ABB DCS800 Firmware Manual

4.5 (2)

DCS800

Firmware manual

DCS800 Drives (20 to 5200 A)

DCS800 Drive Manuals

All the documents available for the drive system DCS800 are listed below:

			Language
		Public. number	E	D	I	ES	F	CN	RU	PL
DCS800 Quick Guide		3ADW000191	x	x	x	x	x
DCS800 Tools & Documentation CD		3ADW000211	x
DCS800 Converter module
Flyer DCS800		3ADW000190	x	x		x	x
Technical Catalogue DCS800		3ADW000192	x	x	x	x	x	x	x
Hardware Manual DCS800		3ADW000194	x	x	x	x	x	x	x	x
Hardware Manual DCS800 update DCF503B/DCF504B		3ADW000194Z0301	x
Firmware Manual DCS800		3ADW000193	x	x	p	x	x	x	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	x	x

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 Analog IO Extension		3AFE64484567	x
RDIO-01 Digital IO Extension		3AFE64485733	x
RRIA-01 Resolver Interface Module		3AFE68570760	x
RTAC-01 Pulse Encoder Interface		3AFE64486853	x
RTAC-03 TTL Pulse Encoder Interface		3AFE68650500	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 04.2010

DCS800 Drive Manuals-List_j.doc

Safety instructions

What this chapter contains

This chapter contains the safety instructions 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

The information is valid for the whole range of the product DCS800, the converter modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the Rebuild Kit DCS800-R00-9xxx.

Usage 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, and advise on how to avoid the danger. Notes draw attention to a particular condition or fact, or give information on a subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause physical injury or death and/or damage to the equipment.

General danger warning warns about conditions, other than those caused by electricity, which can result in physical injury or death and/or damage to the equipment.

Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment.

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

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 and/or damage to the equipment.

WARNING!

•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 the frame is close to 0 V.

2.Voltage between terminals C+ and D- 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 resistance or voltage withstand tests on the drive or drive modules.

•Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor.

•When reconnecting the motor cable, always check that the C+ and D- cables are connected with the proper terminal.

Note:

•The motor cable terminals on the drive are at a dangerously high voltage when the main 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 relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO).

•DCS800 with enclosure extension: Before working on the drive, isolate the whole drive system from the supply.

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

Grounding

These instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic interference.

WARNING!

•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 and marked 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 (e.g. conductive sleeves) of screened cable entries at the cabinet lead-through plate.

•Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system.

Note:

•Power cable shields are suitable as 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.

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

Printed circuit boards and fiber optic cables

These instructions are intended for all who handle the circuit boards and fiber optic cables. Ignoring the following instructions can cause damage to the equipment.

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.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

Mechanical installation

These notes are intended for all who install the drive. Handle the unit carefully to avoid damage and injury.

WARNING!

•DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back.

DCS800 sizes D5 ... D7: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

•Make sure that dust from drilling does not enter the drive when installing. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

•Ensure sufficient cooling.

•Do not fasten the drive by riveting or welding.

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

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 and/or damage to the equipment.

WARNING!

•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 control the motor with the disconnecting device

(disconnecting mains); instead, use the control panel keys and , or commands via the I/O board of the drive.

•Mains connection

You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be 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 disconnect must be locked in its "OPEN" position during any installation and maintenance work.

•EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor, nor will the drive be disconnected from any dangerous potential.

To avoid unintentional operating states, or to shut 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 case of 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.

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

Note:

•When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not

stop the drive. To stop the drive using the control panel, press the LOC/REM key and then the stop key .

