ABB DCS800 Quick Installation Guide

DCS800

Quick guide
DCS800 Drives (20 A to 5200 A)

DCS800 QuiCk GuiDe

english Contents

DC Drives Worldwide Service Network .............................. 3

DCS800 Drive Manuals ......................................................4

DCS800 DC Drives ............................................................. 5

Brief instructions for CD and documents overview ............. 7

Notes on EMC .................................................................... 8

Standard function assignments for the terminals ...............10

Connection example .........................................................11

Fan power connection ...................................................... 13

Terminal locations on the converter ...................................14

Notes For North American Installations .............................15

Safety and operating instructions .....................................17

Installing the DCS800 PC tools on Your computer ............ 18

Commissioning .................................................................19

DCS800 Control Panel .....................................................20

Dimensions, drilling patterns and weights ........................ 77

Fault / Alarm list ............................................................... 79

Diagnosis messages.......................................... ...............88

Macro & Firmware structure ..............................................93

Declaration of conformity ................................................ 106

Certificate of manufacture ..............................................107

deutsch Inhalt

DC Drives Worldwide Service Network .............................. 3

DCS800 Drive Manuals ......................................................4

DCS800 Gleichstromantriebe ........................................... 21

Kurzanweisung CD und Documentations[bersicht ...........23

EMV Filter ......................................................................... 24

Digitaler und analoger E-A/Anschluss von SDCS-CON-4 ..26

Anschlussbeispiel .............................................................27

Lüfterkühlung ...................................................................29

Klemmen- und Steckeranordnung des Stromrichters ........ 30

Sicherheits- und Anwendungshinweise ............................. 31

Installation der DCS800 Programme auf dem PC ............. 32

Inbetriebnahme ................................................................33

DCS800 Steuertafel .......................................................... 34

Abmessungen, Bohrbild und Gewichte ............................ 77

Fehler- und Alarmliste ...................................................... 79

Diagnose.......................................... ................................ 88

Macro & Firmware Struktur ............................................... 93

Declaration of conformity ................................................ 106

Herstellerbescheinigung ................................................. 107

español Contenido

Red de atención mundial de convertidores de CC ..............3

Manuales de convertidores DCS800 ................................... 4

Convertidores de CC DCS800 ......................................... 49

Instrucciones para la descripción del CD y documentación 51

Notas acerca de EMC .....................................................52

Asignaciones de funciones estándar para los terminales ... 54

Ejemplo de conexión ....................................................... 55

Conexión de alimentación del ventilador ..........................57

Ubicación de los terminales en el convertidor ...................58

Instrucciones de seguridad ............................................... 59

Cómo instalar las herramientas para PC del DCS800 ......60

Puesta en funcionamiento ...............................................61

Panel de control del DCS800 ........................................... 62

Dimensiones, patrones de taladrado y pesos....................77

Lista de fallos/alarmas .....................................................79

Mensajes de diagnóstico .................................................88

Estructura del macro & firmware ....................................... 93

Declaración de conformidad ........................................... 106

Certificate of manufacture ............................................... 107

français Sommaire

DC Drives Worldwide Service Network .............................. 3

Manuels du DCS800 (originaux anglais) .............................. 4

Variateurs à courant continu DCS800 ............................... 63

Documentation technique ................................................ 65

Compatibilité électromagnétique (CEM) ............................ 66

Raccordement standard des signaux d’E/S ...................... 68

Exemple de schéma de câblage ....................................... 69

Câblage du ventilateur ...................................................... 71

Emplacement des bornes sur le convertisseur .................. 72

Consignes de sécurité et d’exploitation............................. 73

Installation des outils logiciels du DCS800 sur votre PC .... 74

Mise en service ................................................................. 75

Micro-console DCS800 .................................................... 76

Dimensions, perçages et poids ........................................ 77

Liste des défauts / alarmes .............................................. 79

Messages de diagnostic.......................................... ......... 88

Structure du logiciel macro & système .............................. 93

Déclaration de conformité ............................................... 106

Certificat du fabricant ....................................................107

italiano Indice

DC Drives Worldwide Service Network .............................. 3

DCS800 Drive Manuals / DCS800 Manuali Drive ................4

DCS800 DC Drives ........................................................... 35

Brevi istruzioni CD e documentazione ............................... 37

Note sulle EMC ................................................................. 38

Assegnazione funzioni standard per i morsetti ..................40

Esempi schemi di collegamento........................................41

Fan power connection ...................................................... 43

Terminal locations on the converter ................................... 44

Istruzioni per la sicurezza e il funzionamento ..................... 45

Installa i DCS800 PC tools sul Tuo computer .................... 46

Messa in servizio ..............................................................47

Descrizione display ........................................................... 48

Disegni dimensionali ........................................................77

Fault / Alarm list ............................................................... 79

Diagnosis messages.......................................... ............... 88

Struttura macro & firmware ............................................... 93

Dichiarazione di conformità ............................................. 106

Certificato del costruttore ..............................................107

2

3ADW000191R0500 DCS800 Quick guide edisf e

ABB Drive Service EN

In order to offer the same after sales
service to our customer around the
world, ABB has created the DRIVE
SERVICE CONCEPT.

