 48 REB 3 PIN 48 PIN 1x...

Page 14: ...12 Basic Selection 3ADW000197R0101 DCS800 R Sel e a...

Page 15: ...ted for better and straighter forward engineering All other components which may come or may had been ordered together with the kit are described in detail either within the DCS800 Hardware Manual or...

Page 16: ...need to be plugged on the controller board to get their function Those options will be put at their correct place during production and therefore will come within the housing Plug in modules e g Prfib...

Page 17: ...S REB 2 and SDCS PIN 48 With the help of this board the firing pulse assignment can be changed and adapted to the needs given by the existing power part construction The board will come mounted on a c...

Page 18: ...nents build in natural convection is necessary to keep the temperature of the used components within the limits Because of that it is important to mount the housing as shown on the figure before and t...

Page 19: ...temperature 40 to 55 C Transport temperature 40 to 70 C Converter Module and op tions line chokes fuse holder Pollution degree IEC 60664 1 IEC 60439 1 2 field supply unit etc IP 00 NEMA TYPE OPEN Vib...

Page 20: ...3 IEC 61800 3 EN 61800 3 IEC 61800 3 89 336 EEC 93 68 EEC Declaration of Conformity Provided that all installa tion instructions concern ing cable selection ca bling and EMC filters or dedicated trans...

Page 21: ...s 8 301 317 80 10 260 85 85 85 7 5 5 4 8 5 80 10 Card holder for SDCS PIN 48 10 60 SDCS PIN 48 board and card holder Wiring The gate cathode wires which are a part of the rebuild kit s delivery have t...

Page 22: ...current and scaling with burden resistors to 1 5 V for rated current burden resistors for zero current detection X513 X13 X23 X24 X25 R1 R21 X12S X13S X413S X313S X22 X122 X12 U1 V1 W1 D1 C1 W5 W4 W3...

Page 23: ...ISTING PART S1 S2 X12 S X13 S X313 S X413 S 4 7 nF conductive mounting holes V21 V23 V25 V24 V26 V22 thyristor designation of reverse Bridge DCS8_reb_diagr_wir_p48_p51 dsf X12 X12 X13 X13 X12 X12 X13...

Page 24: ...to be used The insulation clearance must be rated for 990 V AC working voltage PTC temperature sensor Normally there is no temperature sensor in existing converters in this case a separate resistor 2...

Page 25: ...601 700 V 701 800 V 801 990 V Nominal current coding At first make sure that the current transformers are mounted and wired according to the figure before In addition to that two other definitions ar...

Page 26: ...r 97 02 to exactly that se lected rated current 2500 1 4000 1 900 1200 1500 2000 2500 3000 2600 3300 4000 R1 R4 18 R5 18 R6 18 R7 18 R8 18 R9 18 R10 18 R11 18 R12 18 R13 18 R14 18 R15 18 R16 18 R17 33...

Page 27: ...her than the current the calculation was based on keep the coding and use the recalculated current at parameter S ConvScaleCur 97 02 Rn R R R R Rbr 1 4 1 3 1 2 1 1 1 1 Additional settings The followin...

Page 28: ...r the forward bridge is connected to X613 and the pulse transformer board for the reverse bridge is connected to X713 Thyristors in old bridges are often differently positioned on the heat sink than i...

Page 29: ...nal power supply the device is cooled by convection because of that mounting direction is impor tant the device needs to be connected to ground e g because of the metal housing etc care must be taken...

Page 30: ...Electrical characteristics of the SDCS REB 2 Current requirement for 24 V is 100 mA Current requirement for 48 V is 0 4 A for each parallel connected thyristor if there are 4 parallel thyristors the...

Page 31: ...LY 48V 6 6 6 6 6 6 0V 0V 0V 0V separated potential range 6x 0k5 BZP1 BZP2 BZP3 BZP4 BZP5 BZP6 FWD REV 0V 0V 48V 6x Diagram of the SDCS REB 2 board SDCS REB 2 X713 X11 X21 X22 X12 X31 X32 X42 X1 X41 12...

