Hardware Manual
DCS800 Drives (20 to 5200 A)
ABB
DCS800 Drive Manuals
Language
Public. number E D I ES F CN RU PL PT SE
DCS800 Quick Guide 3ADW000191 x x x x x x x
DCS800 Tools & Documentation CD 3ADW000211 x
DCS800 Converter module
Flyer DCS800 3ADW000190 x x x x x
Technical Catalog DCS800 3ADW000192 x x 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 3ADW000194Z 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 x
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 C_____s C_____s_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 x
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 Catalog DCS800-A 3ADW000198 x
Installation of DCS800-A 3ADW000091 x x
DCS800-R Rebuild System
Flyer DCS800-R 3ADW000007 x x
DCS800-R Rebuild Kits 3ADW000197 x
DCS800-R Optical Rebuild Kits 3ADW000415 x
DCS800-R DCS500/DCS600 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
Door mounting kits
Door mounting DCS Control Panel (IP54, click in) 3AUA0000076085 x
Door mounting DCS Control Panel (fix mounting) 3AFE68294673 x
Door mounting DCS Control Panel (IP66, fix mounting) 3AFE68829593 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 01.2015
DCS800 Manuals-list e m.docx
194R0811DCS800 Drives
20 to 5200 A
Hardware Manual
Effective: 01.2015
Supersedes: Rev G 07.2013
Safety instructions
Safety instructions
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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.
• DCS800 with enclosure extension: Before working on the drive, isolate the
whole drive from the supply.
Safety instructions
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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.
• Minimize EMC emission and make a 360° high frequency grounding (e.g.
conductive sleeves) of screened cable entries at the cabinet lead-through
plate.
Safety instructions
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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 (1.4 in.).
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, D4+ and D5 only on their 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.
Safety instructions
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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 in-tended 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.
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
3ADW000194R0811 DCS800 Hardware Manual us h
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Table of contents
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Use of warnings and notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Printed circuit boards and fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table of contents
The DCS800
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The DCS800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Type code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Armature converter DCS800-S0x D1 - D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Armature converter DCS800-S0x D4+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Armature converter DCS800-S0x D5, D6 and D7 (+P905) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Armature converter DCS800-S0x D7 (+P906) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rebuild kit DCS800-R0x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mechanical installation
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Delivery check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Before installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terminal options for converter modules size D1 - D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connection of D4 converter module DC terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Terminal cover according to VBG 4 regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mounting the converter module D4+ inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mounting the converter module D6 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table of contents
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Electrical installation
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking the insulation of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Supply voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Location R-type options and interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
I/O Board Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pulse encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pulse encoder connection principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connecting the signal and control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Routing the cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table of contents
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DCSLink wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Installation checklist
Maintenance
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Technical data
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Current ratings - IEC non regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Current ratings - IEC regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Standard duty cycles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Current ratings – North America non-regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Current ratings – North America regenerative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control Board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Layout of the control board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Memory circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Watchdog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Seven segment display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Terminal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Digital and analog I/O connection of the SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Interface board SDCS-COM-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Ch2 master-follower connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Ch0 DriveBus connection to Advant Controller (star) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Ch0 connection to overriding control (N-type fieldbus adapter) . . . . . . . . . . . . . . . . . . . . . . . 84
Ch3 ring connection to DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Ch3 star connection to DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DDCS branching unit NDBU-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Drive-to-drive board SDCS-DSL-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Digital I/O board SDCS-IOB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Analog I/O and encoder I/O board SDCS-IOB-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Power supply board SDCS-POW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Interface board SDCS-PIN-4 / SDCS-PIN-4b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Armature circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Field circuit interface (D1 - D4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SDCS-PIN-51, SDCS-PIN-46, SDCS-PIN-48 interface to the power part . . . . . . . . . . . . . . . . . . . . 99
Interface board SDCS-SUB-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Galvanic isolation - T90, A92, F11, F90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DC-DC transducer A92 (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Transformer T90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table of contents
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Accessories
DCF803-0016, FEX-425-Int and DCF803-0035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Power part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
DCSLink communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
RS232-Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
DCF803-0016 and DCF803-0035 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
FEX-425-INT configuration (size D4+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
FEX-425-INT configuration (size D5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
DCF803-0050, DCF804-0050, DCF803-0060 and DCF804-0060 . . . . . . . . . . . . . . . . . . . . . . . . . 130
Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Power part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
DCSLink communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
RS232-Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
DCF803-0050 / 0060 and DCF804-0050 / 0060 configuration (e.g. 2 motors) . . . . . . . . . . . 135
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
DCF505 / DCF506 Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Fuses and fuse holders IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Fuses and fuse holders - North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Line reactors IEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Line reactors type ND01 to ND17 (uk = 1 %). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Line reactors type ND401 to ND413 (uk = 4 %). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Line reactors – North America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Autotransformer (T3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Line reactor (L3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Auxiliary transformer (T2) for converter electronics and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Supply transformer (T8) for cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Residual current detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Table of contents
3ADW000194R0811 DCS800 Hardware Manual us h
13
Table of contents
3ADW000194R0811 DCS800 Hardware Manual us h
14
The DCS800
Chapter overview
This chapter describes briefly the operating principle and construction of the
converter modules in short.
The DCS800
The DCS800-S size D1 - D7 are intended for controlling DC motors.
Size D6 Size D7
1900 - 3000 A 2050 - 5200
The DCS800
3ADW000194R0811 DCS800 Hardware Manual us h
15
Type code
The type code contains information on the specification and configuration of the drive. The first digits
from left show the basic configuration (e.g. DCS800-S01-2000). The optional selections are given
thereafter on the name plate by plus code. The main selections are described below. Not all
selections are available for all types.
The drive's basic type code: DCS800-AAX-YYYY-ZZ-B + plus code
Product family DCS800
Type: AA = S0 Standard converter module
= R0 Rebuild kit
= E0 Panel solution
= A0 Enclosed converter
Bridge type: X =1 Single bridge (2-Q)
=2 2 anti-parallel bridges (4-Q)
Module type: YYYY = Rated DC current
Rated AC voltage: ZZ = 04 230 VAC - 400 VAC
= 05 230 VAC - 525 VAC
= 06 270 VAC - 600 VAC
= 07 315 VAC - 690 VAC
= 08 360 VAC - 800 VAC
= 10 450 VAC - 990 VAC
= 12 540 VAC - 1200 VAC
Power connection: - = Standard D1 - D6
=L Left side D7
=R Right side D7
Revision code: B = Standard
=a Second thyristor type D5, D6
=b ErP compliant cooling fan D5, D6, D7 and second thyristor type
Field exciter +0S163 D1 - D4 without OnBoard field exciter
configuration: +S164 D4+ and D5 with internal field exciter, supply external
(D4+ and D5: 25 A, Rebuild kit: 16 A / 25 A)
Fan voltage: Size D4
Standard Fan voltage: 230 V / 1-ph
+S171 Fan voltage: 115 V / 1-ph
Current measurement: +S175 SDCS-CMA-2 (D5 - D7)
Voltage measurement: +S186 120 V SDCS-SUB-4 (D1 - D4+)
+S185 SDCS-PIN-51 configured to 120 V (D5 - D7)
+S180 SDCS-PIN-51 configured to 600 V (D5 - D7), 12-pulse serial / serial sequential
+S181 SDCS-PIN-51 configured to 690 V (D5 - D7), 12-pulse serial / serial sequential
+S182 SDCS-PIN-51 configured to 800 V (D6, D7), 12-pulse serial / serial sequential
+S183 SDCS-PIN-51 configured to 990 V (D6, D7), 12-pulse serial / serial sequential
+S189 SDCS-PIN-51 configured to galvanic isolation (D6, D7)
+P905 Electronic boards are located in the D7 module
+P906 Electronic boards are in an external control unit (outside the D7 module)
SDCS-DSL-4: +S199 With SDCS-DSL-4
+0S199 Without SDCS-DSL-4
DCS Control Panel: +0J404 Without DCS Control Panel
+J409 Door mounting kit, including 3 m cable
Fieldbus: +K454 Profibus RPBA-01
+K451 DeviceNet RDNA-01
+K457 CANopen RCAN-01
+K466 Ethernet/IP, Modbus/TCP RETA-01
+K458 Modbus (RTU) RMBA-01
I/O and DDCS: +L500 Analog Extension RAIO-01
+L501 Digital Extension RDIO-01
+L508 DDCS communication board (10 Mbaud CH0) SDCS-COM-81
+L509 DDCS communication board (5 Mbaud CH0) SDCS-COM-82
The technical data and specifications are valid as of going to press. ABB reserves the right to make
subsequent alterations.