ABB's after sales service is globally
consistent due to common targets,
rules, and the way of operation. This
means for our customers:

Please visit the ABB drive service
homepage

www.abb.com/drivesservices

ABB Drive Service FR

Pour offrir la même qualité de service
à tous nos clients, ABB a créé DRIVE
SERVICE CONCEPT.

Dans le monde entier, les équipes
de service proposent les mêmes
prestations aux mêmes conditions
avec les mêmes objectifs.

Pour en savoir plus, connect­ez-vous sur ABB drive service
homepage

www.abb.com/drivesservices

ABB Drive Service DE

Um jedem Kunden rund um die
Welt die gleiche Service Dienstleis­tung anbieten zu können, hat ABB
das DRIVE SERVICE CONCEPT
entwickelt.

Durch die Definition von einheitlichen
Zielen, Regeln, und Arbeitsvorschrif­ten kann ABB die Dienstleitungs
Produkte weltweit auf gleichwertig
hohem Qualitätsniveau anbieten. Für
unsere Kunden bedeuted dies:

Bitte besuchen Sie die ABB­Homepage Service für Antriebe

www.abb.com/drivesservices

ABB Drive Service IT

ABB ha creato il DRIVE SERVICE
CENCEPT, con lo scopo di offrire ai
nostri clienti lo stesso servizio post
vendita in tutto il mondo.

Attraverso la definizione di obbiettivi
comuni, ruoli e modo di operare, le
attività post vendita di ABB offrono
sevizi coerenti nella loro globalità. Per
i nostri clienti questo significa:

Vi invitiamo a visitare la homepage
ABB drive service

www.abb.com/drivesservices

ABB Drive Service ES

Para poder ofrecer el mismo ser­vicio posventa a nuestros clientes
en todo el mundo, ABB ha creado
el CONCEPTO DE SERVICIO DE
CONVERTIDORES.
El servicio posventa de ABB está
mundialmente consolidado gracias
a unos objetivos y normas comunes,
así como a su funcionamiento. Esto
significa para nuestros clientes:
Visiten el portal de convertidores

de ABB

www.abb.com/drivesservices

DC Drives Worldwide Service Network

Country Local ABB Service Town Service Phone No.
Argentina Asea Brown Boveri S.A. BUENOS AIRES [phone]
Australia ABB NOTTING HILL [phone]
Austria ABB AG WIEN [phone]

Belgium ABB N.V. ZAVENTEM

Brazil ABB Ltda. OSASCO [phone]
Canada ABB Inc. SAINT-LAURENT [phone]
China ABB China Ltd BEIJING [phone] - 24h service
Czech Republic ABB S.R.O. PRAHA [phone]
Finland ABB Oy Service KUUSANKOSKI [phone]
Finland ABB Oy Product Service HELSINKI [phone]
Finland ABB Oy Service NOKIA [phone]

France

Germany ABB Process Industries MANNHEIM [phone]
Greece ABB SA METAMORPHOSSIS [phone]
Ireland ABB Ireland Ltd. TALLAGHT [phone]
Italy ABB MILAN [phone]
Korea, Republic ABB Ltd., Korea CHONAN [phone]
Malaysia ABB Malaysia Sdn. Bhd. KUALA LUMPUR [phone]
Mexico ABB Sistemas S.A. DE C.V. TLALNEPANTLA [phone]
Netherlands ABB B.V. ROTTERDAM [phone]
New Zealand ABB Service ltd AUCKLAND [phone]

Poland ABB Centrum IT Sp.zo.o

Russia ABB Automation LLC MOSCOW +74 95 96 0
Switzerland ABB AG DÄTTWIL [phone]
Singapore ABB Industry Pte Ltd SINGAPORE [phone]
Slovakia ABB Elektro s.r.o. BANSKA BYSTRICA [phone]
South Africa ABB South Africa (Pty) Lt JOHANNESBURG [phone]
Spain ABB Automation Products BARCELONA [phone]
Taiwan ABB Ltd. TAIPEI 105 [phone]
Thailand ABB Limited SAMUTPRAKARN [phone]
Turkey ABB Elektirk Sanayi A.S ISTANBUL [phone]

USA ABB Industrial Products NEW BERLIN
Venezuela ABB S.A. CRCS [phone] / 12

ABB Automation
ABB Process Industry

MONTLUEL from abroad
France

WROCLAW
LODZ

[phone]
[phone] - 24h service

[phone]
+0810 02 00 00

[phone]
[phone]

[phone]
[phone]

3ADW000191R0500 DCS800 Quick guide edisf e

3

DCS800 Drive Manuals

DCS800 Quick Guide
DCS800 Tools & Documentation CD
DCS800 Converter module

Flyer DCS800 3ADW000190 x x x x x x x
Technical Catalogue DCS800 3ADW000192 x x x x x x x
Hardware Manual DCS800 3ADW000194 x x p x 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 x
DCS800 Crane Drive 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 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

Language

4

3ADW000191R0500 DCS800 Quick guide edisf e

english

Standard Features

• compact

• highest power ability

• simple operation

• comfortable assistants, e.g. for autotuning or commissioning

• scalable to all applications

• free programmable by means of integrated IEC61131-PLC

3ADW000191R0500 DCS800 Quick guide edisf e

5

DCS800 DC Drives

Technical data

Mains supply volt. 230...1,200 V,

+/–10 %, 3~

Frequency 50...60 Hz, +/–5

Hz

Electronics supply 115...230 V,
–15 % / +10 %, 1~

DC Output current 20...5,200 A
Overload capability 200 %

Ambient conditions

Ambient temperat. 0° ... +40° C
40° ... 55°C with

reduction
Storage temperat. –40° ... +55° C
Transport temper. –40° ... +70° C
Relative humidity 5 ... 95 %, not

condensing
(max. 50 % betw.