Safety instructions

3ADW000193R0701 DCS800 Firmware Manual e g

Table of contents

Safety instructions	3
What this chapter contains .........................................................................................................	3
To which products this chapter applies ......................................................................................	3
Usage of warnings and notes.....................................................................................................	3
Installation and maintenance work .............................................................................................	4
Grounding .......................................................................................................................	5
Mechanical installation ...............................................................................................................	7
Operation ...................................................................................................................................	8
Table of contents	10
Introduction	23
Chapter overview..........................................................................................................	23
Before You Start ...........................................................................................................	23
What this manual contains ...........................................................................................	23
Start-up	24
Chapter overview..........................................................................................................	24
General .........................................................................................................................	24
Start-up procedure ...................................................................................................................	25
Tools .............................................................................................................................	25
Checking with the power switched off ..........................................................................	25
Checking with the power switched on ..........................................................................	27
Commissioning a DCS800 .......................................................................................................	28
Connect DCS800 to PC with DriveWindow Light .....................................................................	28
Commissioning a DCS800 with the wizard ..............................................................................	29
Commissioning a DCS800 with DriveWindow..........................................................................	30
Requirements ...............................................................................................................	30
01, 02 Macro assistant / Name plate data ....................................................................	30
03 Autotuning field current controller ............................................................................	31
04 Autotuning armature current controller ....................................................................	31
05 Speed feedback assistant .......................................................................................	32
Analog tacho fine tune procedure ................................................................	32
06 Autotuning speed controller .....................................................................................	32
07 Field weakening assistant .......................................................................................	33
Manual tuning...........................................................................................................................	34
I/O configuration ...........................................................................................................	34
Field current controller ..................................................................................................	34
Armature current controller ...........................................................................................	35
Control principle ...........................................................................................	35
Manual tuning ...............................................................................................	36
Analog tacho.................................................................................................................	41
Manual tuning ...............................................................................................	42
Speed controller ...........................................................................................................	42
Basics...........................................................................................................	42
Manual tuning ...............................................................................................	43
EMF controller ..............................................................................................................	45

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Basics............................................................................................................	45
Manual tuning................................................................................................	45
Flux linearization............................................................................................................	47
Basics............................................................................................................	47
Manual tuning................................................................................................	48
Thyristor diagnosis ........................................................................................................	50
Basics............................................................................................................	50
Check all thyristors ........................................................................................	50
Check individual firing pulses ........................................................................	50
Firmware description	52
Chapter overview...........................................................................................................	52
Identification of the firmware versions ...........................................................................	52
Start / stop sequences ..............................................................................................................	53
General..........................................................................................................................	53
Switch on sequence ......................................................................................................	53
Start the drive ................................................................................................................	54
Stop the drive ................................................................................................................	55
Field excitation ..........................................................................................................................	58
General..........................................................................................................................	58
Field Reversal................................................................................................................	58
Field control...................................................................................................	58
Field reference hysteresis .............................................................................	59
Force field current direction...........................................................................	59
Reversal time ................................................................................................	59
Bumpless transition .......................................................................................	59
Optitorque......................................................................................................................	59
Field current reference gain ..........................................................................	59
Field current monitoring.................................................................................................	60
Field minimum trip .........................................................................................	60
Flux reversal..................................................................................................	60
Field reversal hysteresis................................................................................	60
Field reversal active ......................................................................................	60
Field Heating .................................................................................................................	60
Overview .......................................................................................................	60
Modes of operation........................................................................................	61
E-stop ............................................................................................................	62
Field exciter mode.....................................................................................................................	63
General..........................................................................................................................	63
Large field exciter controlled by a DCS800 armature converter....................................	63
Parameters to be set in the DCS800 armature converter: ............................	64
Parameters to be set in large field exciters: ..................................................	64
Field current autotuning for large field exciters: ............................................	65
Stand alone field exciter ................................................................................................	66
Parameters to be set in the stand alone field exciter: ...................................	66
Field current autotuning for stand alone field exciter:....................................	67
DC-breaker, DC-contactor ........................................................................................................	68
General..........................................................................................................................	68
HVCB controlled externally, DC-breaker controlled by the drive...................................	68
DC-contactor US version ..........................................................................................................	69
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ACand DC-breaker controlled by the drive.................................................................	71
No AC-breaker, DC-breaker controlled by the drive .....................................................	72
AC-breaker controlled by the drive, DC-breaker controlled externally..........................	73
No AC-breaker, DC-breaker controlled externally ........................................................	74
Command Trip DC-breaker ..........................................................................................	74
Dynamic braking ......................................................................................................................	75
General .........................................................................................................................	75
Operation ......................................................................................................................	75
Activation......................................................................................................	75
Function........................................................................................................	75
Deactivation..................................................................................................	76
Position counter .......................................................................................................................	78
General .........................................................................................................................	78
Counting procedure ......................................................................................................	78
Synchronization ............................................................................................................	78
I/O configuration	81
Chapter overview..........................................................................................................	81
Digital inputs (DI’s) ...................................................................................................................	81
SDCS-CON-4 / SDCS-IOB-2........................................................................................	81
1st and 2nd RDIO-01 .......................................................................................................	81
Configuration ................................................................................................................	82
Digital outputs (DO’s) ...............................................................................................................	84
SDCS-CON-4 / SDCS-IOB-2........................................................................................	84
1st and 2nd RDIO-01 .......................................................................................................	84
Configuration ................................................................................................................	85
Analog inputs (AI’s) ..................................................................................................................	87
SDCS-CON-4 ...............................................................................................................	87
SDCS-IOB-3 .................................................................................................................	87
1st RAIO-01 ...................................................................................................................	88
2nd RAIO-01...................................................................................................................	88
Configuration ................................................................................................................	89
Scaling ..........................................................................................................................	89
Analog outputs (AO’s) ..............................................................................................................	91
SDCS-CON-4 / SDCS-IOB-3........................................................................................	91
1st RAIO-01 ...................................................................................................................	91
2nd RAIO-01...................................................................................................................	92
Configuration ................................................................................................................	92
Scaling ..........................................................................................................................	93
Communication	94
Chapter overview..........................................................................................................	94
DCSLink with SDCS-DSL-4 .....................................................................................................	94
General .........................................................................................................................	94
Excitation, commissioning a FEX-4..........................................................................................	94
Layout FEX-4................................................................................................................	94
Layout SDCS-DSL-4 ....................................................................................................	94
Set the FEX-4 type .......................................................................................................	95
Set the node numbers, transmission speed and the communication supervision ........	95
Set the DCSLink ...........................................................................................................	96