The DCS800
3ADW000194R0811 DCS800 Hardware Manual us h
16
The DCS800
525 V
EMC filter
Field
Residual current detection supply
525 V
PC + Door Overriding F2 Q1 F3 Fx
DriveWindow mounting Control
F1
kit T2 T3 Tx
JPMP-01
RUSB-02 K3 Kx
max. 500 V
K1
230 V (115 V)
Main circuit and control
K5 Fy
L1 single phase
or three-phase
NDBU95 L3 Lx
DCS800-S0x D1 - D4 F100 - F102
X33
DCS-CP
Slot 1
optical fibre
X9 PIN-4
Fieldbus
X37 X37
CON-4 adapter Rxxx,
RAIO or RDIO X12 X12
400 V and 525 V units with OnBoard field exciter
X13 X13
Master / X19 Slot 3 Slot 2
Follower
600 V units are always without OnBoard field exciter
Ch2
M
COM-8 RTAC
DCF803-0016
DCF803-0035
Ch1 RDIO
Slot1
DCF503B/504B0050
Ch0 RAIO
Slot 4
Memory Card
Slot2
OnBoard field exciter
X2
AIMA
X20
DCF803/804-0050 / -0060
Slot3 X1 24V-
DCS800-S0x as field exciter
X51X52DSL* X53
optical fibre
X3 X4 X5 X6 X7
SDCS-DSL-4
NDBU95
DCSLlink twisted pair
3 1 3 8 7
Advant
controller
M {
IOB-2x IOB-3
* D1 - D4, optional
Legend
PC + 8 8 3 5 digital input / output
)%# RS232 E analog input / output
DWL alternative
T
fuse
line reactor
transformer
SB_800_001_D1-D7_d.ai
1000 V
EMC filter
Field
Residual current detection supply
500 V
PC + Door Overriding F2 Q1 F3 Fx
DriveWindow mounting Control
F1
kit T2 T3 Tx
JPMP-01
RUSB-02 K3 Kx
K1
F3.1
K5 (F301 - F303) Fy
L1 single phase
or three-phase
NDBU95 L3 L3 Lx
DCS800-S0x D4+
X33
DCS-CP
Slot 1
optical fibre
X9 PIN-4
Fieldbus
X37
CON-4 adapter Rxxx,
RAIO or RDIO X12
X13
Master / X19 Slot 3 Slot 2
Follower Ch3 X11 X10
Ch2
M
COM-8 RTAC
D4+ units optional with internal field exciter
SDCS-FEX-4
DCF803-0016
DCF803-0035
RDIO
FEX-425-Int **
Ch1
Slot1
DCF503B/504B0050
Ch0 RAIO
Slot 4
Memory Card
Armature converter DCS800-S0x D4+
Slot2
X2
AIMA
X20
DCF803/804-0050 / -0060
Slot3 X1 24V-
DCS800-S0x as field exciter
X51X52DSL X53
X34 DSL
optical fibre
X3 X4 X5 X6 X7
NDBU95
DCSLlink twisted pair
3 1 3 8 7
Advant
controller
M {
IOB-2x IOB-3
** optional
Legend
PC + 8 8 3 5 digital input / output
)%# RS232 E analog input / output
DWL alternative
T
fuse
line reactor
transformer
SB_800_001_D1-D7_d.ai
17
The DCS800
18
1000 V
The DCS800
EMC filter
Field
Residual current detection supply
500 V
PC + Door Overriding F2 Q1 F3 Fx
DriveWindow mounting Control
F1
kit T2 T3 Tx
JPMP-01
RUSB-02 K3 Kx
500 V max
K1
K5 * Fy
L1 single phase
or three-phase
NDBU95 L3 L3 Lx
DCS800-S0x D5, D6, D7 (+P905)
X33
DCS-CP
Slot 1
optical fibre
X9 POW-4
F3.1
Fieldbus
X37 X37
adapter Rxxx,
(F301 - F303)
RDIO
FEX-425-Int **
Ch1
Slot1
DCF503B/504B0050
Ch0 RAIO
Slot 4
Memory Card
Slot2
X2
AIMA
X20
DCF803/804-0050 / -0060
Slot3 X1 24V-
DCS800-S0x as field exciter
X51X52DSL X53
X34 DSL
NDBU95
DCSLlink twisted pair
3 1 3 8 7
Advant
controller
M {
IOB-2x IOB-3 * three-phase D6 and D7
** only D5, optional
Legend
PC + 8 8 3 5 digital input / output
)%# RS232 E analog input / output
DWL alternative
T
fuse
line reactor
transformer
SB_800_001_D1-D7_d.ai
1000 V
EMC filter
Field
Residual current detection supply
500 V
PC + Door Overriding F2 Q1 F3 Fx
DriveWindow mounting Control
F1
kit T2 T3 Tx
JPMP-01
RUSB-02 K3 Kx
500 V max
K1
Fy
L1 single phase
or three-phase
DCS800-S0x-4800-xxx+P906 L3 Lx
NDBU95
DCS800-S0x-5200-xxx+P906
X33
DCS-CP
Slot 1
optical fibre
X9 POW-4
Fieldbus
X37 X37
CON-4 adapter Rxxx,
RAIO or RDIO X12 X112 X12 X12 PIN-48
CCB-04/05 PIN-51
X13 X113 X13 X13
Master / X19 Slot 3 Slot 2 PIN-48
Follower Ch3 X11 X10
Ch2
M
COM-8 RTAC
DCF803-0016
DCF803-0035
Ch1 RDIO
Slot1
DCF503B/504B0050
Ch0 RAIO
Slot 4
Memory Card
Slot2
X2
AIMA
X20
DCF803/804-0050 / -0060
Slot3 X1 24V-
DCS800-S0x as field exciter
X51X52DSL X53
optical fibre
X3 X4 X5 X6 X7
SDCS-DSL-4
NDBU95
DCSLlink twisted pair
3 1 3 8 7
Advant
controller
M {
IOB-2x IOB-3
Legend
PC + 8 8 3 5 digital input / output
)%# RS232 E analog input / output
DWL alternative
T
fuse
line reactor
transformer
SB_800_001_D1-D7_d.ai
19
The DCS800
20
1000V
EMC filter
The DCS800
Field
Residual current detection supply
500V
Existing parts
Door Overriding F2 Q1 Q1 Fx
PC +
mounting Control F3
DriveWindow F1
kit T2 Tx
RUSB-02 JPMP-01 Kx
K1 K1 K3
Fx
single-phase
or three-phase
F3.1 Fy
L1 L1 (F301 - F303)
NDBU95 ~ ~ L3 Lx
QUINT-PS
DCS800-R0x - -
Rebuild kit DCS800-R0x
X33
DCS-CP
Slot 1
optical fibre
X9 POW 1
POW-4 PIN-48
Fieldbus
X37 X37
CON-4 adapter Rxxx,
RAIO or RDIO X12 X12
PIN 1x
PIN-51
X13 X13
Master / X19 Slot 3 Slot 2 REB-1
Follower Ch3 X11 X10
M
M
FEX-425-Int
Ch0 RAIO
Slot 4
Memory Card
SDCS-CCB-4
X2
AIMA
X20
DCS800-S0x as field exciter
DCF803/804-0050 / -0060
X1 24V-
X51X52DSL X53 PIN-48
X34 DSL
optical fibre
NDBU95
DCSLlink twisted pair
3 1 3 8 7
Advant
controller
M {
IOB-2x IOB-3
Legend
PC + 8 8 3 5 digital input / output
)%# RS232 E analog input / output
DWL alternative
T
fuse
line reactor
transformer
SB_800_006_R0x_d.ai
21
Mechanical installation
Chapter overview
This chapter describes the mechanical installation of the DCS800.
Unpacking the unit
• Open the box,
• take out shock dampers,
• separate manual and accessories.
Attention:
Do not lift the drive by the cover!
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the nameplate of the converter module to verify
that the unit is of the correct type. The label includes an IEC rating, cULus, C-tick
(N713) and 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.
See an example nameplate below.
ABB Automation Products GmbH U1 3 ∼ 525 V U2 610 V Made in Germany
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
22
Before installation
Install the drive in an upright position with the cooling section facing a wall. Check
the installation site according to the requirements below. Refer to chapter
Dimensions and weights for frame details.
Cabinet installation
The required distance between parallel units is five millimetres (0.2 in.) in
installations without the front cover. The cooling air entering the unit must not exceed
+40 °C (+104 °F).
Preventing cooling air recirculation Unit above another
Prevent air recirculation inside and outside the cabinet.
Hot area
Main air flow out
Cool area
BG_800_003_luft_a.ai
BG_800_004_luft_a.ai
Airflow
Lead the exhaust cooling air away from the unit above.
Distances see chapter Dimensions and weights.
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
23
Id No. Remark
3ADV280706P0001 right
3ADV400706P0001 left
7.35
135
71 60
14
95
Lug bars
Bottom view
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
24
Id No. Remark
3ADT631137P0001 D1, D2
3ADV400208P0001 D3
3ADV400207P0001 D4
Mount the D1, D2 cover using the existing lateral pins and than swing it down to snap it into the terminal
row. D3 and D4 mounting is the same, without the snap-in mechanism.
Examples for DC main terminal covers for D3 (left) and D4 (right) converter modules.
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
25
Detail bottom:
Mains Field
X101 X100 X96 X99
DO8 Aux Supply
C1 D1
U1 V1 W1
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
26
~ 100
50 50
air flow air flow air flow air flow Top view Top view
BG_800_002_A6_a.ai
are shown in the figure below. module. This results in four layers of power cables.
100
72.2 Ø14 75
C In case the AC or DC connection or perhaps both
21.8 25 of them have to be made at the right side of the
0 converter module use the space behind the converter.
Move the power terminals via rectangular busbars to
125
D
175
272
312
352
372
25
75
0
250
need to be fixed at the enclosure, not at the converter
module! The figures below give a rough example, how
U
control cables
V A6_cable_term_busb.dsf
drawing below).
(left and right sid e)
converter fan
BG_800_002_A6_a.ai max.
35 mm
BG_800_002_A6_a.ai 468.2
136
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
27
BG_800_001_A7_a.ai
air flow
air flow
SDCS-IOB-2 / IOB-3
pressure
switch
screened cables
w
flo
air
50
BG_800_001_A7_a.ai
Air entry through the bottom plate Use cable ties to fix the
Make sure the converter module gets clean air, fan cable!
because there is no air filter in front of the converter
fan.
Cooling air outlet
To avoid circulating air inside the enclosure make sure Fix all cables, otherwise the air flow from
the exhaust air leaves the enclosure. fan will destroy them!
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
28
For M6
225
100
7,5
2 X112 2 X113
1 1
45
Label
370.5
350
2 X12 2 X13
1 1
SDCS-CCB-4
SDCS-CCB-5
7,5
BL_CCB_001_a.ai
SDCS-CCB-4
SDCS-CCB-5
10.5
MG_800_002_external_b.ai
M6
Control unit
Connect the cables in the control unit as indicated in the picture of
the SDCS-CCB-4 / SDCS-CCB-5. Make sure (once again) X12 and
X13 are plugged into the correct sockets (cross wise connection
results in component damage!!!).
Take care of proper grounding.
X13
X12
Maximum cable length X12, X13 is 4 meter.
Mechanical installation
3ADW000194R0811 DCS800 Hardware Manual us h
29
Chapter overview
This chapter contains the instructions that must be followed when selecting the
motor, cables, protections, cable routing and way of operation for the drive system.
Always follow local regulations. This chapter applies to all DCS800 converter
modules.
Attention:
If the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover. See also Technical Guide.
Options
Configuration B
Line
LLine
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 requirements are
PCC
often defined as a voltage dip in percent of the nominal supply
(Pcc)
LL1
voltage. The combined impedance of ZLine and ZL1 constitute the total
series impedance of the installation. The ratio between the line
impedance and the line reactor impedance determines the voltage dip
at the PCC. In such cases, line chokes with an impedance around 4 %
are often used.
Example calculation with ukLine = 1 % and ukL1 = 4 %:
Voltage dip = ZLine / (ZLine + ZL1) = 20 %. Detailed calculations see
Technical Guide.
Configuration C
Line
If a dedicated transformer / isolation transformer is used, it is possible
PCC to comply with certain connecting conditions per Configuration B
(Pcc) without using an additional line reactor. The condition described in
Configuration A will then likewise be satisfied, since the uk is > 1 %.
Configuration C1
If 2 or more converters should be supplied by one
Line transformer the final configuration depends on the
number of drives in use and their power capability.
PCC
Configuration A or B has to be used, if the drive system
(Pcc)
consists of any of the converters D1, D2, D3, D4, D4+,
D5, D6, D7.
LL1 LL1 LL1 .... In case if only two converters of type D7 are used no
line reactors are necessary because the design of these
converters allows that configuration.
Netzdr_g.dsf
Configuration D
In the case of thyristor converters, frequently transformers are used
for voltage matching. When using an autotransformer for this
purpose, additionally install a line reactor, because the uk of
commonly used autotransformers is too small.
In case of converters size D1 - D4+ the allowed voltage at the PCC is
600 VAC.
Fig. 4 Fig. 5
SB_SIC_002_a.ai
F1 F1
Semiconductor
fuses F2
M M
SB_SIC_003_a.ai
ND30 /
F3.1 built-in
2 Configuration for field circuit
SB_SIC_001_a.ai
Fuses F3.2 and F3.3 are used as line protectors and cannot protect the field
supply unit. Only pure HRC fuses or miniature circuit-breakers must be used.
Semiconductor fuses will be tripped, for example, by the transformer’s inrush
current.