0°...5° C)
Pollution degree Class 2
Protection class IP 00
Altitude < 1,000 m height

above sea level:

nominal Current

> 1,000 m height

above sea level:

with reduction

I/O

Digital inputs: 8 standard, up to

14 optional
Digital outputs: 8 standard, up
to 12 optional
Analog inputs: 4 standard +/–
10 V; 0/2…10 V, up to 8 optional
+/ 20 mA; 0/4…20 mA
Analog outputs: 3 standard (1x
I

) +/-10 V; 0/2…10 V, up to 7

act

optional –20 mA; 0/4…20 mA

PC-Tools

DriveWindow Light: free of

charge with every converter,
Standard RS232 PC-connection
DriveWindow: Real-time optical
connection
ControlBuilder DCS800:
IEC61131 programming tool
DriveSize: Converter- and motor
dimensioning

Maintenance / Diagnosis

Remote diagnosis with any
Internet-PC worldwide

• with internet browser / internet
explorer

• or with DriveWindow full drive
control via OPC

Approvals

Adaptive Programming

pre-defined drive-specific
function blocks, e.g.

• Free process controller (PI­Controller)

• I/O- and digital Operations

With control panel or PC-Tool, no
need for additional hardware

Speed Feedback

EMF
Analogue tacho
Encoder
2nd Encoder possible (RTAC)

Communication

Serial communication

• Ethernet • Profibus

• CANopen • DeviceNet

• ControlNet • DDCS

• Modbus

• CS31 • AF100

• Selma2

Industrial IT© enabled

DCSLink Peer-to-Peer

• up to 800 kBaud, < 2.5 ms

• Master-Follower

• Armature-fieldconverter

• Free selectable data

High Current Solutions

• 12-pulse up to 20,000 A, serial
and parallel

• Hard parallel and sequential

• up to 1,500 V

Protections

Speed feedback monitoring •
Temperature • Overload • Over
speed • Motor stalled • Motor
over current • Motor over voltage

• Field over current • Field over

voltage • Minimum field current

• Zero speed • Armature current

ripple • Mains over- and under
voltage

Integrated IEC 61131-PLC

• Open standard programming

tool ControlBuilder DCS800

• Support of all five IEC-

languages

• Drive-specific function blocks

• Saving of program and source

in Memory Card

• Online debugging and forcing

Current ratings, dimensions

Unit size 2-Q

rated Current

DCS800-01

IDC[A] IDC[A] 400 525 600 690 800 990 1200 [ADC] h x w x d [mm] h x w x d [inch]

D1 20 25

45 50
65 75
90 100
125 140

D2

180 200

230 260

D3 315 350

405 450
470 520

D4 610 680

740 820
900 1000

D5 900 900 25 1050 x 510 x 410 41.35 x 20.10 x 16.15

1200 1200
1500 1500
2000 2000

D6 1900 1900

2050 2050
2500 2500
3000 3000

D7 2050 2050

2600 2600
3300 3300
4000 4000
4800 4800
5200 5200

4-Q

rated Current

DCS800-02

Supply voltage

[V

]

AC

3)

3)

1)

1)

2)

1)

only available as 2-Q drive

2)

max. field

Dimensions
current
internal

6 370 x 270 x 200 14.56 x 10.65 x 7.90

15 370 x 270 x 270 14.56 x 10.65 x 10.65

20 459 x 270 x 310 18.07 x 10,65 x 12,25

25 644 x 270 x 345 25.35 x 10.65 x 13.60

external field

1750 x 460 x 410 68.90 x 18.15 x 16.15
35A, 1~/3~
50/60A, 1~

520A, 3~

external field

35A, 1~/3~

1750 x 760 x 570 68.90 x 29.95 x 22.45

50/60A, 1~

520A, 3~

2)

on request

3)

600V
2-Q -> 290 A / 590 A
4-Q -> 320 A / 650 A

6

3ADW000191R0500 DCS800 Quick guide edisf e

Brief instructions for CD and documents overview

We appreciate that you purchased an ABB DC drive
power converter and thank you for the trust you put in our
products.

This brochure was put together to make sure that you continue
to be satisfied with our product. It is intended to provide you
with a brief overview of the product's key data, EMC notes,
typical applications, start-up and trouble-shooting.

If you need more information about the product you are
provided with a CD-ROM in addition to this brief documen-
tation. The CD-ROM is part of this document and features
the following contents:

System requirements to use the CD-ROM

• Operating system WIN­DOWS 2000, XP

• ACROBAT READER 4.0 is
sufficient (we recommend

8.0 - included on the CD­ROM)

In case the CD ROM does not start automatically please
double-click on Setup.exe.

english

Documentation

Our documentation is basically structured according to the
following system:

Technical catalogue (3ADW000192)
as comprehensive information to engineer complete DC
drive systems.

