- DL manuals
- ABB
- Power Supply
- ProcessMaster 500
- Operating Instructions Manual
ABB ProcessMaster 500 Operating Instructions Manual
Summary of ProcessMaster 500
Page 1
Dcs 500 thyristor power converters for dc drive systems 25 to 5150 a operating instructions dcs 500b / dcf 500b dcp 500b.
Page 2
How the dcs 500 documentation system works system description dcs 500b 3adw000066 volume ii d operating instructions dcs 500b 3adw000055 volume iv d technical data 3adw000054 volume iii description of the converter dcs 500b operating instructions (documentation in hand) including in- formation and a...
Page 3: Dcs 500B / Dcf 500B
2002 abb automation products gmbh. All rights reserved. Thyristor power converters series dcs 500b / dcf 500b dcp 500b 25 to 5150 a operating instructions code: 3adw 000 055 r0401 rev d dcs_oi_e_d.Doc effective: oct. 30th, 2002 supersedes:rev c sept. 14th, 2001.
Page 4
Dcs 500b / dcp 500b operating instructions.
Page 5: Safety Instructions
Safety instructions dcs 500b / dcp 500b operating instructions i overview this chapter contains safety instructions which must be complied with during installation, operation and maintenance of the power convertersseries dcs 500b / dcf 500b or dcp 500b. If these in- structions are not complied with,...
Page 6
Safety instructions ii dcs 500b / dcp 500b operating instructions general warning: this symbol warns you of non- electrical risks and dangers which may result in seri- ous or even fatal injury to persons and/or in damage to equipment. Where appropriate, the text printed ad- jacent to this symbol des...
Page 7
Safety instructions dcs 500b / dcp 500b operating instructions iii notes notes supply information on states requiring particular attention, or indicate that additional information is available on a specific topic. For this purpose, the following symbols are used: caution! Cautions are designed to dr...
Page 8: Contents
Contents iv dcs 500b / dcp 500b operating instructions iv a o perating i nstructions safety instructions chapter 1 - introduction how to use this manual ........................................................................................................... 1-1 contents of this manual...............
Page 9
Contents dcs 500b / dcp 500b operating instructions v running the dc- drive from the cdp31x ................................................................. 3-15 3.15 speed reference setting for the drive.......................................................................... 3-16 chapter 4 - sig...
Page 10
Vi dcs 500b / dcp 500b operating instructions.
Page 11: Chapter 1 - Introduction
Chapter 1 - introduction dcs 500b / dcp 500b operating instructions iv a 1 - 1 how to use this manual the purpose of these operating instructions is to provide detailed in- formation on how to start up a thyristor power converter from the dcs 500b or dcp 500b series. Note: if it is not mentioned exp...
Page 12
Chapter 1 - introduction iv a 1 - 2 dcs 500b / dcp 500b operating instructions incoming inspection after opening this package, you should check whether it contains the following items: ● dcs 500b / dcf 500b or dcp 500b thyristor power con- verter in the configuration ordered ● dcs 500b / dcf 500b or...
Page 13
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 1 general notes caution: it is absolutely essential that the applicable accident prevention regulations be observed by the user (in this context, please also read the chapter entitled "safety instructions")! How th...
Page 14
Chapter 2 - start-up instructions iv a 2 - 2 dcs 500b / dcp 500b operating instructions phase sequence when connecting to the mains / potential isolation no special phase sequence required for the main connections u1, v1 and w1! Phase coordination between electronics section and power section not ne...
Page 15
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 3 symbols for switching the electronics or the power section on and off - switch on electronics - switch on power x6: 7 ⇒ „1“ signal (k20 in connection example) (input on / off) - switch off electronics - switch of...
Page 16
Chapter 2 - start-up instructions iv a 2 - 4 dcs 500b / dcp 500b operating instructions symbol for altering parameters or for establishing new connections enter at keyboard e.G. 1204 = 10000 assign the value of 10000 to parameter 1204 symbol for displaying parameter values or connections display sym...
