ABB DCS800 Hardware Manual
DCS800
Hardware Manual
DCS800 Drives (20 to 5200 A)
DCS800 Drive Manuals
Language
DCS800 Quick Guide
DCS800 Tools & Documentation CD
DCS800 Converter module
Flyer DCS800 3ADW000190 x x p x x p
Technical Catalogue DCS800 3ADW000192 x x x x x x x
Hardware Manual DCS800 3ADW000194 x x p p x x x
Hardware Manual DCS800 update DCF503B/DCF504B 3ADW000194Z0301 x
Firmware Manual DCS800 3ADW000193 x x p x p x x
Installation according to EMC 3ADW000032 x
Technical Guide 3ADW000163 x
Service Manual DCS800 3ADW000195 x x
12-Pulse Manual 3ADW000196 x
CMA-2 Board 3ADW000136 p
Flyer Hard - Parallel 3ADW000213 x
Drive Tools
DriveWindow 2.x - User's Manual 3BFE64560981 x
DriveOPC 2.x - User's Manual 3BFE00073846 x
Optical DDCS Communication Link 3AFE63988235 x
DDCS Branching Units - User´s Manual 3BFE64285513 x
DCS800 Applications
PLC Programming with CoDeSys CoDeSys_V23 x x x
61131 DCS800 target +tool description - Application Program 3ADW000199 x
DCS800 Crane Drive
DCS800 Crane Drive Manual suppl. 3AST004143 R0101 x
DCS800 Crane Drive Product note p
DCS800 Winder ITC
DCS800 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 p
DCS800-R Rebuild System
Flyer DCS800-R 3ADW000007 x x
DCS800-R Manual 3ADW000197 x
DCS500/DCS600 Size A5...A7, C2b, C3 and C4 Upgrade Kits 3ADW000256 x
Extension Modules
RAIO-01 Analogue IO Extension 3AFE64484567 x
RDIO-01 Digital IO Extension 3AFE64485733 x
AIMA R-slot extension 3AFE64661442 x
Serial Communication
Drive specific serial communication
NETA Remote diagnostic interface 3AFE64605062 x
Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) 3AFE64504215 x
Fieldbus Adapter with DC Drives RCAN-02 (CANopen)
Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3AFE64506005 x
Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x
Fieldbus Adapter with DC Drives RMBA (MODBUS) 3AFE64498851 x
Fieldbus Adapter with DC Drives RETA (Ethernet) 3AFE64539736 x
x -> existing p -> planned
Status 10.2008
DCS800 Drive Manuals-List_h.doc
Public. number E D I ES F CN RU
3ADW000191 x x x x x
3ADW000211 x
DCS800 Drives
20 to 5200 A
Hardware Manual
© 2008 ABB Automation Products GmbH. All rights reserved.
3ADW000194R0611 DCS800 Hardware Manual f us
3ADW000194R0611 Rev F
EFFECTIVE: 15.09.2008
3ADW000194R0611 DCS800 Hardware Manual f us
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
To which products this chapter applies
This chapter applies to the DCS800... Size D1 to D7and field exciter unit s DCF800...
Use of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment. They also tell you how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
5
Dangerous voltage warning warns of high voltage which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrost atic discharge which
can damage the equipment.
3ADW000194R0611 DCS800 Hardware Manual f us
Safety instructions
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death.
Only qualified electricians are allowed to install and maintain the drive.
Never work on the drive, motor cable or motor when main power is applied.
•
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1.Voltage between drive input phases U1, V1 and W1 and th e frame is close to
0V.
2.Voltage between terminals C1 and D1 and the frame is close to 0 V.
Do not work on the control cables when power is applied to the drive or to the
•
external control circuits. Externally supplied control circuits may cause
dangerous voltages inside the drive even when the main power on the drive is
switched off.
Do not make any insulation or voltage withstand tests on the drive or drive
•
modules.
When reconnecting the motor cable, always check that the C1 and D1 terminal
•
is correct.
Note:
The motor cable terminals on the drive are at a dangerously high voltage when
•
the input power is on, regardless of whether the motor is running or not.
Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
•
may be present on the terminals of relay outputs SDCS-IOB-2, RDIO.
DCS800 with enclosure extension: Before working on the drive, isolate the
•
whole drive from the supply.
Safety instructions
3ADW000194R0611 DCS800 Hardware Manual f us
WARNING! The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
Ground the drive, motor and adjoining equipment to ensure personnel safety in
•
all circumstances, and to reduce electromagnetic emission and pick-up.