Hardware manual (3ADW000194)
as detailed information, with all important particulars about
the individual components, like module dimensions, electronic
boards, fans and auxiliary components.
Information for mechanical and electrical installation are
also included.

Firmware Manual (3ADW000193)
detailed information with all important issues about firmware
and setting of parameters. The manual includes information
for start-up and maintenance of the entire drive, in detailed
form.
This manual also includes Fault and Alarm codes and infor­mation for trouble shooting.

Service Manual (3ADW000195)
for maintenance and repair of the converters.

Further support

In addition we offer further support, since we can only be
satisfied when you, as our customer, are satisfied with us
and our products.

Internet

On the ABB homepage under

www.abb.com/dc

you'll find abundant information for

• DC products

• service support

• the latest updates

• tools

• downloads, etc.

Please don't hesitate to visit us.

Contacts

If you require any further information, please contact your
nearest ABB Drives office or send an email to:

[e-mail]

Please give us your name, your company address and
phone number. We immediately put you in contact with our
specialist.

Applications

DCS800 DC Drive can include application software e.g.
cranes, winders. In such case following procedures and
assistants can be blocked or not completed. Please check
for further documentation and manuals (check parameter

4.03, 83.01).

Additional information about applications (e.g. 12-pulse)
and technical accessories (e.g. Hardware extension or
Field bus interfaces) are handled by separate manuals. See
table DCS800 Drive manuals.

3ADW000191R0500 DCS800 Quick guide edisf e

7

Notes on EMC

MM

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-voltage network

together with other

loads of all kinds.

Residential area

To other loads which have to be protected from the system disturbances caused by

power converters (HF interference and commutation notches)

Converter

MM

MM

MM

alternative

alternative

Line reactor +
Y-capacitor

Medium-voltage network

Supply transformer for a residential
area (rating normally ≤ 1.2 MVA)

Earthed
neutral

Earthed public 400-V
network with neutral
conductor

To other loads, e.g. drive systems

Mains filter

Line reactor

Converter Converter

Mains filter

Line reactor

Converter Converter

An isolating transformer
with an earthed screen
and earthed iron core
renders mains filter and
line reactor superfluous.

Operation at public

low-voltage network

together with other

loads of all kinds.

To other loads, e.g. drive systems

To other loads which have to be protected from the system disturbances caused by

power converters (HF interference and commutation notches)

Earthed public 400-V
network with neutral
conductor

Operation at public

low-voltage network

together with other

loads of all kinds.

Light industry

Residential area

Commutaion notches < 20%

You will find further informa­tion in publication:

Technical Guide chapter:
EMC Compliant Installa­tion and Configuration for
a Power Drive System

Not applicable

The paragraphs below describe selection of
the electrical components in conformity with
the EMC Guideline.
The aim of the EMC Guideline is, as the name

The EMC Guideline expects EMC to be taken
into account when a product is being developed;
however, EMC cannot be designed in, it can only

be quantitatively measured.
implies, to achieve electromagnetic compa­tibility with other products and systems. The
guideline ensures that the emissions from
the product concerned are so low that they
do not impair another product‘s interference
immunity.
In the context of the EMC Guideline, two

Note on EMC conformity

The conformity procedure is the responsibility of

both the power converter‘s supplier and the manu-

facturer of the machine or system concerned, in

proportion to their share in expanding the electrical

equipment involved.
aspects must be borne in mind:

• the product‘s interference immunity

• the product‘s actual emissions

First environment (residential area with light industry) with PDS category C2

Not applied, since category C1 (general distribution sales channel) excluded

satisfied

satisfied

8

3ADW000191R0500 DCS800 Quick guide edisf e

For compliance with the protection objectives

MMMM

emv_clssif_b.dsf

Converter
transformer

Case-referenced EMC analysis

alternative

Converter
transformer
with earthed

iron core
(and earthed
screen where
appropriate)

alternative

I > 400 A
and/or
U > 500 V

Operation with separate power converter transformer. If there
are other loads at the same secondary winding, these must be
able to cope with the commutation gaps caused by the power
converter. In some cases, commutating reactors will be
required.

To other loads, e.g. drive systems

Converter Converter

Line reactor

Medium-voltage network

Industrial
zone

MM

MM

MM

I

DC

< 100 A

I

DC

< 100 A

I

DC

>100 A

Supply transformer for a
residential area (rating
normally ≤ 1.2 MVA)

Earthed 400-V network
with neutral conductor

;

3~ ≤ 400 A

Operation at low-voltage network together with
other loads of all kinds, apart from some kinds
of sensitive communication equipment.

To other loads, e.g. drive systems

Line reactor +
Y-capacitor

Line reactor

Converter Converter

Mains filter

Earthed
neutral

Medium-voltage network

Industrial zone

alternative

alternative

Line reactor

Converter

alternative

Commutation notches < 40%

of the German EMC Act (EMVG) in systems and
machines, the following EMC standards must
be satisfied:

Product Standard EN 61800-3

EMC standard for drive systems (PowerDrive-
System), interference immunity and emissions

in residential areas, enterprise zones with light
industry and in industrial facilities.
This standard must be complied with in the EU
for satisfying the EMC requirements for systems
and machines!