Page 17
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 5 2.1 preparatory work check the unit for damage in transit or other damage. Install and wire unit; connect all inputs and outputs required. Proceed in the same way for the field supply unit as well. Check whether ...
Page 18
Chapter 2 - start-up instructions iv a 2 - 6 dcs 500b / dcp 500b operating instructions 2.2 scaling intra-unit signals make sure that the existing electronics supply voltage has been set on the sdcs- pow-1 power supply board as well, using the sw1 switch. If an encoder is being used as the speed fee...
Page 19
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 7 set this only for units of the dcp 500 series! 517 = rated power converter current enter numerical value from rating plate here 518 = 500 v (fixed!); rated power converter voltage enter numerical value 500 v here...
Page 20
Chapter 2 - start-up instructions iv a 2 - 8 dcs 500b / dcp 500b operating instructions 2.3 presetting the field supply unit make sure that existing supply voltages for power section, field supply unit (field ex- citer) and field winding, fan, etc. Match the rated data of the components used. Switch...
Page 21
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 9 only for armature-circuit power converters with sdcs-con-2 control board & cdp 312 panel! 1201 = 5 panel display: fex2/3 autotuning activates the field current controller's auto-tuning function. Action has been c...
Page 22
Chapter 2 - start-up instructions iv a 2 - 10 dcs 500b / dcp 500b operating instructions 2.4 adjusting the current controller make sure that static current limitation bridge 1 (2307) and bridge 2 (2308; with 4q-unit) have been set to the same value; values of all parameters for current reference lim...
Page 23
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 11 drive must not turn! Do not preset an external reference! 1201 = 3 panel display: arm. Autotuning activate the current controller's auto-tuning function. Start the next two steps within the next 20 seconds! Swit...
Page 24
Chapter 2 - start-up instructions iv a 2 - 12 dcs 500b / dcp 500b operating instructions 2.5 speed feedback balancing e.M.F. Control active? 2102 = 5 panel display: emf speed act field weakening mode not selected? 1001 = 0 panel display: constant field 2103 = desired speed / or motor rating plate sc...
Page 25
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 13 only when an encoder (pulse encoder) is being used! 12104 = content of pulse counter if the shape of the curve corresponds to the diagram below, this means the wiring is correct and the pulses will be correctly ...
Page 26
Chapter 2 - start-up instructions iv a 2 - 14 dcs 500b / dcp 500b operating instructions 2.6 balancing the field supply unit and the e.M.F. Controller when matching the field supply unit to the system conditions, differences in the proce- dures adopted must be taken into account; these different pro...
Page 27
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 15 2.6.2 field weakening control with setting range caution: not permitted when chapter 2.5 was quit with e.M.F. Control! 1001 = 1 panel display: emf, no field rev field weakening function activated 1012 = speed at...
Page 28
Chapter 2 - start-up instructions iv a 2 - 16 dcs 500b / dcp 500b operating instructions 2.6.3 field weakening control with setting range > 1 : 1.5 caution: not permitted when chapter 2.5 was quit with e.M.F. Control! Only when unit is fitted with an sdcs-con-1 control board! If the field time const...
Page 29
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 17 switch off power! 1201 = 0 panel display: not activated 11202 = save mot1 set save the altered values in the non-volatile memory! When unit is fitted either with an sdcs-con-1 or sdcs-con-2 control board! 1001 =...
Page 30
Chapter 2 - start-up instructions iv a 2 - 18 dcs 500b / dcp 500b operating instructions 12522 = decrease so that motor voltage is 90 %. Flux and thus the field current as well are reduced. How to proceed: 1. Decrease 12522 (in steps of 100 at a time) 2. Press act, read off motor voltage 3. Press pa...
Page 31
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 19 only if analog tacho is used as speed feedback! Switch on power; start drive. Danger: system components now energized! 12516 = increase slowly up to 20000 (=100 % speed). Check motor voltage; if value has been s...
