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ABB DCS800 Hardware Manual
Summary of DCS800
Page 1
Dcs800 hardware manual dcs800 drives (20 to 5200 a).
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Dcs800 single drive manuals language public. Number e d i es f cn res dcs 800 quick guide (191 + cd) 3 adt 645 0 ?? Nn dcs 800 converter module flyer dcs800 3 adw 000 190 x x p p p p jf flyer dcs800 e panel solution 3 adw 000 0?? Jf catalogue dcs800 3 adw 000 192 x p p p p p jf hardware manual dcs80...
Page 3: Hardware Manual
3adw000194r0201 dcs800 hardware manual e b dcs800 drives 20 to 5200 amps hardware manual 3adw000194r0201 rev b effective: 05.10.2005 ¤ 2005 abb automation products gmbh. All rights reserved.Served..
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3adw000194r0201 dcs800 hardware manual e b.
Page 5: Safety Instructions
Safety instructions 5 3adw000194r0201 dcs800 hardware manual e b safety instructions what this chapter contains this chapter contains the safety instructions which you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur...
Page 6: •
Safety instructions 6 3adw000194r0201 dcs800 hardware manual e b installation and maintenance work these warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death. Only qualified electricians are allowed to install and mai...
Page 7: •
Safety instructions 7 3adw000194r0201 dcs800 hardware manual e b warning! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. Grounding these instructions are intended for all...
Page 8: Mechanical Installation
Safety instructions 8 3adw000194r0201 dcs800 hardware manual e b fibre optic cables warning! Handle the fibre optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive...
Page 9: Operation
Safety instructions 9 3adw000194r0201 dcs800 hardware manual e b operation these warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death or damage the equipment. • before adjusting the drive and putting it i...
Page 10: •
Safety instructions 10 3adw000194r0201 dcs800 hardware manual e b note: • when the control location is not set to local (l not shown in the pc tool status row), the stop key on the control panel will not stop the drive..
Page 11: Table Of Contents
Table of contents 11 3adw000194r0201_dcs800 hardware manual_e_b table of contents dcs800 single drive manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 safety instructions what this chapter contains . . . . . . . . . . . . . . . . . ....
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Table of contents 12 3adw000194r0201_dcs800 hardware manual_e_b semiconductor type f1 fuses and fuse holders for ac and dc power lines . . . . . . . . . . . . . 30 fuses f3.X and fuse holders for field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 single-phase t...
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Table of contents 13 3adw000194r0201_dcs800 hardware manual_e_b technical data what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Table of contents 14 3adw000194r0201_dcs800 hardware manual_e_b diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 rs232-port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 15: The Dcs800
The dcs800 15 3adw000194r0201 dcs800 hardware manual e b the dcs800 what this chapter contains this chapter describes briefly the operating principle and construction of the drive in short. The dcs800 the dcs800 size d1...D7 are intended for controlling dc motors. Size d1...D4 20...1000 a size d5 90...
Page 16: Type Code
The dcs800 16 3adw000194r0201 dcs800 hardware manual e b type code the type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.G. Dcs800-s01- 2005). The optional selections are given thereafter, on the name pl...
Page 17: Main Circuit And Control
The dcs800 17 3adw000194r0201 dcs800 hardware manual e b main circuit and control armature circuit converter dcs800 d1...D4 l1 k1 t2 q1 f2 f3 m t3 f1 k5 k3 50 0 v 10 00 v dc s8_s ys_ov w_a.D sf em c fi lt e r dcf 803 / 804 pi n -4 on board fex pin 4 m dc s8 0 0 d1 .. .D 4 50 0 v 23 0 v (115 v ) 8 3 ...
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The dcs800 18 3adw000194r0201 dcs800 hardware manual e b armature circuit converter dcs800 d5...D7 l1 k1 t2 q1 f2 f3 m t3 f1 k5 k3 50 0 v 10 00 v dc s8_s ys_ov w_a.D sf em c fi lt e r dcf 803 / 804 po w-1 pi n -5 1 fex 425 internal ** m pi n -4 1 pi n -4 1 l3 dc s8 0 0 d5 .. .D 7 * th re e -p ha s e...