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Set the supply of the FEX-4...........................................................................................	97
Checking the FEX-4 ......................................................................................................	97
Master-follower, commissioning................................................................................................	98
Set the DCSLink hardware ............................................................................................	98
Set the node ID numbers and transmission speed........................................................	99
Activate the mailboxes...................................................................................................	99
Activate the communication supervision .......................................................................	99
Send and receive values .............................................................................................	100
Firmware structure.......................................................................................................	101
Additional settings .......................................................................................................	102
Drive-to-drive communication .................................................................................................	103
Set the DCSLink hardware ..........................................................................................	103
Set the node ID numbers and transmission speed......................................................	104
Activate the mailboxes.................................................................................................	104
Activate the communication supervision .....................................................................	104
Send and receive values .............................................................................................	105
12-pulse ..................................................................................................................................	106
Set the DCSLink hardware ..........................................................................................	106
Set the node numbers, transmission speed and the communication supervision.......	107
DDCS channels with SDCS-COM-8 .......................................................................................	108
General........................................................................................................................	108
Integer scaling on the DDCS link.................................................................................	108
Ch0 communication to overriding control................................................................................	109
ABB overriding control.................................................................................................	109
Parameter setting example..........................................................................................	109
Received data set table ...............................................................................................	110
Transmitted data set table ...........................................................................................	111
Fieldbus communication (N-type)................................................................................	111
Ch1 I/O devices ......................................................................................................................	112
Ch2 Master-follower link..........................................................................................................	112
General........................................................................................................................	112
Link configuration ........................................................................................................	112
Master..........................................................................................................................	112
Followers .....................................................................................................................	113
Firmware structure.......................................................................................................	113
Toggle between speedand torque control .................................................................	115
Follower diagnostics ....................................................................................................	115
Master-follower link specification.................................................................................	115
Ch3 commissioning and maintenance tools............................................................................	116
DriveWindow ...............................................................................................................	116
Ethernet communication for monitoring with Ethernet adapter NETA-01 ...............................	117
General........................................................................................................................	117
NETA-01 - DCS800 .....................................................................................................	117
Related documentation................................................................................................	117
NETA-01 configuration ................................................................................................	117
Mechanical and electrical installation ..........................................................................	118
Drive configuration.......................................................................................................	118
CANopen communication with fieldbus adapter RCAN-01 .....................................................	119
General........................................................................................................................	119
RCAN-01 - DCS800 ....................................................................................................	119
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Related documentation...............................................................................................	119
Overriding control configuration..................................................................................	119
EDS file.......................................................................................................................	119
Mechanical and electrical installation .........................................................................	119
Drive configuration......................................................................................................	119
Parameter setting example 1 using group 51 .............................................................	119
Further information .....................................................................................................	121
Parameter setting example 2 using groups 90 and 92 ...............................................	122
Switch on sequence ...................................................................................................	124
ControlNet communication with fieldbus adapter RCNA-01...................................................	125
General .......................................................................................................................	125
RCNA-01 - DCS800 ...................................................................................................	125
Related documentation...............................................................................................	125
Overriding control configuration..................................................................................	125
EDS file.......................................................................................................................	125
Mechanical and electrical installation .........................................................................	125
Drive configuration......................................................................................................	125
Parameter setting example 1 using ABB Drives assembly.........................................	125
Parameter setting example 2 using Vendor specific assembly ..................................	127
Setting of parameter groups 51, 90 and 92 ................................................................	128
Further information .....................................................................................................	128
Switch on sequence ...................................................................................................	128
DeviceNet communication with fieldbus adapter RDNA-01 ...................................................	129
General .......................................................................................................................	129
RDNA-01 - DCS800 ...................................................................................................	129
Related documentation...............................................................................................	129
Overriding control configuration..................................................................................	129
EDS file.......................................................................................................................	129
Mechanical and electrical installation .........................................................................	129
Drive configuration......................................................................................................	129
Parameter setting example 1 using ABB Drives assembly.........................................	129
Parameter setting example 2 using User specific assembly ......................................	131
Setting of parameter groups 51, 90 and 92 ................................................................	132
Further information .....................................................................................................	132
Switch on sequence ...................................................................................................	132
Ethernet/IP communication with fieldbus adapter RETA-01 ..................................................	133
General .......................................................................................................................	133
RETA-01 - DCS800 ....................................................................................................	133
Related documentation...............................................................................................	133
EDS file.......................................................................................................................	133
Mechanical and electrical installation .........................................................................	133
Drive configuration......................................................................................................	133
Parameter setting example using Ethernet/IP ABB Drives communication profile.....	133
Up to 4 data words .....................................................................................................	135
Up to 12 data words ...................................................................................................	135
Switch on sequence ...................................................................................................	138
Modbus (RTU) communication with fieldbus adapter RMBA-01 ............................................	139
General .......................................................................................................................	139
RMBA-01 - DCS800 ...................................................................................................	139
Related documentation...............................................................................................	139

