ABB DCS800 Hardware Manual
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ABB DCS800 Hardware Manual

Dcs800 drives (20 to 5200 a)
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DCS800
Hardware Manual
DCS800 Drives (20 to 5200 A)

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Summary of Contents for ABB DCS800

  • Page 1 DCS800 Hardware Manual DCS800 Drives (20 to 5200 A)

  • Page 2: Dcs800 Single Drive Manuals

    DCS 800 Quick Guide (191 + CD) 3 ADT 645 0 ?? DCS 800 converter module Flyer DCS800 3 ADW 000 190 Flyer DCS800 E Panel solution 3 ADW 000 0?? Catalogue DCS800 3 ADW 000 192 Hardware Manual DCS800 00S...
  • Page 3 DCS800 Drives 20 to 5200 Amps Hardware Manual 3ADW000194R0201 Rev B EFFECTIVE: 05.10.2005 ¤ 2005 ABB Automation Products GmbH. All rights reserved. served. 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 4 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 5: Safety Instructions

    To which products this chapter applies This chapter applies to the DCS800... Size D1 to D7and field exciter units DCF800... Use of warnings and notes There are two types of safety instructions throughout this manual: warnings and notes.

  • Page 6: Installation And Maintenance Work

    Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs SDCS-IOB-2, RDIO. • DCS800 with enclosure extension: Before working on the drive, isolate the whole drive from the supply. Safety instructions...

  • Page 7: Grounding

    • 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 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 8: Fibre Optic Cables

    • DCS800 Size D4...D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place the unit only on its back. DCS800 Size D6/D7: The drive is heavy. Lift the drive by the lifting lugs only.

  • Page 9: Operation

    - 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 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 10 Note: • When the control location is not set to Local (L not shown in the PC tool status row), the stop key on the control panel will not stop the drive. Safety instructions 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 11: Table Of Contents

    DCS800 Single Drive Manuals ........
  • Page 12 DCS800 panel cable ........
  • Page 13 Technical data What this chapter contains ............65 Environmental Conditions .
  • Page 14 Diagnosis ............. . .108 RS232-Port .

  • Page 15: The Dcs800

    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 Size D5 20...1000 A 900...2000 A...

  • Page 16: Type Code

    Type code The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. DCS800-S01- 2005). The optional selections are given thereafter, on the name plate by plus code.

  • Page 17: Main Circuit And Control

    DCF 803 / 804 On Board FEX PIN 4 Memory Card Slot 4 Slot 1 Slot 2 Fieldbus RDIO interface R... RAIO Slot 3 COM-8 optical fibre optical fibre NDBU95 NDBU95 Master/ Follower NAMIA The DCS800 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 18: Armature Circuit Converter Dcs800 D5

    DCF 803 / 804 FEX 425 internal ** Memory Card Slot 4 Slot 1 Slot 2 Fieldbus RDIO interface R... RAIO Slot 3 COM-8 optical fibre optical fibre NDBU95 NDBU95 Master/ Follower NAMIA The DCS800 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 19: Rebuild System Dcr800

    DCF 803 / 804 FEX 425 internal Memory Card Slot 4 Slot 1 Slot 2 Fieldbus RDIO interface R... RAIO Slot 3 COM-8 optical fibre optical fibre NDBU95 NDBU95 Master/ Follower NAMIA The DCS800 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 20 The DCS800 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 21: Mechanical Installation

    CE markings, a type code and a serial number, which allow individual identification of each unit. The remaining digits complete the serial number so that there are no two units with the same serial number. Example labels are shown below. Type designation label Mechanical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 22: Before Installation

    COOL AREA max.+40 °C (+104 °F) Air baffle plate Main air flow in Cooling w baffle.dsf Airflow Lead the exhaust cooling air away from the unit above. Distances see chapter Dimensional drawings Mechanical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 23: Mounting The Converter Module D6 Inside An Enclosure

    The converter module is equipped with a thread hole at its end. Because of that the length of the remaining threads is limited to 35 mm (see drawing below). max. 35mm A6_li_air_inlet_a.dsf 468.2 Example right side connection Mechanical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 24: Mounting The Converter Module D7 Inside An Enclosure