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The dcs800 19 3adw000194r0201 dcs800 hardware manual e b rebuild system dcr800 l1 k1 t2 q1 f2 f3 m t3 f1 k5 k3 50 0 v 10 00 v dc s8_s ys_ov w_a.D sf em c fi lt e r co n x - s ho rt d e s ign a tion o f c om p one n ts a n a logu e in put / o utp u t al te rn at iv e e a rt h- fa ul t m o n it or opt...
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The dcs800 20 3adw000194r0201 dcs800 hardware manual e b.
Page 21: Mechanical Installation
Mechanical installation 21 3adw000194r0201 dcs800 hardware manual e b mechanical installation unpacking the unit • open box • take out shock dampers • separate manual and accessories • do not lift the drive by cover. Delivery check check that there are no signs of damage. Before attempting installat...
Page 22: Before Installation
Mechanical installation 22 3adw000194r0201 dcs800 hardware manual e b before installation the drive must be installed in an upright position with the cooling section facing a wall. Check the installation site according to the requirements below. Refer to dimensional drawings for frame details. Requi...
Page 23
Mechanical installation 23 3adw000194r0201 dcs800 hardware manual e b mounting the converter module d6 inside an enclosure cooling air entry the cooling fan takes the air from the backside, both sides and from the area under- neath the converter module. Free space around the conerter module optimum ...
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Mechanical installation 24 3adw000194r0201 dcs800 hardware manual e b mounting the converter module d7 inside an enclosure cooling air entry the cooling fan takes the air from the backside, both sides and from the area underneath the converter module. Free space around the conerter module do not pla...
Page 25: Options For The Drive
Planning the electrical installation 25 3adw000194r0201 dcs800 hardware manual e b planning the electrical installation what this chapter contains this chapter contains the instructions that you must follow when selecting the motor, cables, protections, cable routing and way of operation for the dri...
Page 26
Planning the electrical installation 26 3adw000194r0201 dcs800 hardware manual e b configuration b if special requirements have to be met at the pcc (standards like en 61 800-3, dc and ac drives at the same line, etc), different criteria must be applied for selecting a line reactor. These requiremen...
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Planning the electrical installation 27 3adw000194r0201 dcs800 hardware manual e b line reactors l1 * with forced cooling (1m/s) dcs type 400v-690v 50/60 hz line choke design line choke design type for fig. Type for fig. Configur. A configur. B 2-q converter 4-q converter dcs800-s01-0020-04/05 dcs80...
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Planning the electrical installation 28 3adw000194r0201 dcs800 hardware manual e b aspects of fusing for the armature-circuit and field supplies of dc drives general unit configuration protection elements such as fuses or overcurrent trips are used whenever overcurrents cannot entirely be ruled out....
Page 29
Planning the electrical installation 29 3adw000194r0201 dcs800 hardware manual e b conclusion for the field supply basically, similar conditions apply for both field supply and armature-circuit supply. Depending on the power converter used (diode bridge, half-controlled bridge, fully controlled 4-qu...
Page 30
Planning the electrical installation 30 3adw000194r0201 dcs800 hardware manual e b semiconductor type f1 fuses and fuse holders for ac and dc power lines (dcs800-s01 / dcs800-s02) the converter units are subdivided into two groups: • unit sizes d1, d2, d3 and d4 with rated currents up to 1000 a requ...
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Planning the electrical installation 31 3adw000194r0201 dcs800 hardware manual e b * f3.1 fuse ktk25 included in fex-425-int fuses and fuse holders for 2-phase field supply single-phase transformer t3 for field supply to match voltage levels the field supply units’ insulation voltage is higher than ...
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Planning the electrical installation 32 3adw000194r0201 dcs800 hardware manual e b single-phase commutating reactor for dcf803-0035 and fex-425-int field power converter with external supply must be connected via additionally commutating reactor because of emc considerations if the supply has a sepa...
Page 33
Planning the electrical installation 33 3adw000194r0201 dcs800 hardware manual e b according to en 61800-3 filters are not needed in industrial zone (second environment) for dcs800 drives above 100 a rated current. For rated currents below 100 a the filter requirement is identical to light industry ...
Page 34
Planning the electrical installation 34 3adw000194r0201 dcs800 hardware manual e b single-phase filters for field supply many field supply units are single-phase converters for up to 50 a excitation current. They can be supplied by two of the three input phases of the armature supply converter. Then...
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Planning the electrical installation 35 3adw000194r0201 dcs800 hardware manual e b.