Second environment (industry) with PDS categories C3, C4

For emitted interference, the following apply:

EN 61000-6-3 Specialised basic standard for emissions in light industry

can be satisfied with special features (mains filters, screened
power cables) in the lower rating range *(EN 50081-1).

EN 61000-6-4 Specialised basic standard for emissions in industry

*(EN 50081-2)

For interference immunity, the following apply:

EN 61000-6-1 Specialised basic standard for interference immunity in

residential areas *(EN 50082-1)

EN 61000-6-2 Specialised basic standard for interference immunity in in-

dustry. If this standard is satisfied, then the EN 61000-6-1

standard is automatically satisfied as well *(EN 50082-2).

* The generic standards are given in brackets

Standards

EN 61800-3

english

Not applicable

satisfied

on customer's request

satisfied

PDS category C3 PDS category C4

satisfied

EN 61000-6/3

EN 61000-6/3

EN 61000-6-2
EN 61000-6-1

Classification

The following overview utilises the
terminology and indicates the ac­tion required in accordance with
Product Standard

EN 61800-3

For the DCS800 series, the limit
values for emitted interference
are complied with, provided the
measure indicated is carried
out. PDS of category C2 (for­merly restricted distribution in
first environment) is intended to
be installed and commissioned
only by a professional (person
or organization with necessary
skills in installing and/or com­missioning PDS including their
EMC aspects).

For power converters without
additional components, the fol­lowing warning applies:
This is a product of category C2
under IEC 61800-3:2004. In a
domestic/residential environment
this product may cause radio
interference in which case sup­plementary mitigation measures
my be required.

The field supply is not depicted
in this overview diagram. For the
field current cables, the same
rules apply as for the armature­circuit cables.

3ADW000191R0500 DCS800 Quick guide edisf e

9

X2:

X1:

ATACH

±90...±270 V

±

30...±90 V

±

8...±30 V

AI4
(5 ms)

GND

GND

39k2

+10V

Power

Sense 0 V

Sense 5 V

AI3
(5 ms)

AI1
(3.3 ms)

+/- I-act

47.5

100

µ

100n

GND (AOx)

+10V

GND

-10V

DI1

DI3

DI4

DO4

DO5

DO1

4k75

3

4

5

6

9

X6:1

3

4

10

4

5

1

2

3

6

5

10

8

9

10

5

2

6

8

10

8

X3:1

X4:1

X5:1

X7:

SDCS-CON-4

Firmware

GND

1

3

S1

Con4_I_O-b.dsf

12k8

5k

1k66

+

-

4

6

S1

S2

3

4

250

S3

56

78

S3

3

4

250

+

-

SDCS-IOB-3

(PS5311)

9

8

7

ATACH1

ATACH2

S1

+

-

+

-

+

-

+

-

GND

1

3

S4

2

121

100nF

4

6

S4

5

121

100nF

7

10

S4

8

121

100nF

10k

10k

10k

+

-

+

-

+

-

PIN-4

= 5 V

S4

11

12

2k21 221k

4k75

47nF

Z15

+

-

5 V

Relay driver

Relay driver

Relay driver

Relay driver

Relay driver

Relay driver

Relay driver

X

9

τ

= 10 ms

τ

= 10 ms

τ

= 10 ms

τ

= 10 ms

τ

= 10 ms

τ

= 3.3 ms

τ

= 3.3 ms

ChA

ChB

ChZ

ChA

ChB

ChZ

POW-4

=

5V/

15V/24V

CON-4

= 24 V

Resolution

[bit]

Encoder supply

Input value

Signal

definition by

Output value

Signal

definition by

Standard function assignments for the terminals

10

3ADW000191R0500 DCS800 Quick guide edisf e

Input/output

values

Hardware

15 + sign ±90...270 V

±30...90 V

ScalingbyCommon

mode
range

①

±15 V

Firmware

Remarks

±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 ±15 V

15 + sign -10...0...+10 V Firmware ±15V

Power

+10 V ≤ 5 mA

-10 V ≤ 5 mA

for ext. use
e.g. refer. pot.

11 + sign -10...0...+10 V Firmware ≤ 5 mA
11 + sign -10...0...+10 V Firmware ≤ 5 mA

-10...0...+10 V Firmware+
Hardware

≤ 5 mA

8 V -> min. of
325% of [99.03] or
230% of [4.05]

Remarks

Inputs not isolated
Impedance = 120 W, if selected
max. frequence ≤ 300 kHz

5 V

24 V

≤ 250 mA
≤ 250 mA

Sense lines for GND and supply
to correct voltage drops on cable
(only if 5 V encoder is in use).

Remarks

0...7.3 V

7.5...50 V

Firmware

-> “0“ status

-> “1“ status

Remarks

50 * mA

22 V at no

load

Firmware

Current limit for all 7
outputs = 160 mA
Do not apply any reverse
voltages!

* short circuit protected
① gain can be varied in 15 steps between 1 and 4 by software parame-

ter

F6

DCS8_ans_1_1d.dsf

Connection example

Converters D1...D4 drive configuration using ‘OnBoard‘ field exciter

Terminal selection according FACTORY macro (default)

english

3ADW000191R0500 DCS800 Quick guide edisf e

further information see the following page

11

ON
RUN
RESET

MCW (7.01)

ON
RUN
RESET

ON
RUN
RESET

7.04

gen_ctrl_cmd_a.dsf

USED MCW

HW I/O

command
location (10.01)

PC tool or panel

local /
remote

used
Main Control Word

START, STOP and E-STOP control

K16

K15 K16

K15

DI4

K15

X6:9

CON-4

S1

1

2

Anschl_special_a.dsf

EMER.
STOP

ELEC.
DISCONN.