Page 32
Chapter 2 - start-up instructions iv a 2 - 20 dcs 500b / dcp 500b operating instructions 2.7 balancing the speed controller, plus fine-balancing the e.M.F. And the current controllers 1701 = 11206 change between pot1 and pot2 activated. Extremely reduce the ramp-up time, depending on the system cond...
Page 33
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 21 1204 = 0 1205 = 0 switch off power, thus stopping the drive! 1701 = 11903 501 = rated motor voltage set in chapter 2.2. 1012 = speed at rated motor voltage caution! Please don't forget! 11202 = save mot1 set sav...
Page 34
Chapter 2 - start-up instructions iv a 2 - 22 dcs 500b / dcp 500b operating instructions 2.9 presetting the 3-phase field supply unit dcf 50xb this is a new functionality available for the first time with software version s21.232. When commissioning a drive consisting of a dcs converter for the arma...
Page 35
Chapter 2 - start-up instructions dcs 500b / dcp 500b operating instructions iv a 2 - 23 alarm or fault indication / reaction, if dcf 506 has triggered 3601 = 15 only at dcf 502b; bridge reversal delayed to app. 50ms 3602 = 15 only at dcf 502b; in worst case bridge change over will take place when t...
Page 36
Chapter 2 - start-up instructions iv a 2 - 24 dcs 500b / dcp 500b operating instructions when the display shows not activated (action correctly completed): stop drive switch off power! In case the autotuning failed: 1201 = 4 panel display: arm. Man. Tuning arm.Man_tuning, if the fex2/3 autotuning fa...
Page 37
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 1 3.1 overview the control and display panel [control panel] is used for parame- ter setting, for feedback value measuring and for drive control with series dcs 500b / dcf 500b and dcp 500b thyristor po...
Page 38
Chapter 3 - handling of control panel cdp 31x iv a 3 - 2 dcs 500b / dcp 500b operating instructions 3.2 start mode note: the cdp 31x can be connected to the drive without dis- connecting the auxiliary power ! When connected and power is applied to the electronics, the dis- play of the cdp 31x shows:...
Page 39
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 3 3.3 panel functions the cdp 31x has four different keypad modes: • actual signal display mode (act) • parameter mode (par) • function mode (func) • drive mode (drive) for further extensions actual sig...
Page 40
Chapter 3 - handling of control panel cdp 31x iv a 3 - 4 dcs 500b / dcp 500b operating instructions parameter mode par the parameter mode is used for: - change the structure in the firmware - show signals and their actual status - show and change values of parameters, if they are not write-protected...
Page 41
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 5 drive mode drive drive mode is used to check the configuration. The display will show the type and id-number of the drive to whom the cdp 31x is connected to. Dcs500 id-number 0 total 1 drives device ...
Page 42
Chapter 3 - handling of control panel cdp 31x iv a 3 - 6 dcs 500b / dcp 500b operating instructions step function press key display after key is pressed 1. To enter the parameter mode selection par 0 l 0.0 rpm 00 17 ramp generator 01 ramp.[in] 119.03 2. To select another group. While holding the key...
Page 43
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 7 3.5 saving of the parameters to backup memory step function press key display after key is pressed 1. To enter the parameter mode selection par 0 l 0.0 rpm 00 2 analog outputs 05 ao2.[in] 105.01 2. Se...
Page 44
Chapter 3 - handling of control panel cdp 31x iv a 3 - 8 dcs 500b / dcp 500b operating instructions 3.6 fault resetting (reset) fault resetting and emergency stop resetting (reset) can only be performed via the cdp 31x if local is active. If drive is in remote, please check whether local is a critic...
Page 45
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 9 3.8 fault history display up to 100 faults are stored time related and displayed together with the time they appeared after electronics supply switched on. Step function press key display after key is...