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Planning the electrical installation 36 3adw000194r0201 dcs800 hardware manual e b emc filters you will find further infor- mation in publication: technical guide chapter: emc compliant installa- tion and configuration for a power drive system the paragraphs below describe selection of the electri- ...
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Planning the electrical installation 37 3adw000194r0201 dcs800 hardware manual e b for compliance with the protection objectives of the german emc act (emvg) in systems and machines, the following emc standards must be sat- isfied: for emitted interference, the following apply: en 61000-6-3 speciali...
Page 38
Planning the electrical installation 38 3adw000194r0201 dcs800 hardware manual e b converters d1...D4 drive configuration using ’on board’ field exciter wiring the drive according to this diagram offers the highest degree of standard monitoring functions done by the drive. In 3 ou t 3 in 1 ou t 1 v5...
Page 39
Planning the electrical installation 39 3adw000194r0201 dcs800 hardware manual e b converters d5 drive configuration using ’fex-425-int’ field exciter wiring the drive according to this diagram gives the most flexibility and offers the highest degree of standard monitoring functions done by the driv...
Page 40: Dcf803, Dcf804
Planning the electrical installation 40 3adw000194r0201 dcs800 hardware manual e b converters d5...D7 drive configuration using ’external’ field exciter dcf803, dcf804 wiring the drive according to this diagram gives the most flexibility and offers the highest degree of standard monitoring functions...
Page 41
Planning the electrical installation 41 3adw000194r0201 dcs800 hardware manual e b start, stop and e-stop control the relay logic can be split into three parts: a: generation of the on/off and start/stop command: the commands represented by k20 and k21 (latching interface relay) can be e.G. Generate...
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Planning the electrical installation 42 3adw000194r0201 dcs800 hardware manual e b emer. Stop k16 k15 k16 k15 elec. Disconn. Dix k15 x6:9 con-2 s1 1 2 e-stop reaction e-stop speed timer k15 timer k16 block current control k1 main contactor stop-mode.Dsf e-stop ramp coast.
Page 43
Planning the electrical installation 43 3adw000194r0201 dcs800 hardware manual e b drive configuration with reduced components converters d1...D4 (400...500v) using ’on board’ field exciters converters d5 (400...500v) using fex-425-int field exciter wiring the drive according to this diagram gives t...
Page 44: Power Section Cooling
Planning the electrical installation 44 3adw000194r0201 dcs800 hardware manual e b power section cooling fan assignment for dcs800 fan data for dcs800 converter type model configuration fan type dcs800-s0x-0045-y1 ... Dcs800-s0x-00140-y1 d1 1 2x cn2b2 dcs800-s0x-0180-y1 ... Dcs800-s0x-0260-y1 d2 1 2...
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Planning the electrical installation 45 3adw000194r0201 dcs800 hardware manual e b fan connection for dcs800 monitoring the dcs800 power section a.The size d1...D5 power section is likewise monitored by an electrically isolated ptc thermistor detector, which is installed on the heat sink in an isola...
Page 46
Planning the electrical installation 46 3adw000194r0201 dcs800 hardware manual e b only be detected indirectly, a differential-pressure switch has been additionally installed at the unit’s housing, always located close to the power terminals. The resistance change proportional to the temperature is ...
Page 47
Planning the electrical installation 47 3adw000194r0201 dcs800 hardware manual e b cross-sectional areas - tightening torques recommended cross-sectional area to dinvde 0276-1000 and dinvde 0100-540 (pe) trefoil arrangement, up to 50°c ambient temperature. ➀reduced ambient temperature 40°c ➁option f...
Page 48
Planning the electrical installation 48 3adw000194r0201 dcs800 hardware manual e b selecting the control cables all control cables except 220 v or 115 v must be shielded. Use a double-shielded twisted pair cable (figure a, e.G. Jamak by nk cables, finland or belden type, usa) for analogue signals. T...
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Planning the electrical installation 49 3adw000194r0201 dcs800 hardware manual e b connection of a motor temperature sensor to the drive i/o warning! Iec 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non...
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Planning the electrical installation 50 3adw000194r0201 dcs800 hardware manual e b.
Page 51: Electrical Installation
Electrical installation 51 3adw000194r0201 dcs800 hardware manual e b electrical installation what this chapter contains this chapter describes the electrical installation procedure of the drive. Warning! The work described in this chapter may only be carried out by a qualified electrician. Follow t...