    Cooling air outlet To avoid circulating air inside the enclosore it is rec- ommended to make sure the exhaust air leaves the enclosure. Mechanical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 25: Planning The Electrical Installation

    Always follow local regulations. Note: If the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover. Reference: Technical Guide - publ. no.: 3ADW000163 To which products this chapter applies This chapter applies to the DCS800 Size D1...D7.
  • Page 26 690 V line voltage • are based on a duty cycle • can be used for DCS800 as armature converter as well as field converter but rated line choke current must be considered.
  • Page 27 DCS800-S01-1500-04/05/06/07 DCS800-S02-1500-04/05/06/07 ND15 on request DCS800-S01-2000-04/05 DCS800-S02-2000-04/05 ND16 on request DCS800-S01-2000-06/07 ND16 * on request * with forced cooling (1m/s) Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 28: Aspects Of Fusing For The Armature-Circuit And Field Supplies Of Dc Drives

    Adequate protection against short-circuit and earth fault, as depicted in the EN50178 standard, is possible only with appropriate semiconductor fuses. Semiconductor Semiconductor fuses fuses DCS converter DCS converter 4-Q resp. 2-Q non-regen. 2-Q regenerative Semiconductor fuses Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 29 Only pure HRC fuses or miniature circuit-breakers may be used. Semiconductor fuses would be destroyed, for example, by the transformer’s starting current inrush. F3.2 F3.1 Configurations for field supplies ND30 / F3.3 built-in F3.1 FF_ASP_b.dsf Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 30: Semiconductor Type F1 Fuses And Fuse Holders For Ac And Dc Power Lines

    Table below lists the fuse currents with respect to the table above. The fuses can be sized according to the maximum field current. In this case take the fuse, which fits to the rated field current levels. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 31: Single-Phase Transformer T3 For Field Supply To Match Voltage Levels

    T 3.12 FEX-425-Int ≤16 A T 3.13 = ≤690 V prim ≤30 A DCF803/4-0050 T 3.14 T3 autotransformer ≤50 A DCF803/4-0050 T 3.15 Autotransformer data (details see chapter Technical Data) Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 32: Single-Phase Commutating Reactor

    The filters are suitable for grounded lines only, for example in public European 400 V lines. According to EN 61800-3 filters are not needed in insulated industrial networks with own supply transformers. Furthermore they could cause safety risks in such floating lines (IT networks). Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 33: Three-Phase Filters

    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 (First Environment). Three-phase filters EMC filters are necessary to fulfil the standard for emitted interference if a converter shall be run at a public low voltage line, in Europe for example with 400 V between the phases.
  • Page 34 Then a field supply unit does not need its own filter. If the phase to neutral voltage shall be taken (230 V in a 400 V line) then a separate filter is necessary. ABB offers such filters for 250 V and 6...30 A. Filter type ➀...
  • Page 35 Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 36 Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 37 Screened cable of sensitive communication equipment. able to cope with the commutation gaps caused by the power Unscreened cable with restriction converter. In some cases, commutating reactors will be required. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 38: Converters D1

    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. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 39: Converters D5 Drive Configuration Using 'Fex-425-Int' Field Exciter

    Field converters FEX-425-Int are equipped with their own synchronization and can be supplied from an independent net. For drives up to 500 V mains voltage FEX-425-Int can be supplied internally (3-phase). Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 40: Converters D5

    Field converters DCF803 / DCF804 are equipped with their own synchronization and can be supplied from an independent net. DCF803-0035 can be supplied wit 3-phase aux. supply. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 41: Start, Stop And E-Stop Control

    If the drive has not finished the function within the K15 timer setting, the drive must get the command to switch OFF the current via K16. After K16 timer set has elapsed the main contactor is opened independent of the drives status. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 42 E-STOP ELEC. DISCONN. speed Timer K15 EMER. STOP Timer K16 Block current control K1 main contactor CON-2 X6:9 E-Stop ramp Coast Stop-Mode.dsf E-Stop reaction Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 43: Drive Configuration With Reduced Components