Make sure that grounding conductors are adequately sized as required by
•
safety regulations.
In a multiple-drive installation, connect each drive separately to protective
•
earth (PE).
Minimize EMC emission and make a 360° high frequency grounding of
•
screened cable entries at the cabinet lead-through.
7
Do not install a drive with EMC filter on an ungrounded power system or a high
•
resistance-grounded (over 30 ohms) power system.
Note:
Power cable shields are suitable for equipment grounding conductors only
•
when adequately sized to meet safety regulations.
As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA
•
DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
3ADW000194R0611 DCS800 Hardware Manual f us
Safety instructions
8
Fibre optic cables
WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4 in.).
Mechanical installation
These notes are intended 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 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.
•
Safety instructions
3ADW000194R0611 DCS800 Hardware Manual f us
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
Before adjusting the drive and putting it into service, make sure that the motor
•
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the base speed.
Do not activate automatic fault reset functions of the Standard Application
•
Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.
Do not control the motor with the disconnecting device (disconnecting switch);
•
instead, use the control panel keys and , or commands via the I/O
board of the drive.
Mains connection
•
You can use a switch disconnector (with fuses) in the power supply of the
thyristor power converter to disconnect the electrical components of the unit
from the power supply for installation and maintenance work. The type of
disconnector used must be a switch disconnector as per EN 60947-3, Class B,
so as to comply with EU regulations, or a circuit-breaker type which switches
off the load circuit by means of an auxiliary contact causing the breaker's main
contacts to open. The mains disconnector must be locked in its "OPEN"
position during any installation and maintenance work.
9
EMERGENCY STOP buttons must be installed at each control desk and at all
•
other control panels requiring an emergency stop function. Pressing the ST OP
button on the control panel of the thyristor power converter will neither cause
an emergency motor stop, nor will the drive be disconnected from any
dangerous potential.
To avoid unintentional operating states, or to shut the unit down in case of any
imminent danger according to the standards in the safety instructions it is not
sufficient to merely shut down the drive via signals "RUN", "drive OFF" or
"Emergency Stop" respectively "control panel" or "PC tool".
Intended use the operating instructions cannot take into consideration every
•
possible system configuration, operation or maintenance. Thus, they mainly
give such advice only, which is required by qualified personnel for normal
operation of the machines and devices in industrial installations.
If in special cases the electrical machines and devices are intended for use in
non-industrial installations - which may require stricter safety regulations (e.g.
protection against contact by children or similar). These additional safety
measures for the installation must be provided by the customer during
assembly.
3ADW000194R0611 DCS800 Hardware Manual f us
Safety instructions
10
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.
Safety instructions
3ADW000194R0611 DCS800 Hardware Manual f us
11
Table of contents
DCS800 Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table of contents
The DCS800
What this chapter contains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The DCS800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Type code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Armature circuit 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 size D1...D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connection of DC terminals of D4 converter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Terminal cover according to VBG 4 regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting the converter module D6 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mounting the converter module D7 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Planning the electrical installation
3ADW000194R0611 DCS800 Hardware Manual f us
Table of contents
12
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
To which products this chapter applies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Options for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Line reactors LL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Line reactors LL1 for North America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Aspects of fusing for the armature-circuit and field supplies of DC drives. . . . . . . . . . . . . . . .31
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Conclusion for the armature supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Conclusion for the field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Semiconductor type F1 fuses and fuse holders for AC and DC power lines. . . . . . . . . . . . . .33
Fuses F3.x and fuse holders for field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Single-phase Transformer T3 for field supply to match voltage levels. . . . . . . . . . . . . . . . . . .34
Single-phase Commutating reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Auxiliary transformer T2 for electronic system / fan supply . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Residual current detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Three-phase filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Converters D1...D4 drive configuration using ’on board’ field exciter . . . . . . . . . . . . . . . . . . . . . . . .40
Converters D5 drive configuration using ’FEX-425-Int’ field exciter . . . . . . . . . . . . . . . . . . . . . . . . .41
Converters D5...D7 drive configuration using ’external’ field exciter DCF803, DCF804. . . . . . . . . .42
Converters 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 protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Cross-sectional areas - Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Typical Cable Sizing and Tightening Torque – North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
DCS800 panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Checking the insulation of the assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Supply voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Location R-Extension and Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