Page 52: It (Ungrounded) Systems
Electrical installation 52 3adw000194r0201 dcs800 hardware manual e b it (ungrounded) systems don’t use emc filters. The screen winding of dedicated transformers must be grounded. For installation without low voltage switch (e.G. Contacter, air-circuit-breaker) use overvoltage protection. The voltag...
Page 53
Electrical installation 53 3adw000194r0201 dcs800 hardware manual e b connect the signal cables as described below. Tighten the screws to secure the connection. Interface connector x2: sdcs-iob-3 x1: sdcs-iob-2 dcs800 panel connector x33: slot 1 r io extension module or r-fieldbus module slot 2 r io...
Page 54: I/o Board Configuration
Electrical installation 54 3adw000194r0201 dcs800 hardware manual e b i/o board configuration in-/output signals the converter can be connected in four different ways to a control unit via analogue/ digital signals. Only one of the four choices can be used at the same time. . I/o´s via sdcs-con-4 an...
Page 55: Pulse Encoder Connection
Electrical installation 55 3adw000194r0201 dcs800 hardware manual e b pulse encoder connection connecting a pulse encoder to the dcs800 converter the connection diagram for a pulse encoder to the electronics of a dcs converter is quite similar, if the sdcs-con-4 or the sdcs-iob-3 is used. The basic ...
Page 56: Pulse Encoder Receiver
Electrical installation 56 3adw000194r0201 dcs800 hardware manual e b pulse encoder receiver two different incremental encoder connections are available. -differential connection; pulse encoders generating either voltage or current signals can be used -single-ended (push pull) connection; voltage si...
Page 57
Electrical installation 57 3adw000194r0201 dcs800 hardware manual e b the distance between pulse encoder and interface board is dependent on the voltage drop on the connecting lines and on the output and input configuration of the used components. If cables are used according to the table below the ...
Page 58: Routing The Cables
Electrical installation 58 3adw000194r0201 dcs800 hardware manual e b connecting the signal and control cables the cables for digital signals, which are longer than 3 m and all cables for analogue signals, must be screened. Each screen must be connected at both ends by metal clamps or comparable mea...
Page 59: Dsl Link Wiring
Electrical installation 59 3adw000194r0201 dcs800 hardware manual e b dsl link wiring dsl link is a 800 kbaud serial communcation between: • drive to drive or • drive to field exciter based on can hardware and twisted pair cabling. The topology of the bus must be: bus switched off nodes can remain i...
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Electrical installation 60 3adw000194r0201 dcs800 hardware manual e b.
Page 61: Installation Checklist
Installation checklist 61 3adw000194r0201 dcs800 hardware manual e b installation checklist checklist check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the safety instructions on the first pages of this ma...
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Installation checklist 62 3adw000194r0201 dcs800 hardware manual e b.
Page 63: Maintenance
Maintenance 63 3adw000194r0201 dcs800 hardware manual e b maintenance what this chapter contains this chapter contains preventive maintenance instructions. Reference: service manual - publ. No.: 3adw000195 safety warning! Read the safety instructions on the first pages of this manual before performi...
Page 64: Heatsink
Maintenance 64 3adw000194r0201 dcs800 hardware manual e b heatsink the heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. In a “normal” environment (not dusty, not clean) the heatsink should be checked annually, in a...
Page 65: Technical Data
Technical data 65 3adw000194r0201 dcs800 hardware manual e b technical data what this chapter contains this chapter contains the technical specifications of the drive, e.G. The ratings, sizes and technical requirements, provisions for fulfilling the requirements for ce and other markings and warrant...
Page 66
Technical data 66 3adw000194r0201 dcs800 hardware manual e b regulatory compliance the converter module and enclosed converter components are designed for use in industrial environments. In eea countries, the components fulfil the requirements of the eu directives, see table below. European union di...
Page 67: Current Ratings
Technical data 67 3adw000194r0201 dcs800 hardware manual e b current ratings the current ratings for the dcs800 with 50 hz and 60 hz supplies are given below. The symbols are described below the table. Power converter module currents with corresponding load cycles. The characteristics are based on a...
Page 68
Technical data 68 3adw000194r0201 dcs800 hardware manual e b * as option sizing note 1: the ratings apply at ambient temperature of 40 °c (104 °f). In lower temperatures the d5, d6, d7 ratings are higher (except i max ). Note 2: use the drivesize pc tool for a more accurate dimensioning if the ambie...