F3.2
F3.1 Configurations for field circuit
2
ND30 /
F3.3 built-in
F3.1
2
SB_SIC_001_a.ai
Size Converter type (2-Q) Converter type (4-Q) Fuse Fuse holder Fuse type Fuse holder
North America
DCS800-S01-0020-04/05 DCS800-S02-0025-04/05 50A 660V UR OFAX 00 S3L FWP-50B 1BS101
DCS800-S01-0045-04/05 DCS800-S02-0050-04/05 80A 660V UR OFAX 00 S3L FWP-80B 1BS101
D1
DCS800-S01-0065-04/05 DCS800-S02-0075-04/05 125A 660V UR OFAX 00 S3L FWP-125A 1BS103
DCS800-S01-0090-04/05 DCS800-S02-0100-04/05 125A 660V UR OFAX 00 S3L FWP-125A 1BS103
DCS800-S01-0125-04/05 DCS800-S02-0140-04/05 200A 660V UR OFAX 1 S3 FWP-200A 1BS103
DCS800-S01-0180-04/05 DCS800-S02-0200-04/05 250A 660V UR OFAX 1 S3 FWP-250A 1BS103
D2 DCS800-S01-0230-04/05 DCS800-S02-0260-04/05 315A 660V UR OFAX 2 S3 FWP-300A 1BS103
DCS800-S01-0315-04/05 DCS800-S02-0350-04/05 500A 660V UR OFAX 3 S3 FWP-500A 1BS103
D3 DCS800-S01-0405-04/05 DCS800-S02-0450-04/05 700A 660V UR OFAX 3 S3 FWP-700A See Note 1
DCS800-S01-0470-04/05 DCS800-S02-0520-04/05 700A 660V UR OFAX 3 S3 FWP-700A See Note 1
DCS800-S01-0610-04/05 DCS800-S02-0680-04/05 900A 660V UR 3x 170H 3006 FWP-900A See Note 1
D4 DCS800-S01-0740-04/05 DCS800-S02-0820-04/05 900A 660V UR 3x 170H 3006 FWP-900A See Note 1
DCS800-S01-0900-04/05 DCS800-S02-1000-04/05 1250A 660V UR 3x 170H 3006 FWP-1200A See Note 1
* Fuse (F3.1) KTK25 included in FEX-425-Int package. D4+ field fuses are external. D5 field fuses are
internal.
Fuses and fuse holders for field circuit
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 VAC. Such
lines have a grounded neutral conductor. ABB offers suitable three-phase filters for
400 VAC. For 440 VAC public low voltage lines outside Europe 500 VAC filters are
available. Optimize the filters for the real motor currents:
IFilter = 0.8 • IMOT max; the factor 0.8 respects the current ripple.
Lines with 500 VAC up to 1000 VAC are not public. There are local networks inside
factories, and they do not supply sensitive electronics. Therefore converters do not
need EMC filters if they shall run with 500 VAC and more.
Size Converter type (2-Q) IDC [A] Converter type (4-Q) IDC [A] Filter type Filter type
for y = 4 for y = 5
D1 DCS800-S01-0020-0y 20 DCS800-S02-0025-0y 25 NF3-440-25 NF3-500-25
DCS800-S01-0045-0y 45 DCS800-S02-0050-0y 50 NF3-440-50 NF3-500-50
DCS800-S01-0065-0y 65 DCS800-S02-0075-0y 75 NF3-440-64 NF3-500-64
DCS800-S01-0090-0y 90 DCS800-S02-0100-0y 100 NF3-440-80 NF3-500-80
DCS800-S01-0125-0y 125 DCS800-S02-0140-0y 140 NF3-440-110 NF3-500-110
D2 DCS800-S01-0180-0y 180 DCS800-S02-0200-0y 200 NF3-500-320 NF3-500-320
DCS800-S01-0230-0y 230 DCS800-S02-0260-0y 260 NF3-500-320 NF3-500-320
D3 DCS800-S01-0315-0y 315 DCS800-S02-0350-0y 350 NF3-500-320 NF3-500-320
DCS800-S01-0405-0y 405 DCS800-S02-0450-0y 450 NF3-500-600 NF3-500-600
DCS800-S01-0470-0y 470 DCS800-S02-0520-0y 520 NF3-500-600 NF3-500-600
D4 DCS800-S01-0610-0y 610 DCS800-S02-0680-0y 680A NF3-500-600 NF3-500-600
DCS800-S01-0740-0y 740 — — NF3-500-600 NF3-500-600
— — DCS800-S02-0820-0y 820 NF3-690-1000 ➀ NF3-690-1000 ➀
DCS800-S01-0900-0y 900 DCS800-S02-1000-0y 1000 NF3-690-1000 ➀ NF3-690-1000 ➀
D4+ DCS800-S01-1190-0y 1190 DCS800-S02-1190-0y 1190 NF3-690-1000 ➀ NF3-690-1000 ➀
D5 DCS800-S01-0900-0y 900 DCS800-S02-0900-0y 900 NF3-690-1000 ➀ NF3-690-1000 ➀
DCS800-S01-1200-0y 1200 DCS800-S02-1200-0y 1200 NF3-690-1000 ➀ NF3-690-1000 ➀
DCS800-S01-1500-0y 1500 DCS800-S02-1500-0y 1500 NF3-690-1600 ➀ NF3-690-1600 ➀
DCS800-S01-2000-0y 2000 DCS800-S02-2000-0y 2000 NF3-690-1600 ➀ NF3-690-1600 ➀
D6 3000 3000 NF3-690-2500 ➀ NF3-690-2500 ➀
EMC filters
Further information is The paragraphs below describe selection of the electri- • the product's actual emissions.
available in the cal components in conformity with the EMC Guideline. The EMC Guideline expects EMC to be taken into
Technical Guide: The aim of the EMC Guideline is, as the name implies, account when a product is being developed; however,
to achieve electromagnetic compatibility with other EMC cannot be designed in, it can only be quantita-
products and systems. The guideline ensures that the tively measured.
emissions from the product concerned are so low that
they do not impair another product's interference immu- Note on EMC conformity:
nity. The conformity procedure is the responsibility of both
In the context of the EMC Guideline, two aspects must the power converter's supplier and the manufacturer of
be borne in mind: the machine or system concerned, in proportion to their
• the product's interference immunity and share in expanding the electrical equipment involved.
First environment (residential area with light industry) with PDS category C2
Not applied, since category C1 (general distribution sales channel) excluded
Not applicable satisfied
satisfied
Supply transformer for a residential Light industry Supply transformer for a residential
Residential area area (rating normally ≤ 1.2 MVA)
Residential area
area (rating normally ≤ 1.2 MVA)
Earthed
neutral
Earthed
neutral Earthed public 400 V Earthed public 400 V Earthed public 400 V
network with neutral network with neutral network with neutral
conductor conductor conductor
To other loads, e.g. drive systems
To other loads which have to be protected from the system disturbances caused by
power converters (HF interference and commutation notches)
To other loads which have to be protected from the system disturbances caused by
Line reactor +
Line reactor Y-capacitor Line reactor Line reactor
alternative
M M M M M M
M M
Operation at public Operation at public An isolating transformer
Operation at public An isolating transformer
low-voltage network low-voltage network with an earthed screen
low-voltage network with an earthed screen
together with other together with other and earthed iron core
together with other and earthed iron core
loads of all kinds. loads of all kinds. renders mains filter and
loads of all kinds. renders mains filter and
line reactor superfluous.
line reactor superfluous.
For compliance with the protection objectives of the For emitted interference, the following apply:
German EMC Act (EMVG) in systems and EN 61000-6-3 Specialised basic standard for emissions in light industry can
machines, the following EMC standards must be sat- be satisfied with special features (mains filters, screened power
isfied: cables) in the lower rating range *(EN 50081-1).
Product Standard EN 61800-3 EN 61000-6-4 Specialised basic standard for emissions in industry *(EN
EMC standard for drive systems (PowerDriveSys- 50081-2)
tem), interference immunity and emissions in resi- For interference immunity, the following apply:
dential areas, enterprise zones with light industry EN 61000-6-1 Specialised basic standard for interference immunity in residen-
and in industrial facilities. tial areas *(EN 50082-1)
This standard must be complied with in the EU for EN 61000-6-2 Specialised basic standard for interference immunity in industry.
satisfying the EMC requirements for systems and If this standard is satisfied, then the EN 61000-6-1 standard is
machines! automatically satisfied as well *(EN 50082-2).
* The old generic standards are given in brackets
Standards
Second environment (industry) with PDS categories C3, C4 EN 61800-3
Not applicable EN 61000-6-3
satisfied on customer's request satisfied EN 61000-6-4
satisfied EN 61000-6-2
EN 61000-6-1
PDS category C3 PDS category C4 Classification
Medium-voltage network The following overview uti-
Medium-voltage network
lises the terminology and
Supply transformer for a indicates the action
Industrial zone residential area (rating Industrial Converter
transformer required in accordance with
normally ≤ 1.2 MVA) zone with earthed Product Standard
Converter EN 61800-3
transformer For the DCS800 series, the
Earthed iron core
neutral (and earthed
limit values for emitted inter-
Earthed 400 V network I > 400 A
screen where ference are complied with,
with neutral conductor ; and / or
3~ ≤ 400 A appropriate) provided the measure indi-
U > 500 V
cated is carried out. PDS of
category C2 (formerly
IDC < 100 A
IDC >100 A
Converter Converter
Converter Converter Converter The field supply is not
depicted in this overview
SB_800_004_emv-classif_a.ai
alternative
alternative
alternative
alternative
M M M M
M M M M M M Legend
Screened cable
Operation with separate power converter transformer. If there
Operation at low-voltage network together with Unscreened cable with restriction
are other loads at the same secondary winding, these must be
other loads of all kinds, apart from some kinds
able to cope with the commutation gaps caused by the power
of sensitive communication equipment.
converter. In some cases, commutating reactors will be
required.
T2
230 V E1 EMC Filter
690 V
660 V
600 V
1 1 1 575 V 1 3
F2 F1
F7 F5 F8 525 V
115 V
2 2 2 500 V 2 4
450 V F6 1 3 5 13
415 V
K15 400 V
380 V 14
X96:2
On Start 13
K1 K21 F6
14
1 1 3 1 3 5 1 3 5
E-stop K8 K1 K6
functions done by the drive.
S1 2 4
K20 2 4 6 2 4 6
2
K6 1 K20
F2
S1 see 6.03
K10 bit 0
2
K8 K1 K21
T
_ Legend
Converters size D1 - D4 configuration using an OnBoard field exciter
T2
230 V E1 EMC Filter F3.2
690 V
660 V
600 V
1 1 1 575 V 1 3
F1
F7 F5 F8 525 V F2 T3
115 V 500 V
2 2 2 2 4 500 V
450 V 460 V
F6 1 3 5 13
415 V 415 V
K15 400 V 400 V
380 V 14
365 V
350 V
X96:1 265 V I> I> I>
Off Stop
K10 K11 250 V 2 4 6
90 V
X96:2 60 V
30 V
On Start 13
K1 K21 F6
14
1 1 3 1 3 5 1 3 1 3 5
E-stop K8 K1 K3 K6
S1 2 4
K20 2 4 6 2 4 2 4 6
2
F3.1
(F301-F303)
max. 500 V (single-phase or 3-phase).