    Wiring the drive according to this diagram gives the same control performance, but a lower degree of flexibility. Dynamic Braking keeps the main contactor K1 in state ON during braking. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 44: Power Section Cooling

    Temperatur detector: internal connected ➀ ➀ Increased losses due to increased current with a blocked rotor will not result in a winding temper- ature, higher than permissible for the insulation class being involved. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 45 D6 and D7 power section isolated PTC thermistor is used for air entry temperature. The detector thus measures the power section’s radiated heat and any changes in the cooling air temperature and volume. Since the cooling air volume can Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 46: Thermal Overload And Short-Circuit Protection

    Always protect the input cable with fuses. Size the fuses according to local safety regulations, appropriate input voltage and the rated current of the drive (see chapter Technical Data). High-speed semiconductor fuses provide short-circuit protection, but don’t provide thermal overload protection. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 47: Cross-Sectional Areas - Tightening Torques

    You will find instructions on how to calculate the PE conductor’s cross-sectional area in VDE 0100 or in equivalent national standards. We would remind you that power converters may have a current-limiting effect. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 48: Selecting The Control Cables

    ! Never mix 24 VDC and 115/230 VAC signals in the same cable. DCS800 panel cable The cable connection of the DCS800 panel to the drive must not exceed 3 meters (10 ft). The cable type tested and approved by ABB is used in control panel option kits.

  • Page 49: Connection Of A Motor Temperature Sensor To The Drive I/O

    3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the main circuit of the drive. Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 50 Planning the electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 51: Electrical Installation

    (C1, D1) or (F+, F-) and the Protective Earth by using a measuring voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm. C1, D1 F+, F- Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 52: It (Ungrounded) Systems

    Grounding and sreening of power cables see manual Technical Guide, see Reference Cross sectional areas and tightening torques of power cable see chapter Planning the electrical installation Location R-Extension and Interface Modules Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 53 SLOT 1 Panel connector R IO Extension module X33: R-Fieldbus module SLOT 2 R IO Extension module Interface connector SLOT 3 X2: SDCS-IOB-3 R IO Extension module X1: SDCS-IOB-2 R DDCS interface board Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 54: I/O Board Configuration

    I/O´s: not isolated digital I/O´s: all isolated by means of encoder input: isolated optocoupler/relay, the current source for: PT100/PTC element signal status is indicated by LED current source for: PT100/PTC element Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 55: Pulse Encoder Connection

    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 difference between these 2 boards is the galvanically isolated circuit and pulse receivers via opto coupler on the SDCS-IOB-3 board.

  • Page 56: Pulse Encoder Receiver

    Make sure the threshold is half of the supply voltage and the minimum voltage of the encoder output (saturation voltage UCE of a transistor). differential SDCS-IOB-3 CON-4 IOB-3 X5:1 e.g. CH A 12/24 V 12/24 V +24V differential voltage source 3=park 6=park 10-11 X5:2 9=park 14-15 16-17 differential current source iob14_e.dsf 13-14 Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 57 & GND 0 ... 50 m 1x 0.25 mm² 12x 0.25 mm² 50 ... 100 m 2x 0.25 mm² 12x 0.25 mm² 100 ... 150 m 3x 0.25 mm² 14x 0.25 mm² Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 58: Connecting The Signal And Control Cables

    Lead 24 V and 230 V Not allowed unless the 24 V control cables in separate cable is insulated for 230 V or insulated with an insulation ducts inside the cabinet. sleeving for 230 V. Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 59: Dsl Link Wiring

    1%, 1/4 W 1%, 1/4 W CAN_L CAN_Bus_termination.dsf The bus must be isolated but can be ground terminated at one end only. Example of two DCS800 D5 converters with FEX-425-Int internal field supply. DCS800 D5 Converter DCS800 D5 Converter SDCS-DSL SDCS-DSL...
  • Page 60 Electrical installation 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 61: Installation Checklist

    The external control connections inside the drive are OK. There are no tools, foreign objects or dust from drilling inside the drive. Drive, motor connection box and other covers are in place. Installation checklist 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 62 Installation checklist 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 63: Maintenance

    Ignoring the safety instructions can cause injury or death. Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Maintenance Interval Instruction...