Page 69: Control Board Sdcs-Con-4
Technical data 69 3adw000194r0201 dcs800 hardware manual e b control board sdcs-con-4 layout of the control board sdcs-con-4 memory circuit sdcs-con-4 board is equipped with flashprom which contains the firmware plus the stored parameters. Parameters handled by dcs800 panel or dwl, pctool or by seri...
Page 70
Technical data 70 3adw000194r0201 dcs800 hardware manual e b seven segment display a seven segment display is located on the control board sdcs-con-4 and it shows the state of drive. Terminal description x37: connector is used for supply of sdcs-con-4 from sdcs-pow-1, sdcs-pow-4, sdcs-pin-4 supply v...
Page 71
Technical data 71 3adw000194r0201 dcs800 hardware manual e b the rs232 interface is normally used for setting parameter in the drive via the pc tool. The default settings of this interface are as follows: x8: is need for sdcs-dsl-4 board which provides the serial communication interface to field exc...
Page 72
Technical data 72 3adw000194r0201 dcs800 hardware manual e b digital and analogue i/o connection of the sdcs-con-4 x2: x1 : atach ±90...±270 v ±30...±90 v ±8...±30 v ai4 (10 ms) gnd gnd 39k2 +10v +24 v; 125 ma power sense 0 v sense 5 v ai2 (3.3 ms) ai3 (10 ms) ai1 (3.3 ms) ao1 ao2 +/- i-act 47.5 100...
Page 73: Interface Board Sdcs-Com-8
Technical data 73 3adw000194r0201 dcs800 hardware manual e b interface board sdcs-com-8 this board must be used together with a dcs800 to provide same serial communication ddcs options as acs800. Furthermore the board is equipped with four optical channels (max. Data transmission speed is 4 mb for e...
Page 74
Technical data 74 3adw000194r0201 dcs800 hardware manual e b.
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Technical data 75 3adw000194r0201 dcs800 hardware manual e b.
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Technical data 76 3adw000194r0201 dcs800 hardware manual e b.
Page 77
Technical data 77 3adw000194r0201 dcs800 hardware manual e b ddcs branching unit ndbu-95 ddcs branching unit (dbu) is used (for dcs 600/dcs800) to implement the star topology of ddcs link. This allows a slave unit to fail or become unpowered without disabling the communication. The ndbu receives mes...
Page 78: Dsl Board
Technical data 78 3adw000194r0201 dcs800 hardware manual e b dsl board the dsl board provides a drive to drive communication. The communication hardware and protocol is based on can bus. This communication can be used 12-pulse operation, communication to field exciter either single phase or three ph...
Page 79
Technical data 79 3adw000194r0201 dcs800 hardware manual e b digital i/o board sdcs-iob-2 layout and jumper settings of the sdcs-iob-2x board as described at the beginning of the chapter, there are various options for configuring the inputs/outputs. The board iob-2x has 8 digital inputs and 8 digita...
Page 80
Technical data 80 3adw000194r0201 dcs800 hardware manual e b x4:1 2 3 4 5 6 7 8 x5:1 do1 do2 do3 do4 do5 do6 do7 do8 2 3 4 5 6 7 8 k1 k2 k3 k4 k5 k8 dox 66v 66v di2 di4 di5 di6 di7 di8 3 5 6 8 2 4 w5 w6 w7 w8 w11 w12 x6:1 2 w1 r1 w3 w4 di1 di3 r2 r3 r4 4 r5 r6 w9 w10 r7 7 r8 w13 w14 w15 w16 x7:1 3 s...
Page 81
Technical data 81 3adw000194r0201 dcs800 hardware manual e b analogue and encoder i/o board sdcs-iob-3 layout and jumper settings of the sdcs-iob-3x board as described at the beginning of the chapter, there are various options for configuring the inputs/outputs. The board sdcs-iob-3 consists of the ...
Page 82
Technical data 82 3adw000194r0201 dcs800 hardware manual e b ➀ total smoothing time ≤2 ms ➁ -20...0...+20 ma by setting s1 ➂ 4...20 ma by ➁ + software function ➃ -1...0...-1 v by setting s2/s3 (cmr ±10 v) -2...0...-2 ma by setting s2/s3 + s1 (cmr ±10 v) ➄ designated for pt100 evaluation per firmware...