T
_ Legend
T2
230 V E1 EMC Filter F3.2
690 V
660 V
600 V
1 1 1 575 V 1 3
F1
F7 F5 F8 525 V F2 T3
115 V 500 V
2 2 2 2 4 500 V
450 V F6 1 3 5 13
1 1 3 1 3 5 1 3 1 3 5
E-stop K8 K1 K3 K6
S1 2 4
K20 2 4 6 2 4 2 4 6
2
M
3~
+
T
_ Legend
Line reactor
Wiring the drive according to this diagram offers the highest degree of monitoring
L1 L2 L1 L2 L3 L1 L2 L3 N L1 L1 L2 L3
T2
230 V E1 EMC Filter F3.2
1 690 V
Only needed for DCF803-0016 and DCF803-0035. 660 V
50 A and 60 A field exciters have their own integrated 600 V
line reactor. 1 1 575 V 1 3
F1
F7 F5 525 V F2 T3
115 V 500 V
2 2 2 4 500 V
450 V F8 1 3 5 13 F6 1 3 5 13
460 V
415 V 415 V
K15 400 V 400 V
380 V 14 14
365 V
350 V
X96:1 I> I> I> 265 V I> I> I>
Off Stop
K10 K11 2 4 6 250 V 2 4 6
90 V
X96:2 60 V
30 V
On Start 13 X2:4
K1 K21 F6
14
X2:5
1 1 3 5 1 3
1 3 5 1 3 5
E-stop K8 K1 K3 K6
S1
K20 2 4 6 2 4 6 2 4 2 4 6
2
F3.1
K20 K21 K6 K8 K3 K1 K15
L1 L3 1
IN1 V1
Power supply
OUT1 V2 see 6.03 bit 7 (SDCS-POW-4) D6, D7 *
S1 DCS800 DCF803, DCF804
5 6 field exciter
AITAC AI1 AI2 AI3 AI4
_ + _ + _ + _ + _ + +10 V -10 V AO1 AO2 Iact DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24 V DO1 DO2 DO3 DO4 DO5 DO6 DO7 Encoder
T
Converters size D4+ - D7 configuration using external field exciters
_ Legend
* For D4+ and D5 see chapter
Fuse
their own synchronization and must be supplied from independent mains supply
Converters size D4+ configuration using FEX-425-Int field exciter or further information see chapter
Line reactor
Wiring the drive according to this diagram offers the highest degree of monitoring
Converters size D5 configuration using FEX-425-Int field exciter Start, Stop and E-stop control SA_800_003_D4+-D7_c.ai
functions done by the drive. Field converters DCF803 / DCF804 are equipped with
45
T2
230 V F1
690 V
660 V
600 V
1 1 1 575 V 1 3
F2
F7 F5 F8 525 V
115 V
2 2 2 500 V 2 4
450 V
415 V
K15 400 V
380 V
1 2
If the installation is not equipped with K1 and the
K8 K1 K15 L1 converter is direct supplied from a high voltage
transformer an additional overvoltage protection
control from (capacitors) is required.
armature converter
S1 2
2
Legend SA_800_004_D1-D3_c.ai
HW I/O
On
Run
Reset Local /
Remote
Command
location (10.01)
SF_DCS_001_ctrl-cmd_a.ai
K16
E-stop
electrical
disconnect
(coast)
speed
1
Timer K15
E-Stop
S1 K15
2 Timer K16
K15 K16
Block current control
Main contactor K1
SDCS-CON-4
DI4 X6:9 E-stop ramp Coast
Block
current DZ_LIN_006_E-stop_a.dsf
K15
command
E-stop reaction
SF_CON4_001_E-stop_a.ai
L1
U1 V1 W1 PE
DZ_LIN_007_us_b.ai
C1 D1
_ X10:
+ F+ F-
K1.1 RB
M
SF_800_003_us_b.ai
L1 MP L1 L2 L3
F1
1 1 1
F7 F5 F8
2 2 2
X96:1
Off Stop
X96:2
On Start
K1 K21
1 3 5
monitoring functions.
K1
K20 2 4 6
F6 1 3 5 13
K20 K21 K1
L1
14
4 5
DCS800 OnBoard
AITAC AI1 AI2 AI3 AI4 field exciter
_ + _ + _ + _ + _ + +10 V -10 V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24 V DO1 DO2 DO3 DO4 DO5 DO6 DO7 Encoder
_
+ X10: F+ F-
K20
K1 K21
+
3~
T
Legend
Converters size D1 - D4, 400 - 525 V using OnBoard field exciters.
Fuse
Line reactor
SA_800_005_D1-D4_c.ai
Selection of components: The wiring diagram is valid for a DCS800 converters size D1 - D4 525 V.
The OnBoard field exciter can be used for line voltages up to 525 V. Field currents up to 6 / 15 / 20 / 25 A depending
on the converter size are possible. For larger field currents use a DCF803/804 or a large field exciter (DCS800).
Wiring the drive according to this diagram gives the same control performance, but a lower degree of
49
Cooling fans
Fan assignment for DCS800
Converter type Size Configuration Fan type
DCS800-S0x-0045-04/05 ... D1 1 2 x CN2B2
DCS800-S0x-00140-05/05
DCS800-S0x-0180-04/05 ... D2 2 x CN2B2
DCS800-S0x-0260-04/05
DCS800-S0x-0315-04/05 ... D3 2 x CN2B2
DCS800-S0x-0350-04/05
DCS800-S0x-0405-04/05 ... 2 4 x CN2B2
DCS800-S0x-0520-04/05
DCS800-S0x-0610-04/05 ... D4 3 1 x W2E200 (230 V)
DCS800-S0x-0820-04/05
DCS800-S0x-0610-04/05 ... 1 x W2E200 (115 V)
DCS800-S0x-0820-04/05 Pluscode S171
DCS800-S0x-0900-04/05 ... 1 x W2E250 (230 V)
DCS800-S0x-1000-04/05
DCS800-S0x-0900-04/05 ... 1 x W2E250 (115 V)
DCS800-S0x-1000-04/05 Pluscode S171
DCS800-S0x-1190-04/05 D4+ 4 R2E250-RB
230 V; 1
DCS800-S0x-0900-0y ... D5 4 R2E250-RB
DCS800-S0x-2000-0y 230 V; 1
DCS800-S0x-1900-04/05/08 ... D6 5 GR28C-2DK
DCS800-S0x-3000-04/05/08 400 V / 500 V @ 50 Hz
DCS800-S0x-1900-06/07 ... or
DCS800-S0x-3000-06/07 460 V @ 60 Hz
DCS800-S0x-3300-yy ... D7 6 GR35C-2DD
DCS800-S0x-5200-yy 400 V @ 50 Hz or
460 V @ 60 Hz
y = voltage class
230 VAC
L
230 VAC
L
X2: 1 2 3 4 5 X2: 1 2 3 4 5
N
L
or 115 VAC
X2: 1 2 3 4 5 X2: 1 2 3 4 5
N
L
X2: 1 2 3 4 5 X2: 1 2 3 4 5 X2: 1 2 3 4 5
L N
M M M M J
~ ~ ~ ~ M
~ M55
M55 M56 M55 M56
SA_800_001_fan_c.ai
M M
~ ~
M57 M58
L N
PE TB TB W2 U1 U2 V1 V2 W1 U1 V1 W1 U2 V2 W2 PE TK TK
X2: 1 2 3 4 5
M M
~ J~
M
~ at Connection at Connection
U1-W2 U1-W2
V1-U2 V1-U2
W1-V2 W1-V2
SA_800_001_fan_c.ai
PE TB TB W2 U1 U2 V1 V2 W1
M
~
at Connection
U2 - V2 - W2
* 500 V supply 600 V autotransformer (T8) is strongly recommended, energy saving 20,000 kWh/a
L N TW TW
U1 V1 W1 U2 V2 W2 PE TK TK
X2: 1 2 3 4 5 6
white
white
black
brown
green/yellow
blue
M
J~
grey
grey
M
~J
at Connection
U1-W2
V1-U2
W1-V2
U1 V1 W1 U2 V2 W2 PE TK TK
M
J~
at Connection
U2-V2-W2
SA_800_001_fan_c.ai
Configuration 4 Configuration 5
D5 D6, D7
IDC Iv
[A-] [mm²] [mm²] [A~] [mm²] [mm²] [mm²] [Nm]
DCS800-S0x-0025-xx 25 1x 6 - 21 1x 4 - 1x 4 1 x M6 6
DCS800-S0x-0050-xx 50 1 x 10 - 41 1x 6 - 1x 6 1 x M6 6
DCS800-S0x-0075-xx 75 1 x 25 - 61 1 x 25 - 1x 16 1 x M6 6
DCS800-S0x-0100-xx 100 1 x 25 - 82 1 x 25 - 1x 16 1 x M6 6
DCS800-S0x-0140-xx 140 1 x 35 - 114 1 x 35 - 1x 16 1 x M6 6
DCS800-S0x-0200-xx 200 2 x 35 1 x 95 163 2 x 25 1 x 95 1x 25 1 x M10 25
DCS800-S0x-0260-xx 260 2 x 35 1 x 95 204 2 x 25 1 x 95 1x 25 1 x M10 25
DCS800-S0x-0320-xx 320 2 x 70 1 x 95 220 2 x 50 1 x 95 1x 50 1 x M10 25
DCS800-S0x-0350-xx 350 2 x 70 - 286 2 x 50 1x 50 1 x M10 25
DCS800-S0x-0450-xx 450 2x 95 - 367 2 x 95 - 1x 50 1 x M10 25
DCS800-S0x-0520-xx 520 2x 95 - 424 2 x 95 - 1x 50 1 x M10 25
DCS800-S0x-0650-xx 650 2 x 120 - 555 2 x 120 - 1x120 1 x M12 50
DCS800-S0x-0680-xx 680 2 x 120 - 555 2 x 120 - 1x120 1 x M12 50
DCS800-S0x-0820-xx 820 2 x 150 - 669 2 x 120 - 1x120 1 x M12 50
DCS800-S0x-0900-6/7 900 4x 95 3 x 150 734 4 x 70 3 x 95 1x150 2 x M12 50
DCS800-S0x-1000-xx 1000 2 x 185 - 816 2 x 150 - 1x150 1 x M12 50
DCS800-S0x-1190-xx 1190 4 x 120 - 971 4 x 95 3 x 120 1x185 2 x M12 50
DCS800-S0x-1200-xx 1200 4 x 120 - 979 4 x 95 3 x 120 1x185 2 x M12 50
DCS800-S0x-1500-xx 1500 4 x 185 - 1224 4 x 150 - 2x150 2 x M12 50
DCS800-S0x-2000-xx 2000 8 x 120 6 x 185 1632 4 x 240 - 2x240 2 x M12 50
DCS800-S0x-1900-xx ➁ 1900 8 x 120 6 x 185 1550 4 x 240 3x120 4 x M12 50
DCS800-S0x-2050-xx ➁ 2050 8 x 120 6 x 185 1673 6 x 120 5 x 150 3x120 4 x M12 50
DCS800-S0x-2500-xx ➁ 2500 7 x 185 - 2040 8 x 120 6 x 185 4x120 4 x M12 50
DCS800-S0x-2600-xx 2600 7 x 185 - 2122 8 x 120 6 x 185 4x120 4 x M12 50
DCS800-S0x-3000-xx ➁ 3000 8 x 185 - 2448 7 x 185 - 4x150 4 x M12 50
DCS800-S0x-3300-xx 3300 8 x 185 - 2693 7 x 185 - 4x150 4 x M12 50
DCS800-S0x-4000-xx 4000 7 x 300 - 3264 8 x 240 - 4x240 4 x M12 50
DCS800-S0x-4800-xx ➀ 4800 8 x 300 - 3876 6 x 300 - 3x300 4 x M12 50
DCS800-S0x-5200-xx ➀ 5200 8 x 300 - 4202 6 x 300 - 3x300 4 x M12 50
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.
Excitation:
Size D1 D2 D3 D4, D4+, D5 DCF803-0035
DC output current 6A 15 A 20 A 25 A 35 A
max. cross sectional area 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10 6 mm²/ AWG 10
min. cross sectional area 1 mm²/ AWG 16 2.5 mm²/ AWG 13 4 mm²/ AWG 11 6 mm²/ AWG 10 6 mm²/ AWG 10
Tightening torque 1.5 - 1.7 Nm
WARNING!
IEC 60664 requires double or reinforced insulation between live parts and the
surface of accessible parts of electrical equipment which are either nonconductive or
conductive but not connected to the protective earth.
To fulfill this requirement, the connection of a thermistor (or other similar
components) to the inputs of the drive can be implemented by 3 alternate ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. Rate the insulation of the relay for the same
voltage level as the main circuit of the drive.