I/O Board Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Pulse encoder connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Pulse encoder receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Connecting the signal and control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Routing the cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
DCS Link Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Installation checklist
Table of contents
3ADW000194R0611 DCS800 Hardware Manual f us
13
Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Maintenance
What this chapter contains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fan replacement (D6, D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Technical data
What this chapter contains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Current ratings - IEC non regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Current ratings - IEC regenerative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Current ratings – North America non-regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Current ratings – North America regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Control Board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Layout of the control board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Memory circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Watchdog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Seven segment display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Terminal 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-DSL Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Digital I/O board SDCS-IOB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Analogue and encoder I/O board SDCS-IOB-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Power Supply Board SDCS-POW-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Interface Board SDCS-PIN-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Armature circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Field circuit interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Interface Board SDCS-SUB-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Galvanic isolation - T90, A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DC-DC transducer A92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3ADW000194R0611 DCS800 Hardware Manual f us
Table of contents
14
Transformer T90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Dimensional drawings
Module D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Module D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Module D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Module D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Module D5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Module D6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Module D7 left-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Module D7 right-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Fuses installed inside the converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Accessories
DCF803-0035 and FEX 425 internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Power 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 413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Line reactors – North America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Autotransformer T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Line reactor L3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Supply transformer T2 for electronics and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Optical cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Other cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Table of contents
3ADW000194R0611 DCS800 Hardware Manual f us
The DCS800
What this 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.
15
Size D1...D4
20...1000 A
Size D6
1900...3000 A
Size D5
900...2000 A
Size D7
2050...5200
3ADW000194R0611 DCS800 Hardware Manual f us
The DCS800
16
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. DCS800-S01-
2005). The optional selections are given thereafter, on the name plate by p lus code.
The main selections are described below. Not all selections are available for all
types.
Type code DCS800-AAX-YYYY-ZZ- plus code
Position Plus code
Product series DCS800
A Typ e S0 = Converter module IP00
X Bridge type 1 = Single bridge 2-Q
Y Rated current YYYY = Rated current (e.g. 0025 = 25 amps)
ZZ Rated voltage
(nominal rating in bold)
B Power connection - = Standard D1...D6
Internal field exciter
configuration
Fan voltage
Current measurement +S175 CMA; D6 and D7 converter
Voltage measurement +S186
SDCS-DSL board +S199
+ plug-in options
Control panel 0J404
Fieldbus K454
I/O and DDCS L500
Position
AX Y ZB
R0 = Rebuild system
E0 = Panel solution
A0 = Enclosed converter
2 = Double bridge 4-Q
04 = 400 V
05 = 500 V
06 = 600 V
07 = 690 V
08 = 800 V
10 = 990 V
12 = 1200 V
L = Left side D7
R = Right side D7
+S164
+0S163
+S180
+S181
+S182
+S183
+S189
+0S199
J409
K451
K466
K458
L501
L508
L509
with internal field exciter, external supplied (only D5: 25 A, Rebuild kit: 25 A / 16 A)
without internal field exciter (only D1...D4)
Size D4
Standard fan voltage: 230 V / 1-ph
+S171
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
+S172
120 V SDCS-SUB-4 for D1...D4 converter modules
600 V for D6 and D7 converter modules
690 V for D6 and D7 converter modules
800 V for D6 and D7 converter modules
990 V for D6 and D7 converter modules
galvanic isolation for D6 and D7 converter modules
SDCS-DSL board
no SDCS-DSL board
no DCS800 control panel
Door mounting Kit (3 m cable length)
Profibus RPBA
DeviceNet RDNA
Ethernet IP + Modbus TCP RETA
Modbus RMBA
Analogue Extension RAIO
Digital Extension RDIO
DDCS Adapter (10 Mbaud CH0) SDCS-COM-81
DDCS Adapter (5 Mbaud CH0) SDCS-COM-82
fan voltage: 115 V / 1-ph
600 V / 690 V fan voltage: 400-500 V / 3-ph
The DCS800
3ADW000194R0611 DCS800 Hardware Manual f us
Main circuit and control
Armature circuit converter DCS800-S0x D1...D4
400 V and 500 V units with Onboard field exciter
600 V units are always without Onboard field exciter
17
Power
supply
F3
K3
T3
Three-phase field supply
DCF503B0050
DCF 803 / 804
DCF504B0050
also possible
to field
DCS8_sys_ovw_d.dsf
analogue input / output
Legend
On Board FEX PIN 4
fuse
reactor
transformer
K5
M
L1
EMC filter
Q1
K1
F1
Earth-fault monitor
500V
230 V (115V)
twisted pa i r
F2
T2
500V
500V
PIN-4
Memory Card
X20
Slot 4
DCS link
M
alternative
digital input / output
CON-4 - short des ignation of components
T
T
5
3
DCS800-S0x D1...D4
X9
Slot 1
Fieldbus
interface R...