Page 83
Technical data 83 3adw000194r0201 dcs800 hardware manual e b power supply board sdcs-pow-4 the sdcs-pow-4 board is designed for dcs800 converter modules d5...D7 and is mounted on the electronic support. This board is used for all types of modules independent from current or voltage range. The sdcs-p...
Page 84: Interface Board Sdcs-Pin-4
Technical data 84 3adw000194r0201 dcs800 hardware manual e b interface board sdcs-pin-4 general the sdcs pin4 board is designed for dcs800 converter modules sizes d1 up to size d4 (20 a...1000 a) the board has three different functions: 1. Power supply of con-4 board and the connected options 2. Con...
Page 85
Technical data 85 3adw000194r0201 dcs800 hardware manual e b power supply the power supply (x99:) operates on fly back configuration. The internal dc link voltage is 310 v. The power supply automatically adapts the supply input voltage between 230 v and 115 v and switches relays k301. In case of osc...
Page 86
Technical data 86 3adw000194r0201 dcs800 hardware manual e b armature circuit interface the function for armature circuit interface consist of: • firing the armature bridge of 6 or 12 thyristors. • high ohmic measurement of dc and ac voltage. • interface for ac current transformer for current measur...
Page 87
Technical data 87 3adw000194r0201 dcs800 hardware manual e b typical armature circuit thyristor converter diagram with sdcs-pin-4 board v1 1 v2 4 v2 1 v1 4 1. 4 2. 1 2. 4 1. 1 2. 6 v2 6 v1 3 1. 3 2. 3 1. 6 v2 3 v1 6 2. 2 v2 2 v1 5 1. 5 2. 5 1. 2 v2 5 v1 2 k g k g g k g k g k g k g k k g k g g k k g ...
Page 88
Technical data 88 3adw000194r0201 dcs800 hardware manual e b power interface sdcs-pin-46/sdcs-pin-48/sdcs-pin-5x the power interface of dcs converter modules model d5/d6/d7 from 900 a up to 5200 a consists of two boards - the measuring board sdcs-pin-51 and the pulse transformer board scds-pin-41. T...
Page 89
Technical data 89 3adw000194r0201 dcs800 hardware manual e b layout of the sdcs-pin-51 board measuring board sdcs-pin-51 this board is always used together with sdcs-pin-41 board. On this board there are the circuits located needed for current, voltage and temperature measuring and for hardware codi...
Page 90
Technical data 90 3adw000194r0201 dcs800 hardware manual e b settings of the sdcs-pin-51 board if a dcs converter is equipped with it by abb ➀ the converters can be used at lower line voltage then specified by the y-value without hardware modifications, if the nominal line voltage applied to the con...
Page 91
Technical data 91 3adw000194r0201 dcs800 hardware manual e b typical armature circuit thyristor converter diagram with sdcs-pin-48 and sdcs-pin-51 boards for a 4-quadrant d7 type converter * v1 1 v2 4 v2 1 v1 4 1. 4 2. 1 2. 4 1. 1 2. 6 v2 6 v1 3 1. 3 2. 3 1. 6 v2 3 v1 6 2. 2 v2 2 v1 5 1. 5 2. 5 1. 2...
Page 92
Technical data 92 3adw000194r0201 dcs800 hardware manual e b galvanic isolation - t90, a92 hard and software settings: the galvanic isolation is an option for converters in the current range 2050...5200 a and rated voltages ≤1000 v. For converters with a rated voltage of 1190 v and 12-pulse serial >...
Page 93
Technical data 93 3adw000194r0201 dcs800 hardware manual e b typical armature circuit thyristor converter diagram with sdcs-pin-48 and sdcs-pin-51 boards for a 4-q d7 type converter with galvanic isolation * v1 1 v2 4 v2 1 v1 4 1. 4 2. 1 2. 4 1. 1 2. 6 v2 6 v1 3 1. 3 2. 3 1. 6 v2 3 v1 6 2. 2 v2 2 v1...
Page 94
Technical data 94 3adw000194r0201 dcs800 hardware manual e b dc-dc transducer a92 principle circuit diagram of the dc-dc transducer a92 data the voltage gain and frequency response is especially designed for dcs800 converters. Selectable voltage gains: 675 810 945 1080 1215 1350 1620 v dc switch pos...