Page 32: ...f possible try to avoid connecting thyristors of different bridges to the same SDCS PIN 48 Com missioning and testing will become easier At a power part with parallel thyristors each thyristor gets a...

Page 33: ...SR_2 SDCS CON 4 SDCS PIN 51 C E B D F V 4 V 6 V 2 V 1 V 3 V 5 to thyristor SDCS PIN 48 SR_1BDF A SR_1ACE signal routing SR_1ACE SR_1BDF SR_2ACE SR_2BDF X13 X13 X113 X213 X413 X313 forward X113 X513 1...

Page 34: ...s an input to output connection has thus been established The multilayer construction used for this board enables this method to be em ployed Design hints Name the AC terminals of the existing power p...

Page 35: ...column at a 4 Q system There is only one connection allowed per row Precisely one matrix field with six connections should be assigned per out going plug connector X113 X813 The SR_ACE or SR_BDF outpu...

Page 36: ...D F A C E 2 4 S R 1 1 4 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E SR ACE SR BDF B D F A C E 4 5 S R 2 3 5 1 3 5 4 6 2 1 3 5 4 6 2 SR ACE SR BDF B D F A C E 2 5 S R 1 1 5 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E...

Page 37: ...is presented in the figure below Thyristors for forward bridge current direction 1 SR1 are numbered V11 V12 V16 and thyris tors for reverse bridge current direction 2 SR2 are numbered V21 V22 V26 In...

Page 38: ...313 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 V26 V13 V22 V15 X213 A X13 X12 X12 V25 V12 V23 V16 V21 V14 F X213 4q_c3a_c dsf Firing pulse assignment At figure bel...

Page 39: ...give enough power for parallel connected thyristors The figure below shows the configuration for a 4 quadrant bridge with 4 parallel connected thyristors V424 SDCS PIN 41 B C D E F X113 C G C G C G C...

Page 40: ...shows the configuration for a 2 quadrant bridge with 4 parallel connected thyristors V414 SDCS PIN 41 B C D E F X113 C G C G C G C G C G C G X213 A V411 V416 V413 V412 V415 V314 SDCS PIN 41 B C D E F...

Page 41: ...3 parts 6 1 HFigure 3 is taken as an example and will have these 3 parts marked read the other pictures in a similar way Part 1 consists of the SDCS PIN 48 boards which have to be mounted as close as...

Page 42: ...appr 2 m SDCS POW 4 L2 L1 115 230 V AC 16 16 20 20 3 m 1 m Cable length Cable length 5 m Cable length 2 21k n Mounting plate card holder Ground connection Single multi strand cable not shielded inclu...

Page 43: ...713 X11 X21 X12 X22 X31 X41 X32 X42 X2 X1 24VDC QUINT PS 24VDC 48V 24V 0V Voltages from power part cable length appr 1 m from Current transformers cable length appr 2 m 2 1 2 1 SDCS POW 4 L2 L1 115 23...

Page 44: ...s are missing in 2 Q kits Forward bridge pulse transformer board s X12 s L3 X22 X122 X23 SDCS REB 2 X613 X713 X11 X21 X12 X22 X31 X41 X32 X42 X2 X1 24VDC QUINT PS 24VDC 48V 24V 0V Voltages from power...

Page 45: ...X513 X113 X213 SDCS CON 4 X13 X12 D1 C1 W1 V1 Reverse bridge pulse transformer board s Cables and boards are missing in 2 Q kits Forward bridge pulse transformer board s X12 s L3 X22 X122 X23 SDCS REB...

Page 46: ...18 W17 R26 R22 1 2 2 2 1 1 SDCS PIN 51 S3 W10 W70 W80 W71 W81 W72 W82 W83 X113 X213 X413 S1 S2 X313 2 1 3 4 One PTC Two PTC SDCS REB 1 X213 X513 X613 X713 X113 SDCS REB 2 X713 X11 X21 X22 X12 X31 X32...