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Mechanical and electrical installation ..........................................................................	139
Drive configuration.......................................................................................................	139
Parameter setting example … .....................................................................................	139
… when controlling a drive ..........................................................................................	139
… when used for monitoring only ................................................................................	141
Setting of PLC, parameter groups 90 and 92 ..............................................................	143
Switch on sequence ....................................................................................................	143
Modbus/TCP communication with fieldbus adapter RETA-01 ................................................	144
General........................................................................................................................	144
RETA-01 - DCS800 .....................................................................................................	144
Related documentation................................................................................................	144
Mechanical and electrical installation ..........................................................................	144
Drive configuration.......................................................................................................	144
Parameter setting example using Modbus/TCP ..........................................................	144
Switch on sequence ....................................................................................................	146
Profibus communication with fieldbus adapter RPBA-01........................................................	147
General........................................................................................................................	147
RPBA-01 - DCS800.....................................................................................................	147
Related documentation................................................................................................	147
Overriding control configuration...................................................................................	147
Mechanical and electrical installation ..........................................................................	147
Drive configuration.......................................................................................................	147
Parameter setting example 1 using PPO Type 1 ........................................................	147
Parameter setting example 2 using PPO types 2, 4 and 5..........................................	148
Communication via group 51.......................................................................................	149
Communication via group 90 and group 92.................................................................	150
Switch on sequence ....................................................................................................	151
Data set table ..........................................................................................................................	152
Adaptive Program (AP)	153
Chapter overview.........................................................................................................	153
What is the Adaptive Program.....................................................................................	153
Features ......................................................................................................................	153
How to build the program ............................................................................................	154
How to connect the Application Program with the firmware ........................................	154
Block Parameter Set for block 1 ..................................................................................	155
How to control the execution of the program...............................................................	156
DWL AP ..................................................................................................................................	157
General........................................................................................................................	157
Important keys and buttons .........................................................................................	157
Program modes ...........................................................................................................	157
Change to Edit mode...................................................................................................	157
Insert function blocks...................................................................................................	158
Connect function blocks ..............................................................................................	159
Set the Time level........................................................................................................	161
Saving AP applications................................................................................................	161
Function blocks .......................................................................................................................	162
General rules ...............................................................................................................	162
Block inputs .................................................................................................................	162
Block input attributes ...................................................................................	163
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Parameter value as an integer input ..........................................................	164
How the block handles the input ................................................................	164
How to select the input ...............................................................................	164
Constant as an integer input ......................................................................	165
How to set and connect the input ...............................................................	165
Parameter value as a boolean input...........................................................	166
How the block handles the input ................................................................	166
Constant as a boolean input.......................................................................	167
How to set and connect the input ...............................................................	167
String input .................................................................................................	167
How to select the input ...............................................................................	167
Function blocks ......................................................................................................................	168
ABS ............................................................................................................................	168
ADD ............................................................................................................................	169
AND ............................................................................................................................	169
Bitwise ........................................................................................................................	170
Bset ............................................................................................................................	171
Compare .....................................................................................................................	171
Count ..........................................................................................................................	172
D-Pot ..........................................................................................................................	172
Event ..........................................................................................................................	173
Filter............................................................................................................................	173
Limit ............................................................................................................................	174
MaskSet......................................................................................................................	174
Max .............................................................................................................................	175
Min ..............................................................................................................................	175
MulDiv.........................................................................................................................	175
NotUsed......................................................................................................................	176
OR ..............................................................................................................................	176
ParRead .....................................................................................................................	176
ParWrite......................................................................................................................	177
PI ................................................................................................................................	177
PI-Bal ..........................................................................................................................	178
Ramp ..........................................................................................................................	178
Sqrt .............................................................................................................................	179
SqWav ........................................................................................................................	179
SR...............................................................................................................................	180
Switch-B .....................................................................................................................	180
Switch-I .......................................................................................................................	181
TOFF ..........................................................................................................................	181
TON ............................................................................................................................	182
Trigg ...........................................................................................................................	182
XOR ............................................................................................................................	183
Diagram..................................................................................................................................	184
Signal and parameter list	185
Signals and parameters .........................................................................................................	185
Signal groups list....................................................................................................................	185
Parameter groups list .............................................................................................................	187
Signal and parameter list .......................................................................................................	190