Also see section Fault Tracing / Motor Protection in DCS800 Firmware Manual.
Electrical installation
Chapter overview
This chapter describes the electrical installation procedure of the DCS800.
WARNING!
A qualified electrician may only carry out the work described in this chapter. Follow
the Safety instructions on the first pages of this manual. Ignoring the safety
instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive was already connected to the mains, wait for 5 min. after
disconnecting mains power.
WARNING!
Check the insulation before connecting the drive to the mains. Make sure that the
drive is disconnected from the mains (input power).
1. Check that the motor cables are disconnected from the converter output terminals
C1, D1, F+ and F-.
2. Measure the insulation resistances of the motor cable and the motor between
each circuit (C1, D1) / (F+, F-) and the Protective Earth (PE) by using a
measuring voltage of 1 kV DC. The insulation resistance must be higher than
1 Mohm.
C1, D1
M
Ohm
F+, F-
PE
Ohm
SB_DCS_001_elektr-inst_a.ai
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
60
IT (ungrounded) systems
Don’t use EMC filters in IT systems.
The screen winding of existing dedicated transformers must be grounded.
For installation without low voltage switch (e.g. contactor, air-circuit-breaker) use an
overvoltage protection on the secondary side of the mains transformer.
The voltage shift of the isolated supply must not be larger than the voltage shift in
case on an earth fault.
U1
V1
W1
SA_550_003_netzanschl_a.ai
Supply voltage
Check supply voltages of:
Auxiliary voltage X99 on SDCS-PIN-4 / SDCS-POW-4
Cooling fan Terminals
Mains voltage for field circuit U1, V1, W1 (if used)
Mains voltage for armature circuit U1, V1, W1
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
61
Connect the signal cables as described below. Tighten the screws to secure the
extension modules.
X33: X9:
DCS slot 1 for
Panel connector R-type fieldbusses or
R-type I/O extension
X10:
slot 2 for
R-type I/O extension
X11:
slot 3 for
R-type I/O extension or
SDCS-COM-8
Interface
connector X20:
X2: SDCS-IOB-3 slot 4 for SDCS-MEM-4
X1: SDCS-IOB-2
X34:
DriveWindow Light or
DCS800 Control Buil-
der
R-type extensions:
RAIO (analog I/O)
RDIO (digital I/O)
RTAC (Encoder)
RRIA (Resolver)
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
62
SDCS-CON-4 SDCS-CON-4
X2: X2:
X1: X1:
X3: X4: X5: X6: X7: X3: X4: X5:
X3: X1:
SDCS-IOB-2
SDCS-CON-4 SDCS-CON-4
IO_poss_b.dsf
X2: X2:
X1: X1:
X6: X7:
I/O via SDCS-CON-4 and SDCS-IOB-3 I/O via SDCS-IOB-2 and SDCS-IOB-3
Analog I/O: standard, Analog I/O: standard
one channel for one channel for residual
residual current current detection
detection Digital I/O: isolated by means of
Digital I/O: not isolated (X6, X7) optocoupler / relay, the
Encoder input: isolated signal status is indicated
Analog tacho input: standard (X3) by LED
Current source for: PT100 / PTC element Encoder input: isolated
Analog tacho input: standard (X3)
Current source for: PT100 / PTC element
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
63
Use the sense feedback when the power supply level of a differential pulse encoder
is only 5 V. The sense function automatically compensates voltage drops of up to 1 V
over the cable. The wiring is shown in the figure below.
Commissioning hint:
A
X5:2 ChA- X5:2 correspond to the measured EMF
X5:3 ChB+ X5:3
B
X5:4 ChB- X5:4
speed, F522 SpeedFb may appear
B
Z
X5:5 ChZ+ X5:5 during start-up. If necessary correct it
Z
X5:6
X5:7
ChZ-
Power source
X5:6
X5:10
by exchanging the field connections
+U
0V
X5:8 Sense power X5:9 F1 and F2 or exchange tracks A+ and
X5:9
X5:10
Sense GND X5:8
X5:7
A-.
GND
65535
IOB3x3_g.dsf
Reverse
0
DZ_LIN_008_forw-rev_a.ai
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
64
ENCODER CHANNEL A
+5V +5V
X5:1 1k0 4k7 X5:1 1k0 4k7
121 W
100 nF S10
121 W
3 6 3
2k2
10k 10k
2 5 +24V R 2
S4
100 nF
1 4 1
1k0 4k7 1k0 4k7
+5V +5V
X5:2 X5:2
0V / GND 0V
X5:10 SDCS-IOB-3 ENCODER INPUT A X5:7 SDCS-CON-4 ENCODER INPUT A
single ended
push pull
ENCODER CHANNEL A
+5V +5V
X5:1 1k0 4k7 X5:1 1k0 4k7
121 W
100 nF S10
121 W
3 6 3
2k2
2k2
10k 10k
R 2 5 R 2
+24V
S4
100 nF
1 4 1
1k0 4k7 1k0 4k7
+5V +5V
X5:2 X5:2
0V / GND 0V
X5:10 SDCS-IOB-3 ENCODER INPUT A X5:7 SDCS-CON-4 ENCODER INPUT A
SS_800_003_encoder_a.ai
Jumper settings for single ended connected to Jumper settings for single ended encoders
SDCS-CON-4 connected to SDCS-IOB-3
SDCS-CON-4 SDCS-IOB-3 SDCS-CON-4*
jumper S4 jumper S10 jumper S4
single ended 5V 24 V single ended 5 / 12 / 24 V -
voltage source 2-3 2-3 push-pull 4-5 3 - park
5-6 5-6 10 - 11 6 - park
8-9 8-9 16 - 17 9 - park
10 - 11 11 - 12 single ended 5 / 12 / 24 V -
open collector 5-6 3 - park
11 - 12 6 - park
17 - 18 9 - park
* If an encoder is connected to a SDCS-IOB-3 the S4 jumper
settings on the SDCS-CON-4 are required!
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
65
differential
+5V +5V
X5:7 X5:10
ENCODER CHANNEL A
ENCODER CHANNEL A
+5V +5V
X5:1 1k0 4k7 X5:1 1k0 4k7
121 W
100 nF S10
121 W
3 6 3
10k 10k
2 5 +24V 2
S4
100 nF
1 4 1
1k0 4k7 1k0 4k7
+5V +5V
X5:2 X5:2
0V / GND 0V
X5:10 SDCS-IOB-3 ENCODER INPUT A X5:7 SDCS-CON-4 ENCODER INPUT A
SS_800_003_encoder_a.ai
Jumper settings for differential encoders connected Jumper settings for differential encoders connected to
to SDCS-CON-4 SDCS-IOB-3
SDCS-CON-4 SDCS-IOB-3 SDCS-CON-4*
jumper S4 jumper S10 jumper S4
differential 5V 24 V differential 5V 12 / 24 V -
voltage source 1-2 1-2 voltage source 2-3 4-5 3 - park
4-5 4-5 8-9 10 - 11 6 - park
7-8 7-8 14 - 15 16 - 17 9 - park
10 - 11 11 - 12 differential 13 mA - -
current source 1-2 3 - park
7-8 6 - park
13 - 14 9 - park
* If an encoder is connected to a SDCS-IOB-3 the S4 jumper settings
on the SDCS-CON-4 are required!
The maximum distance between pulse encoder and interface board dependents on
the voltage drop of the connecting lines and on the output and input configuration of
the used components. Use cables according to the table below. The voltage (5 V
supply) regulator can compensate the voltage drop caused by the cable. Use twisted
pair cables with pair shielding plus overall shielding.
Cable length Parallel wires for Cable used
power source & GND
0 to 50 m 1 x 0.25 mm² 12 x 0.25 mm²
50 to 100 m 2 x 0.25 mm² 12 x 0.25 mm²
100 to 150 m 3 x 0.25 mm² 14 x 0.25 mm²
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
66
Connection of cable
screens with metal clamps
to the metal surface of the
electronic tray.
Size D6, D7
screen connection
Motor cable
Drive min 300 mm
Power cable
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
67
DCSLink wiring
The DCSLink is a 500 kBaud serial communication between drives and drives to
field exciters.
It is based on CAN hardware and using twisted cables.
The topology is a bus system.
Switched OFF nodes can remain in the bus and do not disturb the serial
communication.
The function of the interface is predefined:
1 Mailbox function for drive to drive communication (e.g. master - follower).
2 Communication to field exciter types DCF803, DCF804 and large field
exciters using standard DCS800 modules.
3 Communication for 12-pulse operation, DCS800 to DCS800.
Cabling
Every bus device requires its own individual node number. Only two physical ends
are allowed for the bus system.
The bus termination of the twisted pair cable is done using a termination resistor of
120 Ohm inside the drives or field exciters.
The termination resistance of 120 Ohm is selected for typical twisted pair cables.
The cables must be terminated at both ends. This is done using jumpers or switches.
Preferred cable type: DEVICENET
Supplier: Helu Kabel, Germany; type 81910PUR
Belden, USA; type 3084A
CAN_H
CAN_L
SF_DCS_002_can-bus_a.ai
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
68
GNDB GNDB
1 S1 4 2 S2 1 S1 4 2 S2
2 3 2 3
1 1
SB_800_003_bus_b.ai
Ground termination NO NO
(S2 = 3-4) (S2 = 3-4)
Bus termination ON ON
(S1 = 1-2) (S1 = 1-2)
Example of two DCS800 D4+, D5 converters with FEX-425-Int internal field supply.
S1100:2 S1100:2
GNDB GNDB
GNDB GNDB
1 S1 4 2 S2 1 S1 4 2 S2
2 3 2 3
S1100:1 S1100:3 1 1 S1100:1 S1100:3
X3: 3 2 1 X52: 1 2 3 3 2 1 X53: X52: 1 2 3 3 2 1 X53: X3: 2 3 1
(next converter)
SB_800_003_bus_c.ai
Ground termination NO NO NO NO
(S1100:2 open (S2 = 3-4) (S2 = 3-4) (S1100:2 open
S1100:3 open) S1100:3 open)
Bus termination ON OFF OFF ON
(S1100:1 closed) (S1 = 2-3) (S1 = 2-3) at the end of the bus
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
69
DCS800 Converter
SDCS-DSL-4
+24 V X1:1
DCF803-0035 0V X1:2
X51:1 +24 V
X51:2 0V
S1100:2
GNDB
GNDB
1 S1 4 2 S2
2 3
1 S1100:1 S1100:3
X52: 1 2 3 3 2 1 X53: X3: 2 3 1
SB_800_003_bus_c.ai
Ground termination NO NO
(S2 = 3-4) (S1100:2 open
S1100:3 open)
Bus termination ON ON
(S1 = 1-2) (S1100:1 closed)
Cable length
The cable length influences the maximum baudrate.
Baudrate max. cable length
50 k 500 m
125 k 500 m
250 k 250 m
500 k 100 m default and recommended setting
800 k 50 m
888 k 35 m
1000 k 25 m
The bus is designed for a total cable length up to 100 meters. Larger distances on
request.
Electrical installation
3ADW000194R0811 DCS800 Hardware Manual us h
70
Installation 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 manual before you work on the unit.