X10
RDIO
Slot 2
DSL
DSL
RAIO
24V-
X52 X53
X51
84 7
8
8
IOB-2x IOB-3
PLC
X33
kit
kit
Door
Door
Panel
CDP 312
mounting
mounting
RJ45
optical fibre
(PCMCIA)
(ISA)
PC +
NDBU95
-NDPA-02
-NDPC-12
-NISA-03
DriveWindow
CON-4
X11
Slot 3
COM-8
X34
3
Panel
X19
Ch3
Ch2
Ch1
Ch0
X2
X1
X3 X4 X5 X6 X7
RS232
optical fibre
Advant
AIMA
Slot1
Slot2
Master/
Follower
Slot3
NDBU95
control
DWL
PC +
CoDeSys
The DCS800
3ADW000194R0611 DCS800 Hardware Manual f us
18
Armature circuit converter DCS800-S0x D5...D7
Three-phase fie ld suppl y
DCF 803 / 804
L3
FEX 425 internal **
DCF503B0050
DCF504B0050
also possible
M
M
to field
DCS8_sys_ovw_d.dsf
analogue input / output
Legend
fuse
reactor
transformer
alternative
digital input / output
** only D5 types
CON-4 - short desi gnation of components
* three-phas e D6 and D 7
EMC filter
Power
supply
F3
K3
T3
*
K5
L1
Q1
K1
F1
Earth-fault monitor
500V
1000V
F2
T2
POW-4
PIN-46/48
PIN-46/48
twisted pair
T
T
PIN-51
500V
Memory Card
X20
Slot 4
X9
Slot 1
Fieldbus
DCS800-S0x D5...D7
PLC
X33
Panel
kit
kit
Door
Door
Panel
CDP 312
mounting
mounting
RJ45
optical fibre
(PCMCIA)
(ISA)
PC +
NDBU95
-NDPA-02
-NDPC-12
-NISA-03
DriveWindow
interface R...
CON-4
X10
RDIO
Slot 2
X11
Slot 3
COM-8
X19
Ch3
Ch2
Ch1
Master/
Follower
RAIO
Ch0
optical fibre
AIMA
Slot1
Slot2
DSL
DSL
24V-
X52 X53
X51
X34
X2
X1
Slot3
DCS link
84 7
IOB-2x IOB-3
3
X3 X4 X5 X6 X7
Advant
NDBU95
control
5
3
8
8
RS232
DWL
PC +
CoDeSys
The DCS800
3ADW000194R0611 DCS800 Hardware Manual f us
Rebuild system DCS800-R0x
19
Power
supply
F3
K3
T3
Three-phase field supply
DCF 803 / 804
L3
SDCS-FEX 4 internal
M
M
DCF503B0050
DCF504B0050
also possible
to field
analogue input / output
Legend
DCS8_sys_ovw_d.dsf
fuse
reactor
transformer
alternative
digital input / output
CON-4 - short desi gnation of components
EMC filter
K5
L1
Q1
Q1
K1
L1
K1
F1
M
Earth-fault monitor
500V
1000V
Exist ing part
F2
T2
QUINT-PS
-
~
-
~
PIN-48
POW-4
POW 1
PIN-48
REB-3
twisted pair
PIN-51
PIN 1x
REB-1
REB-2
T
T
interface R...
SDCS-CCB4
Memory Card
Slot 4
X10
RDIO
Slot 2
RAIO
X20
DCS link
DSL
DSL
24V-
X52 X53
X51
84 7
5
3
8
8
500V
X9
Slot 1
DCS800-R0x
Fieldbus
IOB-2x IOB-3
PLC
X33
kit
kit
Door
Door
Panel
CDP 312
mounting
mounting
RJ45
optical fibre
(PCMCIA)
(ISA)
PC +
NDBU95
-NDPA-02
-NDPC-12
-NISA-03
DriveWindow
CON-4
X11
Slot 3
COM-8
X34
3
Panel
X19
Ch3
Ch2
Ch1
Ch0
X2
X1
X3 X4 X5 X6 X7
RS232
optical fibre
Advant
AIMA
Slot1
Slot2
Master/
Follower
Slot3
NDBU95
control
DWL
PC +
CoDeSys
3ADW000194R0611 DCS800 Hardware Manual f us
The DCS800
20
The DCS800
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.