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Group 1........................................................................................................................	190
Physical actual values .................................................................................	190
Group 2........................................................................................................................	194
Speed controller signals ..............................................................................	194
Group 3........................................................................................................................	198
Reference actual values..............................................................................	198
Group 4........................................................................................................................	201
Information ..................................................................................................	201
Group 5........................................................................................................................	209
Analog I/O ...................................................................................................	209
Group 6........................................................................................................................	210
Drive logic signals .......................................................................................	210
Group 7........................................................................................................................	216
Control words ..............................................................................................	216
Group 8........................................................................................................................	222
Status / limit words ......................................................................................	222
Group 9........................................................................................................................	228
Fault / alarm words......................................................................................	228
Group 10......................................................................................................................	244
Start / stop select ........................................................................................	244
Group 11......................................................................................................................	257
Speed reference inputs ...............................................................................	257
Group 12......................................................................................................................	264
Constant speeds .........................................................................................	264
Group 13......................................................................................................................	265
Analog inputs ..............................................................................................	265
Group 14......................................................................................................................	269
Digital outputs .............................................................................................	269
Group 15......................................................................................................................	271
Analog outputs ............................................................................................	271
Group 16......................................................................................................................	273
System control inputs ..................................................................................	273
Group 19......................................................................................................................	276
Data storage................................................................................................	276
Group 20......................................................................................................................	278
Limits ...........................................................................................................	278
Group 21......................................................................................................................	282
Start / stop ...................................................................................................	282
Group 22......................................................................................................................	286
Speed ramp.................................................................................................	286
Group 23......................................................................................................................	289
Speed reference..........................................................................................	289
Group 24......................................................................................................................	294
Speed control ..............................................................................................	294
Group 25......................................................................................................................	299
Torque reference.........................................................................................	299
Group 26......................................................................................................................	300
Torque reference handling ..........................................................................	300
Group 30......................................................................................................................	304
Fault functions .............................................................................................	304
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3ADW000193R0701 DCS800 Firmware Manual e g