MECHANICAL INSTALLATION
The ambient operating conditions are allowed (see Environmental Conditions, Current ratings)
The unit is mounted properly on a vertical non-flammable wall (see Mechanical installation)
The cooling air will flow freely (see Cabinet installation, Mounting the converter module inside
an enclosure)
The motor and the driven equipment are ready for start
All screen terminals are checked for tightness (see Connecting the signal and control cables)
All cable connections are seated properly (see Connecting the signal and control cables)
ELECTRICAL INSTALLATION (see Planning the electrical installation, Electrical installation)
The converter modules are grounded properly
The mains voltage matches the converter module‘s nominal input voltage
The mains (input power) connections at U1, V1 and W1 (L1, L2 and L3) and their tightening
torques are OK
The appropriate mains fuses and disconnector are installed
The drive connections at C1, D1 and F+, F- and their tightening torques are OK
Motor cable routing (armature and exitation) is OK
Check that the screens are properly installed at the motor and the drive cabinet
The motor connections L+, L-, F+ and F- and their tightening torques are OK
The control connections are OK
If a pulse encoder is used, check the encoder cables and correct direction of rotation
PTC, klixon cables: Check that the connections are appropriate for the type of sensor used in
the motor
Check the prevention of unexpected start-up (on inhibit, coast stop) circuit for proper function
Proper function of E-stop circuit and relay
Cooling fan power wiring connected
The external control connections inside the drive are OK
There are no tools, foreign objects or drill cuttings inside the drive
Converter, motor connection box and other covers are in place
Installation checklist
3ADW000194R0811 DCS800 Hardware Manual us h
71
Maintenance
Chapter overview
This chapter contains preventive maintenance instructions. For more information
see DCS800 Service Manual.
Safety
WARNING!
Read the Safety instructions on the first pages of this manual before performing any
maintenance on the equipment. Ignoring the safety instructions can cause injury or
death.
Maintenance
3ADW000194R0811 DCS800 Hardware Manual us h
72
Technical data
Chapter overview
The technical data contain the technical specifications of the converter, e.g. the
ratings, sizes and technical requirements, provisions for fulfilling the requirements for
CE and other markings and warranty policy.
Environmental Conditions
System connections Environmental limit values
Voltage, 3-phase: 230 to 1000 V acc. to IEC 60038 Permissible cooling air temp.
Voltage deviation: ±10 % continuous; ±15% short-time * - at converter module air inlet: 0 to +55°C
Rated frequency: 50 Hz or 60 Hz with rated DC current: 0 to +40°C
Static frequency deviation: 50 Hz ± 2 %; 60 Hz ± 2 % with different DC current: +30 to +55°C
Dynamic: frequency range: 50 Hz ± 5 Hz; 60 Hz ± 5 Hz - Options: 0 to +40°C
df/dt: 17 % / s Relative humidity (at 5...+40°C): 5 to 95 %, no condensation
* = 0.5 to 30 cycles Relative humidity (at 0...+5°C): 5 to 50 %, no condensation
Please note: Special consideration must be taken for voltage Change of the ambient temp.: < 0.5°C / minute
deviation in regenerative mode. Storage temperature: -40 to +55°C
Transport temperature: -40 to +70°C
Degree of protection Pollution degree (IEC 60664-1,
Converter module and options IEC 60439-1): 2
(line chokes, fuse holder, field Site elevation
exciter, etc.): IP 00 < 1000 m above M.S.L.: 100 %, without current reduction
Enclosed converters: IP 20/21/31/41 > 1000 m above M.S.L.: with current reduction
Paint finish
Converter module: RAL 9002
Enclosed converter: light grey RAL 7035
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
73
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 Directive Manufacturer's Assurance Harmonized Standards
Converter module Enclosed converter
Machinery Directive
98/37/EEC Declaration of Incorporation EN 60204-1 EN 60204-1
93/68/EEC [IEC 60204-1] [IEC 60204-1]
Low Voltage Directive
73/23/EEC Declaration of Conformity EN 60146-1-1 EN 60204-1
93/68/EEC [IEC 60146-1-1] [IEC 60204-1]
EN 61800-5-1 EN 61800-5-1
(EN 50178 [IEC --]) EN 60439-1
véase también [IEC 60439-1]
IEC 60664
EMC Directive
89/336/EEC Declaration of Conformity EN 61800-3 ① EN 61800-3 ①
93/68/EEC (Provided that all installation instructions concer- [IEC 61800-3] [IEC 61800-3]
ning cable selection, cabling and EMC filters or
dedicated transformer are followed.)
① in accordance with 3ADW000032 ① in accordance with 3ADW000032/
3ADW000091
Effect of the site elevation above sea level on the converter’s load capacity Effect of the ambient temperature on the converter‘s load capacity
100 110
90
100
80
90
70
80
60
50 70
30 35 40 45 50 55°C
1000 2000 3000 4000 5000 m DZ_LIN_017_current-reduction_a.ai
Current reduction to % of nominal converter current Current reduction to % of nominal converter current
Effect of site elevation and ambient temperature on the converter‘s load capacity
Ambient Site elevation in m above M.S.L.
temperature 1000 m 2000 m 3000 m 4000 m
30°C 100 % 100 % 90 % 80 %
35°C 100 % 95 % 85 % 75 %
40°C 100 % 90 % 80 %
45°C 95 % 85 %
50°C 90 % 80 %
55°C 85 %
Current reduction to % of nominal converter current
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
74
* as option
** The 525 V version can be used as large field exciter. Do not forget the SDCS-DSL-4 (+S199).
A 10 % current de-rating is strongly recommended.
Note:
AC current IAC = 0.82 * IDC
➀ 1190 ADC for 35°C and 1140 ADC for 40°C ambient temperature
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
75
* as option ** The 525 V version can be used as large field exciter. Do not forget the SDCS-DSL-4 (+S199).
A 10 % current de-rating is strongly recommended.
Note: AC current IAC = 0.82 * IDC
Sizing: Note 1: The ratings apply at ambient temperature of 40°C (104°F). For lower temperatures the D5, D6, D7
ratings are higher (except Imax).
Note 2: Use DriveSize for detailed dimensioning in case the ambient temperature is below 40°C (104°F)
or the drive is loaded cyclically.
➀ 1190 ADC for 35°C and 1140 ADC for 40°C ambient temperature
Standard duty cycles
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
76
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
77
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
78
S1 23 * Parkposition Steckbrücke; 1 2
D2001
5 D2002
4 X37: Segment-Anzeige
6 Parkposition Steckbrücke; SDCS-PIN-4 / D1000
5
AITAC1+ (X3:4) nicht geerdet SDCS-POW-4
2
1
1 30
4
9 * AITAC1 über SDCS-CON-4
D2100
8
7 X3:4 and X3:1/2/3 X13:
SDCS-PIN-4 /
1
9 reserviert, AITAC2 über SDCS-IOB-3 /
8 SDCS-PIN-51
PS5311 X2:23 and X2:24
7
2
1
1 1
2 2
S2 21 4 * AI1 (X3:5-6): Rin = 200 k; Bereich ±10 V X11: Steckplatz 3 X10: Steckplatz 2
3 X12:
∗∗ SDCS-PIN-4 / E/A-Erweiterung E/A-Erweiterung
2 4 AI1 (X3:5-6): Rin = 250 ; Bereich ±20 mA
230
1 3 SDCS-PIN-51 SDCS-COM-8
2
1
26
1
6 7 kein PTC angeschlossen SDCS-IOB-2 / SDCS-IOB-3 DriveWindow Light
5 8 PTC angeschlossen an X3:7-8, 4,75 k X1 2526 1
2 DCS800 ControlBuilder X8:
6 7 Pull-up Widerstand aktiviert 1
S3 12 5 1 S5
3 9 S24 2
3
8 2 2 4
2
S121 8 2 11 S4 6 9 1 3 SDCS-DSL-4
7 3 1 7 1 10
S4 23 9 * Impulsgeber mit Differenzeingängen; RC-Last 1
1
1 1 1 1
8
1 7
R = 121 and C = 100 nF aktiviert X3 X4 X5 X6 X7
3 9 Impulsgeber mit unsymmetrischen Anschluss
2 8
10 k Pull-up Widerstand aktiviert 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8
1 7
12 * Impulsgebereinspeisung, Spannungsregler SDCS-PIN-4 SDCS-CON-4 SDCS-POW -4 SDCS-CON-4
11
10 X5:8-9 ist aktiviert oder s. SDCS-POW-4 10 11 12 +24 V 10 11 12 24V
5V
12 Impulsgebereinspeisung +24 V, +5 V
11 12V
ungeregelt, von SDCS-CON-4 versorgt S4 15V S4
10
24V
9
Parkposition, wenn ein Impulsgeber
3
2 8 an die SDCS-IOB-3 angeschlossen wird X3:10 X5:10
1 7 Impulsgebereinspeisung Impulsgebereinspeisung
Die 24 V Impulsgebereinspeisung kommt entweder direkt von der
S5 21 4 Firmware laden
3 SDCS-CON-4 (S4 = 11-12) oder von der SDCS-POW-4 (S4 = 10-11).
2 4 * Normale Programmausführung S4 befindet sich auf der SDCS-CON-4.
1 3 oder Texte laden BL_CON4_001_c.ai
* Grundeinstellung
** 250 x 20 mA = 5 V == 100 %
Memory circuit
The SDCS-CON-4 is equipped with a flash PROM that contains the firmware and the parameters. It is
possible to handle the parameters by DCS Control Panel, DW, DWL or overriding control. Changed
parameters are stored immediately in the flash with the exception of parameters for cyclic
communication via the dataset table in groups 90 to 92 and pointers in group 51.
In addition, the fault logger entries are stored in the flash during de-energizing the auxiliary power.
Watchdog function
The SDCS-CON-4 has an internal watchdog. The watchdog controls the proper function of the SDCS-
CON-4 and the firmware. If the watchdog trips, it has the following effects:
• The thyristor firing control is reset and disabled.
• All digital outputs are forced low (zero).
• All programmable AOs are reset to zero (0V).
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
79
Warning
Fault
BE_ANZ_001_7-SEG_b.ai
Terminal description
X37: Connector is used to supply the SDCS-CON-4 from the SDCS-PIN-4 or SDCS-POW-4.
The supply voltages can be measured to ground.
X37:2,3,4 = 48 VDC
X37:5,6 = 24 VDC
X37:7,8 = 15 VDC
X37:11,12 = -15 VDC
X37:13,14 = 5 VDC for encoder
X37:17,19,21,23 = 5 VDC for CPU
Supply voltage monitoring
The 5 VDC for the CPU is monitored. Power dips under 4.75 VDC forces the CPU to reset. In parallel the
CPU monitors the powerfail signal from the power supply (SDCS-PIN-4 or SDCS-POW-4).
X12: and X13: Connectors are used to measure voltage, current and temperature as well as distributing
the firing pulses to the thyristors via SDCS-PIN-4, SDCS-PIN-51, SDCS-PIN-46 or SDCS-PIN-48.
See chapter Power interfaces.
X33: Is used to connect the DCS Control Panel. It can be connected direct via 40 mm jack or via a CAT
1:1 cable (RJ45).
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
80
The RS232 interface is normally used to set parameters in the drive via DWL.
The default settings of this interface are:
Parity-Bit: Odd
X34: Description
1 Not connected
2 TxD
3 RxD 5 1
X34
4 Not connected 9 6
X8: Is needed for the SDCS-DSL-4 which provides the serial communication interface for field exciters,
12-pulse communication, master-follower and drive-to-drive communication.
X9:, X10: and X11: Slots 1 to 3 are used for extension IO modules and serial communication interface
adapters.
For detailed description see chapter DCS800 Manuals.
X20: Slot 4 is used for the SDCS-MEM-8 (Memory Card), see description DCS800 ControlBuilder.