5
3
21
4
2
1
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,
CULUS
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.
T ype designation label
and CE
Rated input voltage
Rated input current
3ADW000194R0611 DCS800 Hardware Manual f us
Rated internal
field exciter current
Rated output current
Rated fan voltage
Plus code
Mechanical installation
22
Before installation
The drive must be installed in an upright position with the cooling section facing a
wall. Check the installation site according to the requirements below. Refer to
Dimensional drawings for frame details.
Requirements for the installation site
See Technical data for the allowed operation conditions of the drive.
Wall
The wall should be as close to vertical as possible, of non-flammable material and
strong enough to carry the weight of the unit. Check that there is nothing on the wall
to inhibit the installation.
Floor
The floor/material below the installation should be non-flammable.
Free space around the unit
Required free space around the drive to enable cooling air flow, service and
maintenance see chapter Dimensional drawings.
Cabinet installation
The required distance between parallel units is five millimetres (0.2 in.) in
installations without the front cover. The cooling air entering the unit must not
exceed +40 °C
Preventing cooling air recirculation
Prevent air recirculation inside and outside the cabinet.
Main air flow out
Main air flow in
HOT
COOL AREA
(+104 °F).
Air baffle plates
Unit above another
max.+40 °C (+104 °F)
Air baffle plate
Mechanical installation
Cooling w baffle.dsf
Airflow
Lead the exhaust cooling air away from the unit above.
Distances see chapter Dimensional drawings
3ADW000194R0611 DCS800 Hardware Manual f us
Terminal options converter size D1...D4
There are different options for protection and connection the terminals for converter
sizes D1...D4
Connection of DC terminals of D4 converter module
In special cases it is beneficial to use the lug bar for easier connection of the DC
cables.
DC terminals of
D4 module
∅ 7.35
23
Id No. Remark
3ADV280706P0001 right
3ADV280706P0002 left
135
95
71
14
∅
60
Bottom view of lug bar mounted on a D4 module
Terminal cover according to VBG 4 regulations
For converter modules D1...D4 we provide shrouds for protection against contact
Id No. Remark
3ADT631137P0001 D1...D2
3ADV400208P0001 D3
3ADV400207P0001 D4
3ADW000194R0611 DCS800 Hardware Manual f us
Mechanical installation
24
Mounting the D1/D2 cover by using the excisting lateral pins and than swing downward to snap-in at the
terminal row. D3 and D4 mounting is accordingly, without the snap-in mechanism.
Examples for covering the DC main terminals on D3 (left) and D4 (right) converter modules.
Mechanical installation
3ADW000194R0611 DCS800 Hardware Manual f us
Mounting the converter module D6 inside an enclosure
Cooling air entry
The cooling fan takes the air from the backside, both sides and from the area
underneath the converter module.
View from: the right side the back the left side
Free space around the converter module
optimum compromise
50
TMR
25
~ 100
air flow
air flow
air flow
air flow
A6_li_air_inlet.dsf
Cable entries Power cable connection
The power cable connection is performed via Terminal
the module must be fixed
at the upper side with
TMR (Top Mounting Rail)
C
D
U
V
do not unscrew these bolts !
W
option 01 for D6. This option consists of one right
angle copper busbar. The mechanical details are
shown by the figure below.
100
72.2
21.8
0
0
25
75
electronics power supplycontrol cables
Ø14
125
175
250
When mounting the right angle busbars or connecting
cables directly please make sure the correct bolts are
used. The converter module is equipped with a thread
hole at left side. Because of that the length of the
remaining threads is limited to 35 mm (see drawing
below).
air flow
5050
Top view
~ 100
Top view
Cooling air outlet
To avoid circulating air inside the enclosure it is recom-
air flow
mended to make sure the exhaust air leaves the enclosure.
The figure below gives an example, how the right angle
busbars can be mounted in case all cable connections
are still made at the left side of the converter module.
This results in four layers for the power cables.
75
25
In case the AC or DC connection or perhaps both of
them have to be made at the right side of the converter
module use the space behind the converter and move
the power terminals via a right angle busbar up to that
272
312
352
372
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-
140
A6_cable_term_busb.dsf
tion can be made.