Group 31.....................................................................................................................	315
Motor 1 temperature ...................................................................................	315
Group 34.....................................................................................................................	317
DCS800 Control Panel display ...................................................................	317
Group 40.....................................................................................................................	318
PID control..................................................................................................	318
Group 42.....................................................................................................................	321
Brake control ..............................................................................................	321
Group 43.....................................................................................................................	327
Current control............................................................................................	327
Group 44.....................................................................................................................	333
Field excitation ...........................................................................................	333
Group 45.....................................................................................................................	340
Field converter settings ..............................................................................	340
Group 47.....................................................................................................................	347
12-pulse operation......................................................................................	347
Group 49.....................................................................................................................	348
Shared motion ............................................................................................	348
Group 50.....................................................................................................................	360
Speed measurement ..................................................................................	360
Group 51.....................................................................................................................	367
Fieldbus......................................................................................................	367
Group 52.....................................................................................................................	368
Modbus.......................................................................................................	368
Group 60, …, 69 .........................................................................................................	369
Application program parameters ................................................................	369
Group 70.....................................................................................................................	370
DDCS control .............................................................................................	370
Group 71.....................................................................................................................	375
Drivebus .....................................................................................................	375
Group 83.....................................................................................................................	375
Adaptive Program control ...........................................................................	375
Group 84.....................................................................................................................	377
Adaptive Program.......................................................................................	377
Group 85.....................................................................................................................	380
User constants ...........................................................................................	380
Group 86.....................................................................................................................	382
Adaptive Program outputs ..........................................................................	382
Group 88.....................................................................................................................	383
Internal .......................................................................................................	383
Group 90.....................................................................................................................	385
Receiving data sets addresses 1 ...............................................................	385
Group 91.....................................................................................................................	387
Receiving data sets addresses 2 ...............................................................	387
Group 92.....................................................................................................................	388
Transmit data sets addresses 1 .................................................................	388
Group 93.....................................................................................................................	390
Transmit data sets addresses 2 .................................................................	390
Group 94.....................................................................................................................	391
DCSLink control .........................................................................................	391

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	19
Group 97......................................................................................................................	399
Measurement ..............................................................................................	399
Group 98......................................................................................................................	407
Option modules ...........................................................................................	407
Group 99......................................................................................................................	415
Start-up data ...............................................................................................	415
DCS800 Control Panel operation	420
Chapter overview.........................................................................................................	420
Start-up........................................................................................................................	420
DCS800 Control Panel ................................................................................................	420
Display overview..........................................................................................................	421
General display features..............................................................................................	421
Output mode................................................................................................................	422
Other modes................................................................................................................	423
Maintenance ................................................................................................................	428
Fault tracing	429
Chapter overview.........................................................................................................	429
General........................................................................................................................	429
Fault modes ................................................................................................	429
Converter protection ...............................................................................................................	429
Auxiliary undervoltage .................................................................................................	429
Armature overcurrent...................................................................................................	429
Converter overtemperature .........................................................................................	429
Auto-reclosing (mains undervoltage)...........................................................................	430
Mains synchronism......................................................................................................	431
Mains overvoltage .......................................................................................................	431
Communication loss ....................................................................................................	431
Fan, field and mains contactor acknowledge ..............................................................	432
External fault................................................................................................................	432
Bridge reversal ............................................................................................................	433
Analog input monitor....................................................................................................	433
Motor protection ......................................................................................................................	435
Armature overvoltage ..................................................................................................	435
Residual current detection...........................................................................................	435
Measured motor temperature ......................................................................................	435
Klixon...........................................................................................................................	438
Motor thermal model....................................................................................................	438
Field overcurrent..........................................................................................................	441
Armature current ripple................................................................................................	441
Speed feedback monitor..............................................................................................	442
Stall protection.............................................................................................................	443
Overspeed protection ..................................................................................................	443
Current rise..................................................................................................................	444
Field undercurrent .......................................................................................................	444
Tacho / pulse encoder polarity ....................................................................................	444
Tacho range ................................................................................................................	444
Status messages ....................................................................................................................	445
Display of status, fault and alarm signals ....................................................................	445
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20
Categories of signals and display options ..................................................	445
General messages .....................................................................................................	446
Power-up errors (E) ....................................................................................................	446
Fault signals (F) ..........................................................................................................	447
SDCS-COM-8 messages ...........................................................................	464
Alarm signals (A) ........................................................................................................	465
Disappearing system alarm ........................................................................................	475
User defined alarm by Adaptive Program...................................................................	475
Notices........................................................................................................................	477
Appendix A: Firmware structure diagrams	479
Appendix B: SDCS-CON-4 Terminal Allocation	484
Appendix C: Index of signals and parameters	485

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3ADW000193R0701 DCS800 Firmware Manual e g

Chapters not yet available

3ADW000193R0701 DCS800 Firmware Manual e g

Introduction

Chapter overview

This chapter describes the purpose, contents and the intended use of this manual.

Before You Start

The purpose of this manual is to provide you with the information necessary to control and program the drive.