Prepared function of:
SDCS-COM-8 x
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
81
SDCS-CON-4 Firmware
SDCS-IOB-3
±90... ±270 V AITAC2
(PS5311)
X3:1 -
±30...±90 V
39k2 9 Resolution Input/output Scaling Common Remarks
2 + 8 AITAC [bit] values by mode
X2:
12k8
±8...±30 V - 7
3 S1
S1 3 2 1 5k 1k66
AITAC1
Hardware range
4 +
S1
6 5
GND
4 ±90...270 V
5 S2
-
3 4 250 AI1 15 + sign ±30...90 V Firmware ±15 V Analog tacho
6 S3 6 5 4k75 +
(3.3 ms)
7
8 7
+10V
-
±8...30 V
S3
8
3 4 250
+
AI2 15 + sign ±10 V Firmware ±15 V For AI1 - AI4 use a
(3.3 ms)
9 - 15 + sign ±10 V Firmware ±15 V potentiometer with
AI3
10 + (5 ms) 15 + sign ±10 V Firmware ±15 V minimum 2 k
15 + sign ±10 V Firmware ±15 V resistance.
X4:1 -
AI4
2 +
(5 ms)
3 GND
Power
4 +10V
+10 V 5 mA
5 -10V
GND (AOx)
-10 V 5 mA
6
100µ 47.5 11 + sign ±10 V Firmware 5 mA
7 AO1 (5ms)
8
100n
AO2 (5ms)
11 + sign ±10 V Firmware 5 mA
9
±10 V Firmware, 5 mA 8 V -> min. of
Hardware 325% of (99.03) or
10 GND X
230% of (4.05)
+/- I-act
ChA +
X5:1 S4
2
121 100nF 1 2 3 ChA - Encoder supply Remarks
3
10k ChB
+ Inputs are not isolated
S4
4
121 100nF 4 5 6 ChB - Impedance = 120 , if selected
5
10k
S4
ChZ + maximum frequency 300 kHz
250 mA
121 100nF 7 8 9 ChZ
6 - 5V Sense lines for GND and supply to
GND
200 mA
10k
7 24 V correct voltage drops on cable (only
Sense 0 V
8 available for 5 V encoders)
Sense 5 V S4 PIN-4 = 5 V
9 10
POW-4 = 5V/
Power 11
12V/24V
10 12 CON-4 = 24 V
2k21 221k 5V
-
X6:1 4k75 47nF Z15 + DI1
2 τ = 10 ms DI2
3 τ = 10 ms DI3
τ = 10 ms
Input Signal Remarks
4 DI4
5 τ = 10 ms DI5 definition
6 τ = 10 ms DI6 0...7.3 V Firmware -> “0“ status
7 τ = 3.3 ms DI7 7.5...50 V -> “1“ status
8 τ = 3.3 ms DI8
9 +24 V; 125 mA
max.
24 VDC 10
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
82
The board is equipped with four optical channels (max. data transmission speed is 4 Mb for each optical
channel):
• Channel 0 is used for communication with the overriding control (e.g. FCI, AC 800M)
• Channel 1 is used for the I/O Module Adapter AIMA-01, FEA-01
• Channel 2 is used for master - follower
• Channel 3 is prepared to connect DriveWindow or IBA interface
148
SDCS-COM-8
D100
D200
V6
D400
86
CH 3
CH 2
CH 1
CH 0
V1
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
grey
dark e
dark
dark
dark
grey
grey
grey
grey
grey
grey
grey
blu
X19
BL_COM8_001_a.ai
conductive support
Type Revision Optical components Channel 0 used for Max. driver current Cunductive
support
Ch 0 Ch 1 Ch 2 Ch 3
PLC I/O M/F DW
SDCS-COM-81 G - I 10 Mb 5 Mb 10 Mb 10 Mb ABB PLCs Ch 0, 2, 3 50 mA x
SDCS-COM-82 G - I 5 Mb 5 Mb 10 Mb 10 Mb N-type fieldbus Ch 2, 3 50 mA x
adapters
SDCS-COM-81 K and 10 Mb 10 Mb 10 Mb 10 Mb ABB PLCs Ch 0 - 3 50 mA x
higher
SDCS-COM-82 K and 5 Mb 10 Mb 10 Mb 10 Mb N-type fieldbus Ch 1 - 3 50 mA x
higher adapters
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
83
D400 V6
CH 3
CH 2
CH 1
CH 0 D400
CH 3
CH 2
CH 1
CH 0
V1
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
CH 3
CH 2
CH 1
CH 0
V1
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
grey
dark
dark
dark
dark e
grey
grey
grey
grey
grey
grey
grey
blu
X19 V1
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
grey
dark
dark
dark
dark e
grey
grey
grey
grey
grey
grey
grey
blu
X19
grey
dark
dark
dark
dark e
grey
grey
grey
grey
grey
grey
grey
blu
X19
BL_COM8_002_bus_b.ai
Plastic optic fiber
CH 2
CH 1
CH 0
CH 3
CH 2
CH 1
CH 0
CH 3
CH 2
CH 1
CH 0
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
grey
grey
grey
dark
dark
dark
grey
grey
grey
grey
grey
grey
grey
dark
dark
dark
dark
dark
dark
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
...
dark
dark
dark
...
TxD
TxD
TxD
RxD
RxD
RxD
RxD
BL_COM8_002_bus_b.ai
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
84
Manual
instead of
DriveWindow
grey
NETA internet
TxD
connected, see
module can be
3AFE64605062
Maximum 20 m;
CH 3
dark
grey RxD
Technical data
D200
grey TxD
CH 2
dark
grey RxD
grey TxD
Fieldbus
grey TxD CH 1
CH 3 dark
dark RxD
Internet/Ethernet
grey
grey RxD
D200
RxD grey TxD
grey TxD
SDCS-COM-82
CH 0
CH 2
dark TxD RxD
NETA
grey RxD blue
grey TxD
Nxxx-xx
CH 1
dark
RxD
grey
grey TxD
SDCS-COM-8x
CH 0
grey
dark e RxD
blu
grey TxD
CH 3
dark
grey RxD
D200
grey TxD
CH 2
dark
grey TxD grey RxD
CH 3
dark
grey RxD grey TxD
D200
CH 1
CH 0
grey TxD
CH 1 TxD RxD
dark blue
RxD
grey
...
grey TxD
Nxxx-xx
SDCS-COM-8x
CH 0
RxD grey
dark e RxD
blu
...
TxD
grey RxD
grey TxD
CH 2 grey TxD
Ch0 connection to overriding control (N-type fieldbus adapter)
dark
RxD CH 1
...
grey
dark
RxD
grey grey
Plastic optic fiber
TxD
CH 1
dark RxD grey TxD
RxD
grey
SDCS-COM-82
CH 0
grey TxD TxD RxD
blue
SDCS-COM-8x
CH 0
grey
dark e RxD
blu
Nxxx-xx
BL_COM8_002_bus_b.ai
10 m
BL_COM8_002_bus_b.ai
30 m - SDCS-COM-8 Rev D and higher
85
CH 3
CH 2
CH 1
CH 0
CH 3
CH 2
CH 1
CH 0
CH 3
CH 2
CH 1
CH 0
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
TxD
grey
grey
grey
dark
dark
dark
dark
dark
dark
dark
dark
dark
dark e
dark e
dark e
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
grey
blu
blu
blu
...
Plastic optic fiber
30 m - SDCS-COM-8
Rev D and higher
HCS
200 m - SDCS-COM-8
Rev D and higher
... ...
TxD
TxD
TxD
TxD
TxD
TxD
RxD
RxD
RxD
RxD
RxD
RxD
0, 1, 2 ... NDBU-95 ...8
... 0, 1, 2 ... NDBU-95 ...8
TxD
RxD
TxD
RxD
Branching Branching
unit unit
HCS 200 m
Maximum 20 m;
...
instead of
TxD
TxD
RxD
RxD
DriveWindow
0, 1, 2 ... NDBU-95 ...8
NETA internet
module can be
TxD
RxD
connected, NETA
Internet/Ethernet
see Manual
Branching
3AFE64605062
unit
Plastic HCS
optic fiber 200 m
30 m
TxD
RxD
RUSB-02
BL_COM8_002_bus_b.ai
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
86
Optical links:
Master channels 1 DDCS input and 1 DDCS output
Drive channels 9 DDCS inputs and 9 DDCS DBU
41
outputs
Data rate 1 - 4 MBd, (see X12)
CH8 RXD
MBIT/S
CH5 RXD
Remark: Only channels with the same hardware V113
++ ++
+ + + + X12
1 2 4
components (e.g. 10 Mb component) are
allowed to be connected together. TXD
V112
CH4 RXD
V111
TXD
V108
CH2 RXD
V107
TRANSM
SETTING
TXD
+ + + + X2-
V106 + + + + X11
CH1 RXD
DIS
V105 LONG
MEDIUM
SHORT
TXD
V104
CH0 RXD
V103
TXD
V102
MSTR RXD
V101
+5V OK
1 24 V DC
X1
2 0V
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
87
The communication hardware is equipped with an isolated power supply and an isolated transmitter.
The bus termination can be set by jumper S1. See also chapter DCSLink communication.
77
SDCS-DSL-4
30
S1
X51 X52 X53 X54
3
1 2
4
2
S2
1
1 2 1 2 3 1 2 3 1 2 3
3
Jumper coding
- X51 supplies 24 VDC
S1 Bus termination - X52 and X53 are connected in
3
2 120 Ohm parallel and provide
1 two connectors for the DCSLink
3 - X54 is not used
2 no termination, park position
1 *
S2 Ground termination
2 4 0 Ohm (direct) ground
1 3 termination
2 4 200 kOhm R-C ground
3
1 termination
2 4
1 3
* no termination, park position
* Default value
B L _ D S L 4 _ 0 0 1 _ + T a b _ a .d s f
.
SDCS-DSL-4 Software Supply Remarks
X8: CON-4 24 V 200 mA 24 V grounded supply for DCF803-
X51:1 24 V / 200 mA 0016, FEX-425-Int and DCF803-0035
2 field exciters; short circuit protected
X52:1 S1
250 mA
2 CANL
2 1 3
3
CANH DSL communication Remarks
S2 GNDB Bus termination
X53:1 3 4 Termination 200 kOhm S1 1-2 120 Ohm
1 2
2 2-3 no termination; park position
3 Ground termination
X54:1 S2 2-4 200 kOhm R-C ground termination
2
TxD 1-3 0 Ohm ground termination
RxD 3-4 no termination; park position
3
RS 485 communication Remarks
DSL-4_dia_a.dsf no isolation
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
88
As described at the beginning of the chapter, there are I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
various options for configuring the inputs and outputs.
SDCS-CON-4 SDCS-CON-4
The SDCS-IOB-2x has 8 digital inputs and 8 digital
outputs.
There are three different types existing, depending on
the input voltage level: X2: X1: X2: X1:
233.5
S7
2
X3 X1 SDCS-IOB-2x
4
W16
3
W100 **
DO4 DO8
1
W10
W12
W14
W2
W6
W8
2
W4
4
DO6 DO7
3
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8
1
S8
K1 K2 K3 K4 K5 K8
97.5
4*
W7
W11
W3
W5
W1
W9
W13
W15
R1 R2 R3 R4 R5 R6 R7 R8
Line potential !
70
1 1 1 1
5 X4 X5 X6 X7 5 70
4 4
* Default value
** Connected voltage 2 ms 10 ms
24 VDC Ok Ok
115 / 230 VAC not permitted Ok
BL_Iob2_001_+Tab_b.ai
There is a card holder available as option for fastening the SDCS-IOB-2. For more information see
chapter Card holder for SDCS-IOB-2/3.
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
89
Note:
SDCS-IOB-2x Software When the SDCS-IOB-2 is connected to a SDCS-CON-4, DIs
DOx and DOs of the SDCS-CON-4 cannot be used (connectors X6
X4:1 DO1
K1 and X7).