Page 46
Chapter 3 - handling of control panel cdp 31x iv a 3 - 10 dcs 500b / dcp 500b operating instructions 3.9 uploading and downloading of parameters (upload/download) caution! The drive must be in standstill condition with given stop command (controllers blocked, power section disconnected from the netw...
Page 47
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 11 depending on the drive´s condition and the status of the commis- sioning, upload has to take place before download, otherwise a warning may be displayed: **warning** not uploaded downloading not poss...
Page 48
Chapter 3 - handling of control panel cdp 31x iv a 3 - 12 dcs 500b / dcp 500b operating instructions 3.10 setting of the display contrast step function press key display after key is pressed 1. To enter the function mode. Func 0 l 0.0 rpm 00 upload download => => contrast 7 2. To select a function. ...
Page 49
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 13 3.12 selecting output pins note for cdp 310 / cdp 311: newly selected actual signals will be used for display until the elec- tronics power supply is switched off. Note for cdp 312: if there is a nee...
Page 50
Chapter 3 - handling of control panel cdp 31x iv a 3 - 14 dcs 500b / dcp 500b operating instructions 3.13 drive mode display of the id-number for the drive and for the control panel cdp 31x as well as display of the status (status display) step function press key display after key is pressed 1. To e...
Page 51
Chapter 3 - handling of control panel cdp 31x dcs 500b / dcp 500b operating instructions iv a 3 - 15 3.14 running the drive operational com- mand keys operational commands can be given from the control panel cdp31x every time when the status row is displayed. Operational commands include start and s...
Page 52
Chapter 3 - handling of control panel cdp 31x iv a 3 - 16 dcs 500b / dcp 500b operating instructions 3.15 speed reference setting for the drive step function press key display after key is pressed 1. Press one of these keys to get the status row displayed. Act par func 0 l 0.0 rpm 00 speed ac 0.0 rp...
Page 53: F 14
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 1 4.1 display of status, alarm and fault signals categories of signals and possibilities of display the signals (messages) to be available for thyristor power con- verters series dcs 500b / dcf 500b or dcp 50...
Page 54
Chapter 4 - signals and troubleshooting iv a 4 - 2 dcs 500b / dcp 500b operating instructions 4.2 general messages the general messages will only be shown on the seven segment display of the control board sdcs-con-x. Code seven segm. Display text on lcd of control panel cdp 31x definition – remark 8...
Page 55
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 3 4.4 fault signals (f) the fault signals will be shown on the seven segment display of the control board sdcs-con-x as codes f . . As well as on the lcd of the control panel cdp 31x as clear text. All fault ...
Page 56
Chapter 4 - signals and troubleshooting iv a 4 - 4 dcs 500b / dcp 500b operating instructions code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 3 conv.Fan curr.Fault current converter fan not within limits the current of the con...
Page 57
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 5 code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 8 current rise fault actual current changed faster than allowed the rate of current ...
Page 58
Chapter 4 - signals and troubleshooting iv a 4 - 6 dcs 500b / dcp 500b operating instructions code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 20 local & discon- nected no communication between cdp 31x/cmt and dcs 500b / dcf 50...
Page 59
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 7 code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 28 armature over- voltage armature (dc circuit) overvoltage check: - setting of para...
Page 60
Chapter 4 - signals and troubleshooting iv a 4 - 8 dcs 500b / dcp 500b operating instructions code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 34 arm. Curent ripple armature current ripple one or several thyristors carry no cur...
Page 61
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 9 code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark field weakening range too big / threshold too high check: - do selection parameters ma...
Page 62
Chapter 4 - signals and troubleshooting iv a 4 - 10 dcs 500b / dcp 500b operating instructions code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 44 i/o-board not found missing input/output (i/o-) boards iob1/2x/3/ioe1 the exista...
Page 63
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 11 code seven segm. Display text on lcd of control panel cdp 31x definition / action status signal (fault_word_1/2) remark f 65 reversal fault reversal of direction of current is not o.K. The reversal of the ...