Page 95
Technical data 95 3adw000194r0201 dcs800 hardware manual e b transformer t90 data principle diagram of the transformer t90 selectable transfer ratios u prim : 502, 601, 701, 800,1000, 1200 v ac rms output voltage: 7.3 v ac rms insulation voltage: 1200 v isolation test voltage: 3500 v ambient tempera...
Page 96
Technical data 96 3adw000194r0201 dcs800 hardware manual e b.
Page 97: Dimensional Drawings
Dimensional drawings 97 3adw000194r0201 dcs800 hardware manual e b dimensional drawings dimensional drawings of the dcs800 are shown below. The dimensions are given in milllimeters. Module d1 dcs800-s01-0020 dcs800-s01-0045 dcs800-s01-0065 dcs800-s01-0090 dcs800-s01-0125 dcs800-s02-0025 dcs800-s02-0...
Page 98: Module D4
Dimensional drawings 98 3adw000194r0201 dcs800 hardware manual e b module d4 dcs800-s01-0610 dcs800-s01-0740 dcs800-s01-0900 dcs800-s02-0680 dcs800-s02-0820 dcs800-s02-1000 weight appr. 38 kg for size d4 d4_dim_a.Dsf.
Page 99: Module D5
Dimensional drawings 99 3adw000194r0201 dcs800 hardware manual e b module d5 dcs800-s0x-0900 dcs800-s0x-1200 dcs800-s0x-1500 dcs800-s0x-2000 weight appr. 110 kg 510 450 127.5 125 125 u1 v1 w1 55 276 400 461 483 10 2 earthing m12 c1 d1 325.5 65.5 25 50 50 50 Ø 14 17.75 44. 5 80 69 773 400 85.5 17 26 ...
Page 100: Module D6
Dimensional drawings 100 3adw000194r0201 dcs800 hardware manual e b module d6 dcs800-s0x-1900 dcs800-s0x-2050 dcs800-s0x-2500 dcs800-s0x-3000 weight appr. 180 kg pressure switch 63 458.2 10x20 20 17 25 c d u v w 385 445 10 x2 0 10 79 .5 15 425 375 250 c d u v w a6_dim.Dsf m12 409 22 5 20 0 17 5 0 20...
Page 101: Module D7
Dimensional drawings 101 3adw000194r0201 dcs800 hardware manual e b module d7 left-hand dcs800-s0x-2050-xxl dcs800-s0x-2600-xxl dcs800-s0x-3300-xxl dcs800-s0x-4000-xxl dcs800-s0x-4800-xxl dcs800-s0x-5200-xxl weight appr. 315 kg 80 80 80 80 93 230 530 350 for m10 20 0 22 5 20 0 20 0 17 25 a7_dim_a.Ds...
Page 102: Module D7
Dimensional drawings 102 3adw000194r0201 dcs800 hardware manual e b module d7 right-hand dcs800-s0x-2050-xxr dcs800-s0x-2600-xxr dcs800-s0x-3300-xxr dcs800-s0x-4000-xxr dcs800-s0x-4800-xxr dcs800-s0x-5200-xxr weight appr. 315 kg a7_dim_a.Dsf 20 0 22 5 20 0 20 0 17 2 5 75 9 .5 25 for m10 for m10 pres...
Page 103
Dimensional drawings 103 3adw000194r0201 dcs800 hardware manual e b fuses installed inside the converter ➀ 12 fuses per bridge (2x per f1x) converter type model fuse f1 size type 400 v / 500 v dcs800-s0x-1200-04/05 d5 800a 660v ur 5 170m 6162 dcs800-s0x-1500-04/05 d5 1250a 660v ur 5 170m 6166 dcs800...
Page 104
Dimensional drawings 104 3adw000194r0201 dcs800 hardware manual e b size 5, 6 size 7...10 ma x d max d 108 c 11 11 14 17 139 6 b a b indicator size a b c d 5 50 29 30 76 6 80 14 30 76 15 4xm10 min 10 deep Ø 3 3 25 25 100 67 .5 82 .5 Ø 11 max 105 Ø5 6 a 8 ma x 1 0 5 size a 7 62 8 90 9 105 10 120 rema...