A6_li_air_inlet_c.dsf
switch
pressure
converter fan
(left and right side)
max.
35mm
3ADW000194R0611 DCS800 Hardware Manual f us
468.2
136
Example right side connection
Mechanical installation
26
Mounting the converter module D7 inside an enclosure
Cooling air entry
The cooling fan takes the air from the backside, both
sides and from the area underneath the converter
module.
View from front
left side / (right side)
Cable entries
The cable entries are existing symmetrically on both
sides. Nevertheless only the entries on the left side
should be used for cables going to the electronics
power supply (SDCS-POW-1) or the controller board
(SDCS-CON-4).
air flow
w
o
l
f
r
i
a
air flow
View from bottom
Free space around the converter module
Do not place the converter module in a corner. In case
the fan cannot take the air through the bottom plate of
the enclosure none of the remaining entries can be
blocked.
>20
50
TMR
A7_re_air_inlet_b.dsf
Screened cable for
hardware interface
connection IOB2/IOB3
board is strongly recommended
electronics power supply
Provide sufficient
grounding of card
holder
IOB2/IO B3
PE
control cables
pressure
converter fan
screened cables
switch
A7_re_air_inlet_b.dsf
Internal cable ducts
are used for snubber
circuit wiring. Don’t
use these cable
ducts for other
cables or process
signals.
Air entry through bottom plate
Make sure the converter module gets clean air,
because there is no air filter in front of the fan at the
converter.
Cooling air outlet
To avoid circulating air inside the enclosure it is recommended to make sure the exhaust air leaves the
enclosure.
Mechanical installation
3ADW000194R0611 DCS800 Hardware Manual f us
Use cable straps for
fan cable
Do not have loose cables. The air flow from
fan will destroy the cables!
Planning the electrical installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive system. Always
follow local regulations.
Note: If the recommendations given by ABB are not followed, the drive may
experience problems that the warranty does not cover.
Reference: Technical Guide - publ. no.: 3ADW000163
To which products this chapter applies
This chapter applies to the DCS800-S Size D1...D7.
Options for the drive
27
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 volt age dips in the
mains PCC (point of common coupling). For the connection of a power converter
system to the mains, one of the following configurations can be applied:
Configuration A
Line
When using the power converter, a minimum of impedance is
required to ensure proper performance of the snubber circuit. A line
reactor can be used to meet this minimum impedance requirement.
The value must therefore not drop below 1% u
voltage). It should not exceed 10% u
, due to considerable voltage
k
(relative impedance
k
drops at converter output.
u
PCC
(Pcc)
k L1
> 1%
3ADW000194R0611 DCS800 Hardware Manual f us
Planning the electrical installation
28
Line
L
Line
PCC
(Pcc)
L
L1
Line
PCC
(Pcc)
Configuration B
If special requirements have to be met at the PCC (standards like EN
61 800-3, DC and AC drives at the same line, etc), different criteria
must be applied for selecting a line reactor. These requirements are
often defined as a voltage dip in percent of the nominal supply
voltage.
The combined impedance of Z
and ZL1 constitute the total series
Line
impedance of the installation. The ratio between the line impedance
and the line reactor impedance determines the voltage dip at the
connecting point. In such cases line chokes with an impedance
around 4% are often used.
Example calculation with U
=4%; V olt age Dip = Z
U
k L1
k Line
Line
=1%;
/(Z
Line+ZL1
)=20%. Detailed calculation
see Technical Guide.
Configuration C
If an isolation transformer is used, it is possible to comply with certain
connecting conditions per Configuration B without using an additional
line reactor. The condition described in Configuration A will then
likewise be satisfied, since the u
is >1 %.
k
Configuration C1
If 2 or more converters should be supplied by one
Line
PCC
(Pcc)
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 converters (D1, D2, D3, D4, D5, D6, D7). In case
only two converters type D7 are involved no
L
L1
L
L1
....
L
L1
commutation chokes are necessary because the design
of these converters is adapted to that wiring.
Netzdr_g.dsf
With reference to the power converter:
The line reactors listed in table below
• have been sized to the units nominal current
• are independent of converter's voltage classification; at some converter types the
same line choke is used up to 690 V line voltage
• are based on a duty cycle
• can be used for DCS800 as armature converter as well as field converter but
rated line choke current must be considered.