Page 64
Chapter 4 - signals and troubleshooting iv a 4 - 12 dcs 500b / dcp 500b operating instructions 4.5 alarm signals (a) the alarm signals will be shown on the seven segment display of the control board sdcs-con-x as codes a . . As well as on the lcd of the control panel cdp 31x as plain text. Alarm sig...
Page 65
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 13 code seven segm. Display text on lcd of control panel cdp 31x definition / possible source signal number (alarm_word_1/2) remark a 108 ram-backup failed alarm no battery backup function for ram capacitor f...
Page 66
Chapter 4 - signals and troubleshooting iv a 4 - 14 dcs 500b / dcp 500b operating instructions code seven segm. Display text on lcd of control panel cdp 31x definition / possible source signal number (alarm_word_1/2) remark a 127 ext. Fan ack.Alarm alarm no acknowledge from external fan (of motor) c...
Page 67
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 15 code seven segm. Display text on lcd of control panel cdp 31x definition / possible source signal number (alarm_word_1/2) remark a 134 backup not allowed alarm change of parameter set not allowed signal wi...
Page 68
Chapter 4 - signals and troubleshooting iv a 4 - 16 dcs 500b / dcp 500b operating instructions code seven segm. Display text on lcd of control panel cdp 31x definition / possible source signal number (alarm_word_1/2) remark a 143 macro change failed alarm change from macro x to macro y has failed at...
Page 69
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 17 4.6 status signals the status of drive functions (autotuning of controllers; saving val- ues) is shown by status signals named 11201 and 11202. The status of the first and / or the second field exciter, th...
Page 70
Chapter 4 - signals and troubleshooting iv a 4 - 18 dcs 500b / dcp 500b operating instructions para- meter code / bit text on lcd of con- trol panel cdp 31x definition / explication of the signal remark 11201 -- ---- gives feedback status information when the drivemode parameter (1201) was used to s...
Page 71
Chapter 4 - signals and troubleshooting dcs 500b / dcp 500b operating instructions iv a 4 - 19 para- meter code / bit text on lcd of con- trol panel cdp 31x definition / explication of the signal remark 6 read appl blocks load application; if additional function blocks are ac- tivated and saved via ...
Page 72
Chapter 4 - signals and troubleshooting iv a 4 - 20 dcs 500b / dcp 500b operating instructions para- meter code / bit text on lcd of con- trol panel cdp 31x definition / explication of the signal remark 12 (field2_curr_min_l) 1 = motor 2 field current above min level 11204 -- ---- tc_status: status ...
Page 73
Appendix a - connection diagrams dcs 500b / dcp 500b operating instructions iv a a - 1 connection diagram 1 for detailed information see system description dcs 500b / dcf 500b. In 3 ou t 3 in 1 ou t 1 v5 v6 v1 v2 x9 6 : do 8 12 x 99 : 12 x 2: 4 5 x 2: 1 2 3 u1 w 1 v1 pe k1 k2 0 k2 1 k2 0 k1 x9 6 :1 ...
Page 74
Appendix a - connection diagrams iv a a - 2 dcs 500b / dcp 500b operating instructions connection diagram 2 for detailed information see system description dcs 500b / dcf 500b. In 3 out 3 in 1 out 1 v5 v6 v1 v2 x9 6 : do 8 12 x 99 : 12 x 2: 4 5 x 2: 1 2 3 u1 w 1 v1 pe k1 f6 k2 0 k2 1 k2 0 k 3 k 1 x9...
Page 75
Appendix a - connection diagrams dcs 500b / dcp 500b operating instructions iv a a - 3.
Page 76
Abb automation products gmbh postfach 1180 lampertheim • germany tel: +49 (0) 62 06-5 03-0 fax: +49 (0) 62 06-5 03-6 09 www.Abb.Com/dc *055r0401a2440000* *055r0401a2440000* ident. No.: 3adw 000 055 r0401 rev d 09_01.