  • Page 64: Heatsink

    If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 65: What This Chapter Contains

    Effect of the site elevation above sea level on the converter’s load capacity Effect of the ambient temperature on the converter module load capacity 5000 m 1000 2000 3000 4000 55°C Current reduction to (%) Current reduction to (%) for converter modules Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 66 • or on request >600 V to 1000 V EN / IEC xxxxx see table EN / IEC types: on above. request(for details see Available for converter table above modulesincluding field exciter units. Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 67: Current Ratings

    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 an ambient temperature of max. 40°C and an elevation of max.

  • Page 68: Sizing

    D7 ratings are higher (except I Note 2: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 °C (104 °F) or the drive is loaded cyclically. Derating Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 69: 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 Serial communication parameter service are stored immediately in the FlashPROM. Parameters handled by cyclic serial communication (dataset table Group 90 - 92) are not stored in the Flash PROM.

  • Page 70: Seven Segment Display

    X1: and X2: are used to connect SDCS-IOB-2 and SDCS-IOB-3 board. see chapter Technical data X33: is used to connect DCS800 Panel. It can be connected direct via 40 mm jack or via CAT 1:1 cable (RJ45). X34: is used for download firmware and for DWL and IEC1131 programming connection.
  • Page 71 X20 (Slot 4) is used for Memory Card, see description IEC1131 Programming. Prepared function of: Slot 1 Slot 2 Slot 3 Slot 4 X10: X11: X20: RDIO / RAIO R... Fieldbus adapter SDCS-COM-8 Second fieldbus RMBA Memory Card Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 72: Digital And Analogue I/O Connection Of The Sdcs-Con-4

    = 160 mA Relay driver load Do not apply any reverse Relay driver voltages! * short circuit protected ➀ gain can be varied in 15 steps between 1 Con4_I_O.dsf and 4 by software parameter Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 73: Interface Board Sdcs-Com-8

    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 each optical channel): •...
  • Page 74 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 75 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 76 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 77: Ddcs Branching Unit Ndbu-95

    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 messages from the master (PC) and sends them to all the slave units simultaneously.

  • Page 78: Dsl Board

    120 ohm Termination 200 kOhm no termination; park position Ground termination 200 kOhm R-C ground termination X54:1 0 Ohm ground termination no termination; park position RS 485 communication Remarks no isolation DSL-4_dia.dsf Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 79: Digital I/O Board Sdcs-Iob-2

    4.3 mm time constant input 10ms * this dimension may vary (4/5 mm) DI 7 depending on revision ** W100 as printed circuit DI 8 iob2x1_c.dsf default value Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 80 X7:2, but controlled by the source, connected to X7:1, must be cut off. The same method is needed for the other jumpers Wx. High frequency grounding is done by 100 nF capacitor. Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 81: Analogue And Encoder I/O Board Sdcs-Iob-3

    S1:3-4 S1:5-6 Temperature sensor supply PT100 1.5 mA 5 mA AI3 S1:7-8 AI4 S1:9-10 S1:11-12 S1:13-14 Characteristics for pulse encoder inputs single ended: 12/24 V differential: 12/24 V 13 mA default value Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 82 8 to 33 volts at PS5311. - input range ”20mA” , or * short circuit proof - input range ”10V”, or - earth fault monitoring by Isum not equal to zero via X3:11 and X3:12 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 83: Power Supply Board Sdcs-Pow-4

    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-POW-4 works on a switched mode basis in fly back configuration. It generates all necessary DC voltages for the SDCS-CON-4 and all other electronic boards.

  • Page 84: Interface Board Sdcs-Pin-4

    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. Control of armature bridge and measurement 3.

  • Page 85: Power Supply

    230 V AC capacitance to the existing ones to increase the mains buffering time. More detailed data Tolerence -15%/+10% -15%/+10% is available on request via your ABB Frequency 45 Hz ... 65 Hz 45 Hz ... 65 Hz representative. Power con-...