You will find further information in publication:
Technical Guide chapter: Line reactors
Planning the electrical installation
3ADW000194R0611 DCS800 Hardware Manual f us
29
Line reactors L
DCS Type
400V-690V
50/60 Hz
2-Q Converter 4-Q Converter
DCS800-S01-0020-04/05 DCS800-S02-0025-04/05 ND01 1 ND401 4
DCS800-S01-0045-04/05 DCS800-S02-0050-04/05 ND02 1 ND402 4
DCS800-S01-0065-04/05 DCS800-S02-0075-04/05 ND04 1 ND403 5
DCS800-S01-0090-04/05 DCS800-S02-0100-04/05 ND06 1 ND404 5
DCS800-S01-0125-04/05 DCS800-S02-0140-04/05 ND06 1 ND405 5
DCS800-S01-0180-04/05 DCS800-S02-0200-04/05 ND07 2 ND406 5
DCS800-S01-0230-04/05 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-S01-0740-04/05 DCS800-S02-0820-04/05 ND13 3 ND412 5
DCS800-S01-0900-04/05 DCS800-S02-1000-04/05 ND13 3 ND413 5
DCS800-S01-0900-06/07 DCS800-S02-0900-06/07 ND13 3 on request DCS800-S01-1200-04/05 DCS800-S02-1200-04/05 ND14 3 on request DCS800-S01-1500-04/05/06/07 DCS800-S02-1500-04/05/06/07 ND15 3 on request DCS800-S01-2000-04/05 DCS800-S02-2000-04/05 ND16 3 on request DCS800-S01-2000-06/07 ND16 * 3 on request -
L1
Line choke Design Line choke Design
type for Fig. type for Fig.
configur. A configur. B
* with forced cooling (1m/s)
Fig. 1 Fig. 2
Fig. 3
Fig. 4 Fig. 5
3ADW000194R0611 DCS800 Hardware Manual f us
Planning the electrical installation
30
Line reactors LL1 for North America
Unit Type Line Choke for Config. A Line Choke for Config. B
2Q Converters 4Q Converters 1.5% imp. 5% imp.
500 Vdc
DCS800-S01-0020-05 DCS800-S02-0025-05 KLR21BTB KLR21CTB
DCS800-S01-0045-05 DCS800-S02-0050-05 KLR45BTB KLR45CTB
DCS800-S01-0065-05 DCS800-S02-0075-05 KLR80BTB KLR80CTB
DCS800-S01-0090-05 DCS800-S02-0100-05 KLR110BCB KLR110CCB
DCS800-S01-0125-05 DCS800-S02-0140-05 KLR130BCB KLR130CCB
DCS800-S01-0180-05 DCS800-S02-0200-05 KLR200BCB KLR200CCB
DCS800-S01-0230-05 — KLR200BCB KLR200CCB
— DCS800-S02-0260-05 KLR250BCB KLR250CCB
DCS800-S01-0315-05 DCS800-S02-0350-05 KLR300BCB KLR300CCB
DCS800-S01-0405-05 — KLR360BCB KLR360CCB
DCS800-S01-0470-05 DCS800-S02-0450-05 KLR420BCB KLR420CCB
— DCS800-S02-0520-05 KLR480BCB KLR480CCB
DCS800-S01-0610-05 DCS800-S02-0680-05 KLR600BCB KLR600CCB
DCS800-S01-0740-05 DCS800-S02-0820-05 KLR750BCB KLR750CCB
DCS800-S01-0900-05 — KLR750BCB KLR750CCB
— DCS800-S02-1000-05 KLR850BCB KLR850CCB
DCS800-S01-1200-05 DCS800-S02-1200-05 KLR1100BCB KLR1100CCB
DCS800-S01-1500-05 DCS800-S02-1500-05 KLR1250BCB KLR1250CCB
600 Vdc
DCS800-S01-0290-06 — KLR250BCB KLR250ECB
— DCS800-S02-0320-06 KLR300BCB KLR300ECB
DCS800-S01-0590-06 DCS800-S02-0650-06 KLR600BCB KLR600ECB
DCS800-S01-0900-06 DCS800-S02-0900-06 KLR750BCB KLR750ECB
DCS800-S01-1500-06 DCS800-S02-1500-06 KLR1250BCB KLR1250ECB
Recommended AC Line Reactors are available directly from TCI.
For information, see their web page www.transcoil.com
Planning the electrical installation
3ADW000194R0611 DCS800 Hardware Manual f us
Loading...