Page 105: Accessories
Accessories 105 3adw000194r0201 dcs800 hardware manual e b accessories dcf803-0035 and fex 425 internal the field exciter dcf803 0035 and fex425intern are half controlled three-phase field converter. Both field converters are based on the same controller board sdcs fex4. The board is equipped with o...
Page 106
Accessories 106 3adw000194r0201 dcs800 hardware manual e b electrical data control unit the control includes the following main blocks: • micro controller h8 for current control synchronization and fault handling. • two channel actual field current measurement of dc circuit. • h8 controller for seri...
Page 107
Accessories 107 3adw000194r0201 dcs800 hardware manual e b voltage ripple of u dc voltage depending on operation modes dcs link communication the field converter is controlled from armature converter via dcs link serial communication based on can hardware. Node address is set by: s800 digit 0 (node ...
Page 108
Accessories 108 3adw000194r0201 dcs800 hardware manual e b diagnosis all messages are sent to armature converter and displayed by armature converter control panel. If communication is broken or node numbers are mixed up a simple fault display on sdcs-fex-4 board can be used. Therefore the unit is eq...
Page 109
Accessories 109 3adw000194r0201 dcs800 hardware manual e b rs232-port the rs232 interface is used for download the 'field exciter firmware package'. The default settings of this interface are as follows: signal level: rs232 (+12v / -12v) data format: uart message format: modbus-protocol transmission...
Page 110: Fuses And Fuse Holders
Accessories 110 3adw000194r0201 dcs800 hardware manual e b fuses and fuse holders dimensions [mm] size 0...4 main dimensions of fuse holders type resistance [m Ω] fuse f1 size fuse holder 170m 1558 30 10a 660v ur 0 ofax 00 s3l 170m 1559 21 21a 660v ur 0 ofax 00 s3l 170m 1561 15 25a 660v ur 0 ofax 00...
Page 111: Line Chokes
Accessories 111 3adw000194r0201 dcs800 hardware manual e b line chokes line chokes type nd 01...Nd 16 line chokes for use in industrial environment (minimum requirements), low inductive voltage drop, deep commutation notches. Line chokes nd01...Nd06 are equipped with cables. The bigger ones nd07...N...
Page 112
Accessories 112 3adw000194r0201 dcs800 hardware manual e b line chokes type nd 07...Nd 12 type a b c c1 e f g h i k l busbar nd 07, 08 285 230 86 100 250 176 65 80 9x18 385 232 20x4 nd 09 327 250 99 100 292 224 63 100 9x18 423 280 30x5 nd 10, 11 408 250 99 100 374 224 63 100 11x18 504 280 60x6 nd 12...
Page 113
Accessories 113 3adw000194r0201 dcs800 hardware manual e b line chokes type nd 401...Nd 413 line chokes for use in light industrial/residential environment, high inductive voltage drop, reduced commutation notches. These chokes are designed for drives which usually operate in speed control mode at 4...
Page 114
Accessories 114 3adw000194r0201 dcs800 hardware manual e b line chokes type nd 403...Nd 408 line chokes type nd 409...Nd 413 type a b c d e f Ø g Ø h Ø k nd 403 220 230 120 135 100 77.5 7 9 6.6 nd 404 220 225 120 140 100 77.5 7 9 6.6 nd 405 235 250 155 170 125 85 10 9 6.6 nd 406 255 275 155 175 125 ...
Page 115
Accessories 115 3adw000194r0201 dcs800 hardware manual e b autotransformer t3 ➀ 690 v transformer input cannot be used for the field converters sdcs-fex-1 and sdcs-fex-2 (isolation only 600 v max.) line choke l3 for sdcs-fex-2 type for field curr. Transformer's weight power loss fuse f3 secondary cu...
Page 116
Accessories 116 3adw000194r0201 dcs800 hardware manual e b supply transformer t2 for electronics and fan the supply transformer t2 has been re-designed. The new power and current rating allows to supply then 2-phase fans and the electronics by one transformer only in case a5 converters are used in a...
Page 117: Optical Cables
Accessories 117 3adw000194r0201 dcs800 hardware manual e b optical cables for the bus communication of the dcs converters there are different optical cables available. Kind of cable connector cable length ident. No. Fig. Plastic fibre optic single cable plug 0.5...20 m 3adt 693324 1 plastic fibre op...
Page 118
Accessories 118 3adw000194r0201 dcs800 hardware manual e b.
Page 120
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