  • Page 86: Armature Circuit Interface

    AWG 6 AWG 6 AWG 6 AWG 6 min. cross sectional area 1 mm² 2.5 mm² 4 mm² 6 mm² AWG 16 AWG 12 AWG 10 AWG 8 Fuse type KTK - 25 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 87 Typical armature circuit thyristor converter diagram with SDCS-PIN-4 board Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 88: Power Interface Sdcs-Pin-46/Sdcs-Pin-48/Sdcs-Pin-5X

    X22 X122 X23 SDCS-PIN-5x SDCS-PIN-46/PIN-48 4q_c3a_b.dsf Pulse transformer board SDCS-PIN-46/PIN-48 Layout of the SDCS-PIN-46/PIN-48 pulse transformer board Gate Cathode The board consists of six pulse transformers with amplifiers. X113 X213 SDCS-PIN-4x Pin4x.dsf Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 89 Layout of the SDCS-PIN-52 In the past some converters for line voltages lower/equal 500 V had been equipped with SDCS- PIN-52 boards. The SDCS-PIN- 51 board serves as a spare part for those converters. SDCS-PIN-52 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 90 Settings of the SDCS-PIN-51 board if a DCS converter is equipped with it by ABB Current coding Construction type Current transf. ratio 2500:1 2500:1 4000:1 Rated current [A DC] 1200 1500 2000 1900 2050 2500 3000 2050 2600 3300 4000...
  • Page 91 Typical armature circuit thyristor converter diagram with SDCS-PIN-48 and SDCS-PIN-51 boards for a 4-Quadrant D7 type converter 100R 120R 270R 560R Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 92: Galvanic Isolation - T90, A92

    3ADT 745047 Secondary Terminals * * 12-pulse serial and sequential have a different selection between S CONV NOM VOLT (42.08) and the scaling of measurement channel. See 12-pulse manual for DCS 600. Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 93 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 100R 120R 270R 560R Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 94: Dc-Dc Transducer A92

    The voltage gain and frequency response is especially designed for DCS800 converters. Dimensions in mm Location of terminals Side view Buttom view 112.0 76.0 10.0 70.0 Gain selector 50.0 9 10 60.0 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 95: Transformer T90

    Put in the cable lug, swing in the shrowding cover and fasten the con- nection by turning the screw clockwise. 5.2 x 7.7 118..120 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 96 Technical data 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 97: Dimensional Drawings

    Dimensional drawings Dimensional drawings of the DCS800 are shown below. The dimensions are given in milllimeters. Module D1 for size D1 for size D2...D3 DCS800-S01-0020 direction of air flow DCS800-S01-0045 DCS800-S01-0065 DCS800-S01-0090 screw M6 fan terminal DCS800-S01-0125 DCS800-S02-0025 DCS800-S02-0050 DCS800-S02-0075...

  • Page 98: Module D4

    Module D4 for size D4 DCS800-S01-0610 DCS800-S01-0740 DCS800-S01-0900 DCS800-S02-0680 DCS800-S02-0820 DCS800-S02-1000 Weight appr. 38 kg D4_dim_a.dsf Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 99: Module D5

    The upper and lower holes in the back plate of the converter should be used to fix the converter in that position. Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 100: Module D6

    Module D6 458.2 DCS800-S0x-1900 DCS800-S0x-2050 DCS800-S0x-2500 Air outlet DCS800-S0x-3000 10x20 Weight appr. 180 kg Pressure switch Air entry A6_dim.dsf from the front, right, left and 468.2 back Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 101: Module D7 Left-Hand

    Module D7 left-hand for M10 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 Pressure switch for M10 A7_dim_a.dsf Busbars in mm: AC and DC 100 x 10 Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 102: Module D7 Right-Hand

    Module D7 right-hand for M10 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 Pressure switch for M10 A7_dim_a.dsf Busbars in mm: AC and DC 100 x 10 Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 103: Fuses Installed Inside The Converter

    DCS800-S0x-2050-10 1800A 1250V UR 170M 7976 DCS800-S0x-2600-10 1800A 1250V UR 170M 7976 DCS800-S0x-3300-10 2500A 1250V UR 170M 7978 DCS800-S0x-4000-10 2500A 1250V UR 170M 7978 ➀ 12 fuses per bridge (2x per F1x) Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 104 Size 5, 6 Size 7...10 Indicator max 105 4xM10 min 10 deep max d Ø 11 Size Size Remark: Given dimensions may be exceeded in some cases. Please take them only for information. Dimensional drawings 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 105: Accessories