Page 47: ...L3 X22 X122 X23 SDCS REB 2 X613 X713 X11 X21 X12 X22 X31 X41 X32 X42 X2 X1 48V 24V 0V SDCS REB 3 X11 X21 X32 X42 X1113 X1213 X113 X813 Voltages from power part cable length appr 1 m from Current tran...

Page 48: ...mer board s Cables and boards are missing in 2 Q kits Forward bridge pulse transformer board s X12 s L3 X22 X122 X23 SDCS REB 2 X613 X713 X11 X21 X12 X22 X31 X41 X32 X42 X2 X1 48V 24V 0V SDCS REB 3 X1...

Page 49: ...D F A C E 2 3 S R 1 1 3 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E SR ACE SR BDF B D F A C E 4 4 S R 2 3 4 1 3 5 4 6 2 1 3 5 4 6 2 SR ACE SR BDF B D F A C E 2 4 S R 1 1 4 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E...

Page 50: ...F A C E 2 3 S R 1 1 3 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E SR ACE SR BDF B D F A C E 4 4 S R 2 3 4 1 3 5 4 6 2 1 3 5 4 6 2 SR ACE SR BDF B D F A C E 2 4 S R 1 1 4 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E S...

Page 51: ...F A C E 2 3 S R 1 1 3 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E SR ACE SR BDF B D F A C E 4 4 S R 2 3 4 1 3 5 4 6 2 1 3 5 4 6 2 SR ACE SR BDF B D F A C E 2 4 S R 1 1 4 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E S...

Page 52: ...D F A C E 2 3 S R 1 1 3 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E SR ACE SR BDF B D F A C E 4 4 S R 2 3 4 1 3 5 4 6 2 1 3 5 4 6 2 SR ACE SR BDF B D F A C E 2 4 S R 1 1 4 1 3 5 4 6 2 1 3 5 4 6 2 B D F A C E...

Page 53: ...ons In case there is more than one connection between two or more boards e g connection made by cable B2 all the cables will have the same marking Marking at 6 6 HFigure 13 Order number Remark A 3ADT...

Page 54: ...113 C G C G C G C G C G C G X213 A X1 X2 V124 V121 V126 V123 V122 V125 X11 X21 X12 X22 X31 X41 X32 X42 20 20 20 20 20 20 20 20 SDCS PIN 48 B C D E F X113 C G C G C G C G C G C G X213 A X1 X2 V114 V111...

Page 55: ...the re build kit DCS800 R0x Use of warnings and notes There are two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result in se...

Page 56: ...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 th...

Page 57: ...safety in all circumstances and to reduce electromagnetic emission and pick up Make sure that grounding conductors are adequately sized as re quired by safety regulations In a multiple drive installa...

Page 58: ...ter the drive when in stalling Electrically conductive dust inside the unit may cause damage or lead to malfunction Ensure sufficient cooling Do not fasten the drive by riveting or welding Operation T...

Page 59: ...dangerous potential To avoid unintentional operating states or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merel...

Page 60: ...58 Safety Instructions 3ADW000197R0101 DCS800 R Sel e a...

Page 61: ...efore need to be observed with extreme care When listing the different steps of the start up procedure additional warnings will be given Based on the possible variations caused by the individual proje...

Page 62: ...nd grounding screening and other points which need further considerations The manual Technical Guide gives some help within the chapter EMC Compliant Installation and Configuration for a Power Drive S...

Page 63: ...elect a place for the electronics housing and mount it Take care for the cable length towards the SDCS PIN 51 Take the same grounding guidelines as be fore Wiring the Kit The system still has to be in...

Page 64: ...r complete converter modules Safety Instructions local safety regulations etc Check the engineering e g make sure the selected voltage levels are correct and selector switches if existing are in the c...

Page 65: ...aried and does not hit the limit set by the parameter above or inverter limit position De pending on the value of the minimum firing angle perhaps higher than 120 el perhaps close to 150 el it may hap...

Page 66: ...fully cabled on a panel Very fast installation and commissioning Squeezes shut down times in revamp projects to a minimum Fits into Rittal cabinets Compact version up to 450 A and Vario version up to...

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