Block
current
command

Timer K15

Timer K16

Stop-Mode_a.dsf

E-STOP

speed

Block current control

K1 main contactor

E-Stop ramp Coast

The relay logic can be split into three parts:
a: Generation of the ON/OFF and START/STOP com-

mand:
The commands represented by K20 and K21 (latching inter­face relay) can be e.g. generated by a PLC and transferred to
the terminals of the converter either by relays, using galvanic
isolation or directly via 24V signals.
These commands can be as well transferred via serial
communication. Even a mixed solution can be realized by
selecting different possibilities for the one or the other signal
(see parameter group 11).

b: Generation of control and monitoring signals:
The main contactor K1 for the armature circuit is controlled
by a dry contact (DO 8) located on the SDCS-PIN-4. Status
of fans and fans klixon can be monitored by means of fan
ack signals: MotFanAck (10.06) and ConvFanAck (10.20).

If the drive has not finished the function within the K15 timer
setting, the drive must get the command to switch OFF the
current via K16. After K16 timer set has elapsed the main
contactor is opened independent of the drives status.

c: OFF2, OFF3 Stop function:
Beside ON/OFF and START/STOP, the drive is equipped
with two additional stop functions, OFF2 and OFF3, accor­ding to Profibus standard. OFF3 is a scalable stop function
(rampstop, max torque stop, dynamic braking …) 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 the
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 normal DC motor load the time to switch
OFF the DC current is below 20 ms. This function should be
connected to all signals and safety functions opening the main
contactor. This function is important for 4-quadrant drives.
Do not open main contactor during regenerative current.

The correct sequence is

1. switch off regenerative current

2. then open the main contactor

In case of the E-STOP is hit, the information is transferred
to the converter via digital input 5. In case of rampstop, or
max torque selection the converter will decelerate the motor
and then open main contactor.

12

3ADW000191R0500 DCS800 Quick guide edisf e

E-Stop reaction

Fan power connection

1 2 3

X2:

4 5

L

N

230 Vac

1 2 3

X2:

4 5

L

N

115 Vac

M

~

1 2 3

X2:

M

~

4 5

M55 M56

M

~

1 2 3

X2:

M

~

4 5

M55 M56

M

~

M

~

M57 M58

M55

M

~

1 2 3 4 5

X2:

L

N

L

N

1 2 3

X2:

4 5

L

N

230 Vac

1 2 3

X2:

4 5

L

N

115 Vac

ϑ

230 VAC

or

115 VAC with Pluscode +S171

DCS8 fan conn D1-D4.dsf

Fan assignment for DCS800

Converter type Model Configuration Fan voltage

DCS800-S01-0020-04/05...
DCS800-S02-0025-04/05

DCS800-S0x-0045-04/05...
DCS800-S0x-0140-04/05

DCS800-S0x-0180-04/05...
DCS800-S0x-0260-04/05

DCS800-S0x-0315-04/05...
DCS800-S0x-0350-04/05

DCS800-S0x-0405-04/05...
DCS800-S0x-0520-04/05

DCS800-S0x-0610-04/05...
DCS800-S0x-0820-04/05

DCS800-S0x-0610-04/05...
DCS800-S0x-0820-04/05

Pluscode S171

DCS800-S0x-0900-04/05...
DCS800-S0x-1000-04/05

DCS800-S0x-0900-04/05...
DCS800-S0x-1000-04/05

Pluscode S171

Fan connection for DCS800

Terminals on top of converter housing

D1 - no fan

D1 1 115 or 230 VAC

D2 1 115 or 230 VAC

D3 1 115 or 230 VAC

D3 2 115 or 230 VAC

D4 3 230 VAC

D4

3 115 VAC

D4 3 230 VAC

D4

3 115 VAC

english

Configuration 1

D1- D3

Configuration 2

D3

3ADW000191R0500 DCS800 Quick guide edisf e

Configuration 3

D4

13

DCS800 terminal alloc.dsf

X4X3 X5 X6 X7

1 1 1 1 1

2

S5

1

15

6 9

S3

S2

1

X1

X2

X17

2

25
26

1
2

25
26

S4

1
2

1

2

1

2

1

2

H2500

1

2

D2100

1

D2001

D2001

D1000

1 30

1

2

1

2

1

2

1

26

S1

1

42

1

2

3

10

11

12

1

82

1

42

1

2

3

7

8

9

Jumpers shown in default position

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

X8

1

42

S2

S1

1

2

3

X51 X52 X53 X54

24V

DCS Link

24V

0V

GND B

CANL

CANH

GND B

CANL

CANH

grey

grey

grey

grey

dark

grey

dark

grey

d

ark

grey

blue

blue

RxD

CH 1

TxD

RxD

CH 2

TxD

RxD

CH 3

TxD

RxD

Terminal locations on the converter

Macro finder

DI function

Jog1 --> DI1
Jog2 --> DI2
Ext Fault --> DI 3
Ext Alarm --> DI4

Jog1 --> DI1
Jog2 --> DI2
Ext Fault --> DI 3
Main Cont Ack --> DI4

Fix speed1 --> DI1
Ext Fault --> DI 3
Main Cont Ack --> DI4

Fix speed1 --> DI1
Ext Fault --> DI 3
Ext Alarm --> DI4

Jog1 --> DI1
Jog2 --> DI2
Ext Fault --> DI 3
Ext Alarm --> DI4

Jog1 --> DI1
Jog2 --> DI2
Direction --> DI 3
SpC - KP, KI --> DI4

Control select --> DI2
Reference select --> DI2
Direction select --> DI 3

Motor pot up --> DI1
Motor pot down --> DI2
Direction select --> DI 3
Reference select --> DI4

Direction select --> DI 1
Motor pot up --> DI2
Motor pot down --> DI3
Motor pot minimum --> DI4

OFF2 (coast stop) --> DI1
Torque select --> DI2
Ext Fault --> DI 3

Standard

Macro name

Main

Contactor

ON / OFF

Start/Stop

AC Static

2-wire DC cont. US

DC Static

3-wire DC cont. US

DC Pulse

3-wire Standard

Torque limit

Manual / Const

AC Pulse

AC Static

AC Pulse

Hand / Auto

AC Static

Hand / Mot Pot

AC Pulse

AC Static

AC Static

Motor Pot

Torque Ctrl

Comment DI5 --> ESTOP

Hardware I/O control x

Hardware I/O control x

Hardware I/O control x

Hardware I/O control x

Hardware I/O control

+ Torque limit

Hardware I/O control

select gain

Hardware I/O control

or field bus control

Hardware I/O control

Reference hardware or Motor

potentiometer

Hardware I/O control

Reference Motor potentiometer

Hardware I/O control

Speed control or Torque

reference

DI6 --> Reset

x

x

x

x

x

x

Enabling a macro

Use the

[DCS800Wizard] 2. Macro
assistant of DriveWindow

Light or

Parameter browser, either
through the control panel,
DriveWindow, or DriveWindow
Light.

Use the following parameters:

ApplMacro (99.08) =

Macro selection

Applrestore (99.07) =

YES = execute selection

MacroSel (8.10) =

double check

NOTE
Functions and inputs defined
by macro can be changed la­ter on without restrictions.

NOTE
Macro diagrams see page
93 ...

14

3ADW000191R0500 DCS800 Quick guide edisf e

Notes For North American Installations

1. EMC conformity is not usually required in North Ame­rica. In most cases, the section “Notes on EMC” can be
bypassed. In this manual, you will see references to DIN, EN
and VDE standards. These are European standards and,
generally, do not apply to North America. It is, however,
the responsibility of the user to determine which standards
need to be followed.

2. If using a DC contactor, you must connect an auxiliary

contact to a digital input of your choice and set para. Main-
ContAck accordingly. Set the following parameters:
MainContAck (10.21) = DI-1 (or any input you

choose for the DC cont.
auxiliary contact)

DO8BitNo (14.16) = 10
MainContCtrlMode (21.16) = DCcontact (3)

Set these parameters AFTER macros are loaded but BEFORE
the drive is commissioned.

Digital output 8 (DO-8) must be used to turn the DC
contactor on and off.

DC contactor US:

DC contactor US K1.1 is a special designed contactor with 2x
NO contacts for C1 and D1 connection and 1x NC contact for
connection of Dynamic Brake resistor RB.
The contactor should be controlled by signal 6.03 Bit 10.
The acknowledge can be connected to parameter:

10.21 MainContAck

10.23 DCBreakAck

3. If using Dynamic Braking, the drive allows you to se­lect the stopping method under three different situations.
Parameters 21.02, 21.03 and 21.04 select the stopping
method for loss of
the OnOff, run command (StartStop, Jog1, Jog2, etc.), and
E-Stop input, respectively.
Each can be set to:

• RampStop • TorqueLimit

• CoastStop • DynBraking

In order to command the drive to perform a DB stop, one
or more of these parameters must be set to DynBraking.
Most users will want the drive to ramp stop when OnOff or a
run command (StartStop, Jog1, Jog2, etc.) input is cleared,
and dynamically brake when the E-Stop input is cleared. In
that case, use the following settings:

• Off1Mode (21.02) = RampStop

• StopMode (21.03) = RampStop

• E StopMode (21.04) = DynBraking

However, any case is allowed and the final decision is left
to the user.

Other parameters control stops during faults.
See:
LocalLossCtrl (30.27) ComLossCtrl (30.28)
FaultStopMode (30.30) SpeedFbFltMode (30.36)

If using EMF feedback with dynamic braking, set:

• DynBrakeDly (50.11) = t
Where: t = the time (sec) it normally takes the motor

to stop during dynamic braking

english

Overview of the Installation and Commissioning Process

Step 1:

Check converter for damage. Contact ABB Technical Support
if damage is found. In North America, call 1-800-435-7365

(1-800-HELP-365)

Step 2:

Select supporting hardware for the converter:

For specific recommendations for fuses, reactors, and
contactors, see the DCS800 hardware manual or technical
catalog.