Study carefully the Safety instructions at the beginning of this manual before attempting any work on or with the drive. Read through this manual before startingup the drive. The installation and commissioning instructions given in the DCS800 Hardware Manual and DCS800 Quick Guide must also be read before proceeding.

This manual describes the standard DCS800 firmware.

What this manual contains

The Safety instructions can be found at the beginning of this manual.

Introduction to this manual, the chapter you are currently reading, introduces you to this manual.

Start-up, this chapter describes the basic start-up procedure of the drive.

Firmware description, this chapter describes how to control the drive with standard firmware.

I/O configuration, this chapter describes the I/O configuration of digital and analog inputs and outputs with different hardware possibilities.

Communication, this chapter describes the communication capabilities of the drive.

Adaptive Program (AP), this chapter describes the basics of the Adaptive Program and instructs how to build a program.

Signal and parameter list, this chapter contains all signals and parameters.

DCS800 Control Panel operation, this chapter describes the handling of the DCS800 Control Panel.

Fault Tracing, this chapter describes the protections and fault tracing of the drive.

Appendix A: Firmware structure diagram

Appendix B: SDCS-CON-4 Terminal Allocation

Appendix C: Index of signal and parameters

Introduction to this manual

3ADW000193R0701 DCS800 Firmware Manual e g

Start-up

Chapter overview

This chapter describes the basic start-up procedure of the drive. A more detailed description of the signals and parameters involved in the procedure can be found in section Signal and parameter list.

General

The drive can be operated:

locally from DriveWindow, DriveWindow Light or DCS800 Control Panel

respectively remote from local I/O or overriding control.

The following start-up procedure uses DriveWindow (for further information about DriveWindow, consult its online help). However, parameters can also be changed with DriveWindow Light or the DCS800 Control Panel.

The start-up procedure includes actions that need only be taken when powering up the drive for the first time in a new installation (e.g. entering the motor data). After the start-up, the drive can be powered up without using these start-up functions again. The start-up procedure can be repeated later if the start-up data needs to be altered.

Refer to section Fault tracing in case problems should arise. In case of a major problem, disconnect mains and wait for 5 minutes before attempting any work on the drive, the motor, or the motor cables.

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

Start-up procedure

The Safety Instructions at the beginning of this manual have to be observed with extreme care during the start-up procedure!

The start-up procedure should only be carried out by a qualified electrician.

Check the mechanical and electrical installation the drive according to the DCS800 Hardware Manual.

Tools

For drive commissioning following software tools are mandatory:

DriveWindow Light including commissioning wizard and DWL AP for Adaptive Program and

DriveWindow for fast drive monitoring using SDCS-COM-8.

For drive commissioning following tools are mandatory in addition to standard tools:

An oscilloscope including memory function with either galvanically isolating transformer or isolating amplifier for safe measurements.

A clamp on current probe. In case the scaling of the DC load current needs to be checked it must be a DC clamp on current probe.

A voltmeter.

Make sure that all equipment in use is suitable for the voltage level applied to the power part!

Checking with the power switched off

Check the settings of:

the main breaker (e.g. overcurrent = 1.6 * In, short circuit current = 10 * In, time for thermal tripping = 10 s),

time, overcurrent, thermal and voltage relays,

the earth fault protection (e.g. Bender relay)

Check the insulation of the mains voltage cables or busbars between the secondary side of the dedicated transformer and the drive:

disconnect the dedicated transformer from its incoming voltage,

check that all circuits between the mains and the drive (e.g. control / auxiliary voltage) are disconnected,

measure the insulation resistance between L1 - L2, L1 - L3, L2 - L3, L1 - PE, L2 - PE, L3 - PE,

the result should be M s

Check the installation:

crosscheck the wiring with the drawings,

check the mechanical mounting of the motor and pulse encoder or analog tacho,

make sure that the motor is connected in a correct way (armature, field, serial windings, cable shields),

check the connections of the motor fan if existing,

make sure that the converter fan is connected correctly especially in modules size D6 and D7 were star or delta connection is possible,

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

if a pulse encoder is used make sure that pulse encoder's auxiliary voltage connection corresponds to its voltage and that the channel connection corresponds to correct direction of rotation,

check that the shielding of the pulse encoder's cable is connected to the TE bar of the DCS800,

if an analog tacho is used make sure that it is connected to the proper voltage input at the SDCS-CON-4:

X3:1 - X3:4 (90 - 270 V) X3:2 - X3:4 (30 - 90 V) X3:3 - X3:4 (8 - 30 V)

for all other cables make sure that both ends of the cables are connected and they do not cause any damage or danger when power is being switched on