    Setting of switchable burden resistors by rated field current Field Fex4x1.dsf Layout of the SDCS-FEX-4 board X110 T110 T113 X100 T112 S800 T111 U730 D800 S801 U731 R106 V110 X101 R107 R108 Fex4_layout.dsf Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 106: Electrical Data

    If the unit is used as a single phase supply the terminal U and W must be used. For single-phase supply an autotransformer for voltage adaption is recommended. Please see comparison of output voltage ripple between single-phase and three phase-supply. Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 107: Dcs Link Communication

    ==> S800 = 3 and S801 = 1 Selection of communication speed is set by S1100 S1100:6 S1100:5 S1100:4 Baudrate Selection of armature kBaud * converter 1000 * see Parameter 94.08, 94.09 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 108: Diagnosis

    Fault Field AC supply voltage < 30V Fault Field AC supply voltage < 650V Fault maximum temperature heatsink Y=12 Fault Auxiliary voltage Y=14 Fault general hardware No RESET Y=15 Fault general software No RESET Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 109: Rs232-Port

    Description not connectedßtext1 not connected SGND Signal ground 6...9 not connected The programming procedure is activated by setting S1:1-2 during auxiliary voltage is switched ON. Setting for field exciter mode is S1:3-4 (default). Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 110: Fuses And Fuse Holders

    HxWxD [mm] Protection OFAX ... OFAX 00 S3L 148x112x111 IP20 OFAX 1 S3 250x174x123 IP20 OFAX 2 S3 250x214x133 IP20 OFA X 2 S3 OFAX 3 S3 265x246x160 IP20 170H 3006 (IP00) 170H3006_a.dsf Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 111: Line Chokes

    Line chokes type ND 01...ND 06 X, Y, Z A, B, C A, B, C X, Y, Z ND1_to_6_a.dsf Type mm² ND 01 ND 02 ND 03 ND 04 ND 05 ND 06 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 112: Line Chokes Type Nd 07

    ND 12 13x18 40x6 Line chokes type ND 13, 14 Line chokes type ND 15, 16 all busbars 40x10 all busbars 60x10 ±2 ±2 ±2 ø13 ø13 ±1 ±2 ND13_14_c.dsf ±2 ND15_16_c.dsf ±1 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 113: Line Chokes Type Nd 401

    F Ø G Ø H ND 401 160 190 75 80 51 175 ND 402 200 220 105 115 75 200 Terminals: WAGO Type 202 UL File E45172 ø H tin-coated ø G ø G+5 F±1 E±2 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 114 13 2x11 ND 412 385 350 205 280 175 115 12 13 2x11 ND 413 445 350 205 280 175 115 12 13 2x11 ø H tin-coated øK AL ø E ±2 F ±2 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 115: Autotransformer T3

    295 175 176 141 380 12x18 95 T 3.05 / T 3.15 Line choke L3 for SDCS-FEX-2 Type line choke data L3 Weight Pow loss peak [ µ H] [kg] [W] [mm²] ND30 2x >500 4.5 Ø max 80 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 116: Supply Transformer T2 For Electronics And Fan

    The transformer is designed to work as a 230 V / 230 V transformer to open/ 230 V avoid ground loops. This is done via the 380 V and 600 V taping according to the left picture. 230 V 115 V T2_a.dsf Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...

  • Page 117: Optical Cables

    HCS silica (double) with plastic jacket plug 50...200 m 3ADT 693356 4 Figure 1 blue black Figure 2 blue black black blue Figure 3 orange orange 5 mm black black Figure 4 blue blue 8 mm Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 118 Accessories 3ADW000194R0201 DCS800 Hardware Manual e b...
  • Page 120 ABB Automation Products GmbH Postfach 1180 68619 Lampertheim • GERMANY Telefon: +49 (0) 62 06 5 03-0 Telefax: +49 (0) 62 06 5 03-6 09 www.abb.com/dc *194R0201A5400000* *194R0201A5400000*...

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