Circuit breaker or disconnect:
Current rating = Idc * 0.816 * 1.25 (min)
= Idc * 0.816 * 2.50 (max)
Where: Idc = nominal DC motor current

Fuses:
AC Line Fuses: To properly protect the converter, semi­conductor fuses on the incoming AC power line are required
in all cases.

DC Output Fuses: Fuses between the motor and the
converter are required for all regenerative (4-Q) converters.

This is to protect the motor and converter if a commutation
fault should occur. NOTE: DC output fuses are the same
type and size as AC line fuses.

Line reactor:
All thyristor-based dc converters cause notching in the AC
line due to motor commutation. A properly sized line reactor
will mitigate the effect on the line. Unless the converter uses
a dedicated isolation transformer, each converter requires
its own line reactor.

AC or DC contactor:
A contactor is required to safely disconnect the motor from
the incoming power when the converter is off. The contactor
can be installed between the line and the converter (an AC
contactor) or between the converter and the motor (a DC
contactor). Do not use both.

IMPORTANT: Other equipment may be necessary de­pending on application and local codes.

3ADW000191R0500 DCS800 Quick guide edisf e

15

Step 3:

Mount and wire the converter and supporting hardware in­side an industrial enclosure with adequate cooling (DCS800
modules have rating of NEMA type OPEN).
The following control and signal wiring is required:
o If using an AC contactor, we recommend wiring an auxi-

liary contact to the digital input you have designated as

MainContAck (10.21) or Start/Stop (10.16).
o If using a DC contactor, you must wire an auxiliary contact

from the contactor to the digital input you have designated

as MainContAck (10.21).
o Wire 115 or 230 Vac 1-phase power to terminal block 99

for converter control power.
o Wire 1-phase power to converter for cooling fans. See

table and wiring diagrams in this manual.

• D1 – D3 frames: 115/230 Vac selectable. Fan

terminal X2 is on top of the converter.

• D4 frame: If type code includes +S171, use 115

Vac; otherwise use 230 Vac. Fan terminal X2 is
on top of the converter.

o Wire tachometer or encoder to terminal block X3 (tacho)

or X5 (encoder).
o Wire analog inputs (e.g., speed reference) and outputs

(e.g., meters for motor voltage, current) to terminal block

X3 and/or X4.
o Wire high speed serial interface if needed. (Requires

optional fieldbus interface board.)
o The DCS800 allows you to choose the usage of each

digital and analog input and output. The converter has

factory default settings which can be changed by loading

a macro, but some designations are universal. They

include:

• Digital input 5: Estop

• Digital input 6: Fault reset

• Digital input 7: On/Off (maintained) or On-Start

(pulsed)

• *Digital input 8: Start/Stop (maintained) or Off-

Stop (pulsed)

• Digital output 8: Main Contactor On (3 Amps

max. at 115 – 230 Vac)
*except Hand/Auto macro
o Other signals may be required depending on your ap-

plication (e.g., motor fan acknowledge input, Off2 input,
fan-on output, brake output).

o You will select the macro and / or choose the configuration

for digital and analog inputs and outputs in step 2 of the
commissioning process, or by updating group 10 and 14
parameters.

o Check all wire terminations (with continuity tester) before

proceeding to the next step.

Step 4:

Connect the drive system to incoming power and the motor to
the converter (both field and armature) as well as accessory
equipment (motor fan, thermal switch, brake, etc.).
o See hardware manual for typical cable size and tightening

torque recommendations.

o IMPORTANT: Be sure all safety equipment is properly

sized for your application

Step 5:
Apply control power to the converter.
o IMPORTANT: See section “Safety and Operating

Instructions” in this manual before proceeding.

o Apply power to terminal block 99 and X2. The keypad

should light up and show the menu screen. The converter
fans should start to run (if converter has fans).

Step 6:
Commission the converter using Drive Windows Light
(preferred) or the control panel.
o IMPORTANT: See safety alerts and general instructions

in the section “Commissioning” before proceeding.

o Install the DCS800 PC tools on your computer. Instructions

are in this manual. Use DriveWindow Light to commission
your converter.

o If no PC is available, commission your drive using the

control panel as follows:

• On the control panel, press the softkey to select
MENU.

• Using the down arrow, select ASSISTANTS. Then
press ENTER.

• Starting with “name plate data,” press SEL.
Change the value with the arrow keys. Then press
SAVE.

• Repeat above with other parameters. Follow
directions on the screen.

Configuring and Displaying analog and digital I/O

HINT: To see if the drive is responding to an “on” or “run” command, view signal 8.08.

Control Panel:

o Digital Status: View signal 8.05 (DI’s) or 8.06 (DO’s).

Display is in hexadecimal.
o Configure digital inputs with Group 10.
o Analog Status: View signal 5.03 (AI1) or 5.11 (AO1).

Display is in Volts.
o Configure analog speed ref. with Group 11.

DriveWindow Light:

o Connect to the DCS800 and go on line by clicking on

File, then New Online Drive.
o Click on Wizard, at left side of the screen.
o Click on Advanced.
o Check the box for “I/O assistant,” then click on Next.
o Click on “edit parameters” in the appropriate section

(analog or digital inputs or outputs).

16

3ADW000191R0500 DCS800 Quick guide edisf e