Measuring the insulation resistance of the motor cables and the motor:

isolate the motor cables from the drive before testing the insulation resistance or voltage withstand of the cables or the motor,

Instructions how to measure the insulation resistance

measure the insulation resistance between:

1.+ cables and PE,

2.- cables and PE,

3.armature cables and field cables,

4.field - cable and PE,

5.field + cable and PE,

the result should be M s

Setting of Jumpers:

The boards of the DCS800 include jumpers to adapt the boards to different applications. The position of the jumpers must be checked before connecting voltage. For specific jumper settings consult the DCS800 Hardware Manual.

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

Drive data

Check following items for each drive and mark the differences in the delivery documents:

motor, analog tacho or pulse encoder and cooling fan rating plates data,

direction of motor rotation,

maximum and minimum speed and if fixed speeds are used,

speed scaling factors:

e.g. gear ratio, roll diameter,

acceleration and deceleration times,

operating modes:

e.g. stop mode, E-stop mode,

the amount of motors connected

Checking with the power switched on

There is dangerous voltage inside the cabinet!

Switching the power on:

prior to connecting the voltage proceed as follows:

1.ensure that all the cable connections are checked and that the connections can't cause any danger,

2.close all doors of enclosed converter before switching power on,

3.be ready to trip the supply transformer if anything abnormal occurs,

4.switch the power on

Measurements made with power on:

check the operation of the auxiliary equipment,

check the circuits for external interfaces on site:

1.E-stop circuit,

2.remote control of the main breaker,

3.signals connected to the control system,

4.other signals which remain to be checked

Connecting voltage to the drive:

check from the delivery diagrams the type of boards and converters which are used in the system,

check all time relay and breaker settings,

close the supply disconnecting device (check the connection from the delivery diagrams),

close all protection switches one at a time and measure for proper voltage

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

Commissioning a DCS800

Nominal values of the converter can be found in group 4, check following signals:

ConvNomVolt (4.04), nominal AC converter voltage in V read from

TypeCode (97.01) or S ConvScaleVolt (97.03),

ConvNomCur (4.05), nominal converter DC current in A read from

TypeCode (97.01) or S ConvScaleCur (97.02),

ConvType (4.14), recognized converter type read from TypeCode (97.01),

QuadrantType (4.15), recognized converter quadrant type read from

TypeCode (97.01) or S BlockBrdg2 (97.07),

MaxBridgeTemp (4.17), maximum bridge temperature in degree centigrade read from TypeCode (97.01) or S MaxBrdgTemp (97.04)

If signals are not correct adapt them, see group 97 in this manual.

Connect DCS800 to PC with DriveWindow Light

Connect a normal serial cable from the PC COM port to X34 on the drive:

Start DriveWindow Light and check the communication settings:

Example with COM1.

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

Commissioning a DCS800 with the wizard

To launch the commissioning wizard start DriveWindow Light and press the Wizard button:

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

Commissioning a DCS800 with DriveWindow

Requirements

1.Before starting with the commissioning, connect the drive (via Ch3 on SDCS-COM-8) with DriveWindow (via e.g. NDPA-02 and NDPC-12). All workspaces are ‘online’ workspaces, thus use Ch3 NodeAddr (70.22) = 1.

2.The preconfigured workspaces are available from Your local ABB agent or can be found - after the DCS800 CD (tools CD) is installed - under:

Location of workspaces

01, 02 Macro assistant / Name plate data

1.Open the workspace 01, 02 DCS800 Name plate data & macro assistant.dww1.

2.Set all parameters to default by means of ApplMacro (99.08) = Factory and

ApplRestore (99.07) = Yes. Check with MacroSel (8.10).

3.Enter the motor data, the mains (supply) data and the most important protections [M1SpeedMin (20.01), M1SpeedMax (20.02), ArmOvrCurLev (30.09), M1OvrSpeed (30.16), Language (99.01), M1NomVolt (99.02), M1NomCur (99.03), M1BaseSpeed (99.04), NomMainsVolt (99.10) and M1NomFldCur (99.11)].

4.After filling out the parameters it is - in most cases - possible to turn the motor for the first time.

5.Select an application macro by means of ApplMacro (99.08) = <macro> and ApplRestore (99.07) = Yes. Check with MacroSel (8.10).

Start-up

3ADW000193R0701 DCS800 Firmware Manual e g

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