2 Output value Signal definition by Remarks
3 DO2
K2 K1 - K5, K8 Firmware Isolated by relays
4 (NO contacts)
5 DO3 Contact ratings:
K3 AC: 250 V~/ 3 A~
6 DC: 24 V-/ 3 A- or
7 DO4 115/230 V-/ 0.3 A-
K4 MOV-protected (275 V)
8
7 R7
Power supply for digital inputs (X7:3,4):
DI7 • Only available at SDCS-IOB-21
W13 W14
• 48 V / 50 mA
8 R8 • Not isolated from the DCS electronics!
DI8 If the inputs are supplied from the internal +48 V (X7:3 and/or X7:4) a
W15 W16
connection must be routed from either X7:1 and/or X7:2 to ground of
X7:1 the DCS800 module. Usually the ground is identical to the converter's
2 W100 frame.
up to revision D
3 from If the inputs are supplied by any external source (+48 VDC, 115 VAC or
revision E on 230 VAC) the neutral line / - line must be connected to either X7:1 or
4 +48V X7:2. If the inputs should be controlled with the same voltage level, but
from two different voltage sources, having probably two different
conductive support ground levels, the first neutral line should be connected to X7:1 and
SA_IOB2_001_a.ai
the second to X7:2. In this case the jumpers Wx connecting the inputs
Only available at
to X7:2, but controlled by the source, connected to X7:1, must be cut
SDCS-IOB-21
out.
The same method is needed for the other jumpers Wx.
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
90
As described at the beginning of the chapter, there are I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
various options for configuring the inputs and outputs.
SDCS-CON-4 SDCS-CON-4
The board SDCS-IOB-3 consists of the 5 analog
inputs, 3 analog outputs, a galvanically isolated pulse
encoder interface and a current source for tempera-
ture measuring devices. X2: X1: X2: X1:
outside the DCS module. They must be mounted in a X1: X2: X3: X1: X1: X2:
way, that the conductive supports have a good con-
SDCS-IOB-3 SDCS-IOB-2 SDCS-IOB-3
nection to ground of the installation.
The SDCS-IOB-3 is substituting the standard AI, AO
and encoder connections of the SDCS-CON-4.
Also see I/O Board Configuration.
The cable length between X1-X1 and X2-X2 is max.
1.7 m (D1 - D5 converters) or max. 4 m screened
(required for D6 and D7 converters). Between X1-X3 it
is max. 0.5 m because of EMC reasons.
See chapter Other cables.
Conductive supports
V17
SDCS-IOB-3
X1 X2
2 14
S1*
T1
1 13
8 7 8 7 S10 *
S5 * S4
*
3 24 85
R110 1 2 1 2
2 1 2 1 2 23
3 4
1 22
70 S2* S3* 70
11 12
1 12 1 12 10
1
X3 X4 X5
5 5
4 4
Jumper coding
Differential: 5V 12 V / 24 V 13 mA
*
3 24 3 24 3 24
2 23 2 23 2 23
1 22 1 22 1 22
* Default value
When using the SDCS-IOB-3 encoder
3 12
input, the following S4 jumper setting S4 on SDCS-CON-4 2 11
has to be made on the SDCS-CON-4. 1 10
BL_IOB3_001_+Tab_a.ai
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
91
There is a card holder available as option for fastening the SDCS-IOB-3. For more information see
chapter Card holder for SDCS-IOB-2/3.
Note:
When the SDCS-IOB-3 is connected to a SDCS-CON-4 AIs, AOs and
encoder connections of the SDCS-CON-4 cannot be used
(connectors X3, except for terminals 1, 2, 3, 4, X4 and X5). As an
exception analog tachos have to be connected at the SDCS-CON-4
X2:
SDCS-IOB-3 SDCS-CON-x Software
- S1 100k 100k (connector X3:1-4).
X3:1 2 1 1n
+ 500 100k 1n 100k AITAC
2
-
3 4 3 Resolution Input / output Scaling Common Remarks
+ AI1
4 [bit] values by mode
3.3 ms
- 3 S2 1 hardware range
5 6 5 4 2
+ 6
x10 8 AI2
6 5 7 15 + sign ±10 V Firmware ±20 V ➀➁➂➅
- 3 1
3.3 ms
7 8 7 4 2
+ x10
8 6
5 7
8 AI3 15 + sign ±10 V Firmware ±20 V ➀➁➂
S3 10 ms
-
9
+
10 9
AI4 15 + sign ±10 V Firmware ±40 V ➀➁➂➃➄
10 12 14 10 ms
~ S1
11
11 13
15 + sign ±10 V Firmware ±40 V ➀➁➂➃➄
100
12 ~
15 + sign ±10 V Firmware ±40 V ➀➁➂➆
100m 47.5
X4:1 100n AO1
2 0V 5 ms Power
3 AO2
5 ms 11 + sign ±10 V Firmware 5 mA*
4 0V
100m 47.5
5 100n
x +/- I-act 11 + sign ±10 V Firmware 5 mA*
8 V = max. 325% [99.03]
6 0V
R110
or 230% [4.05]
Analog ±10 V R110 5 mA* Gain: 0.5 - 5
7 +10V
8 0V Ri = 3 5 mA* For external use
9 -10V
5 mA* E.g. reference pot.
1 2
100m 1.5 mA
10 S5
5 mA
3 4 1.5 mA Current source for
11 0V
5 mA PTC or PT100
12
S10 S10
X5:1 4 5 6 +24V 1 2 3 ChA + Encoder supply Remarks
2 ChA - Inputs not isolated
3 10 11 12 ChB + Impedance = 120 , if selected
+24V 7 8 9
4 max. frequence 300 kHz
ChB -
5 ChZ +
5V 250 mA * Sense lines for GND and supply to cor-
16 17 18 +24V 13 14 15
12 V / 24 V 200 mA * rect voltage drops on cable (only avail-
6 ChZ -
V17 able for 5 V or 12 V encoders)
7 Power-
Sense Power + Source
8
Sense GND
9
10 S4 GND
SA_IOB3_001_b.ai
➀ Total filter time 2 ms ➆ Residual current detection is selected as default. If the jumpers S1:11-12 and S1:13-14 are set, inputs X3:9 and
➁ ±20 mA by setting S1 X3:10 and jumper S1:9-10 must not be used. Inputs X3:11 and X3:12 now serve as input for the current signal taken
➂ 4 - 20 mA by ➁ + Firmware function from a current transformer. This detection is based on a sum current transformer where the secondary side is
➃ ±1 V by setting S2/S3 (CMR ±10 V) connected through a diode bridge to a 100 resistor. Voltage will appear across the resistor, if the sum of the
±2 mA by setting S2/S3 + S1 (CMR ±10 V) 3-phase currents is not zero. In case AI4 should be used for a different purpose, use the inputs / jumpers accordingly
➄ Designated for PT100 evaluation via firmware and and take the block diagram as a help.
hardware Restrictions using jumper S1, S2 or S3:
➅ Should always be used directly at SDCS-CON-4 The selection of the burden resistor across the input terminals can be done independent from S2 or S3 settings for inputs
X3:1-4 AITAC, AI1, AI2, AI3 and AI4.
* Short circuit proof If the gain is set to 10 by using S2 or S3 and the 500 burden resistor is activated, the input signal level is changed to
±2 mA.
For input AI4 there are the following configurations available:
- Input range ±20 mA
- Input range ±10 V
- Residual current detection by Isum not equal to zero via X3:11 and X3:12
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
92
➂ Jumper coding
+
S3 Encoder supply selection X95
-
S4 S3 S4 S5
Sense-
function
S5
220
15V B B
5 V* 24V A A
yes
15V B B
12 V yes
SDCS-POW-4
S3
S4
S5
24V A A
15 24
B A
B A
X37
15 V 15V B B no
24V A A
- X37 and X137 are con-
15V B B
nected in parallel
24 V no
24V A A X137 X14 - X14 is used to connect the
SDCS-PAR-1 in hard parallel
* default value converters
110
BL_POW4_001_+Tab_a.ai
Frequency 45 Hz - 65 Hz 45 Hz - 65 Hz X99:
Power consumption 120 VA 120 VA
Power loss 60 W 60 W F1
Recommended fusing 6 AT 6 AT
Mains buffering min. 30 ms min. 300 ms SS_POW4_001_in-out_a.ai
Powerfail 95 V 95 V
* Frequently switching ON and OFF increases the inrush current
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
93
General
The SDCS-PIN-4 / SDCS-PIN-4b is designed for DCS800 converter modules sizes D1 to D4+
(20 A - 1190 A).
It has three different functions:
1. The power supply for all small voltages of the whole drive and the connected options (D1 - D4+).
2. Control of armature bridge including high ohmic measurement of DC- and AC voltage and an
interface for the current transformer measuring the armature current (D1 - D4+).
3. Control of the OnBoard field exciter and field current measurement (D1 - D4).
The board is connected to ground at points ( ) inside the module.
The board is used for mains supply voltages from 230 V up to 525 V and 600 V.
The DCS800 provides an automatic adjustment for current and voltage measurement, burden resistor
settings and 2-Q or 4-Q operation by means of setting parameters in the firmware.
Layout SDCS-PIN-4
Field current measurement Armature firing Power supply
High voltage
T100
X37
6A 4x
25A 1x
X18
X16
X13
X15
X17
X12
SDCS-PIN-4 X95 +
X5 X22
High voltage
Field firing
X11 X4
X3 S1 1
1-2 = automatisch =
X31 2
Grundeinstellung
X1 X2 X7 3
2-3 = 230 V fest
X8 X9 K301
F100
F101
F102
K400
X10
F400 F300
W1 D1 X96 X99
C1 U1 V1
X24 X21 X25 X23 X20
Conducting point
Relay Input
output Aux.
(DO8) supply
Output field BL_PIN4_001_b.ai
current
Layout SDCS-PIN-4
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
94
Layout SDCS-PIN-4b
Field current measurement Armature firing Power supply
High voltage
X19
24V
T100
T300
X37
X18
X16
X13
X15
X17
X30
X12
X95
SDCS-PIN-4b
X5 X22
R301
Field firing
High voltage
X4
X11
X3 X31
X2 X7 L400
X1
R100
X9
F100
F101
F102
R300
K400
R310
X10 R400
C1 U1 W1 D1 X96 X99
V1
X24 X21 X23 X20
Conducting point
Relay Input
output Aux.
(DO8) supply
Output field
current BL_PIN4_004_PIN4B_b.ai
Layout SDCS-PIN-4b
Power supply
SDCS-PIN-4:
The SDCS-PIN-4 automatically adapts the auxiliary voltage of either 230 VAC or 115 VAC and switches
relay K301 in case of jumper setting S1 = 1-2.
In case of varying 230 VAC input voltage (e.g. diesel generator network) the operation must be fixed to
230 VAC by setting jumper S1 = 2-3.
SDCS-PIN-4b:
The SDCS-PIN-4b automatically adapts the auxiliary voltage of either 230 VAC or 115 VAC.
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
95
Technical data
Auxiliary incoming power X99
Auxiliary voltage 115 VAC 230 VAC 230 VDC (SDCS-PIN-4b only)
Tolerance -15 % / +10 % -15 % / +10 % -15 % / +10 %
Frequency 45 Hz - 65 Hz 45 Hz - 65 Hz -
Power consump- 120 VA 120 VA -
tion
Power loss 60 W 60 W 60 W
Inrush current 20 A / 20 ms 10 A / 20 ms 10 A / 20 ms
Recommended 6 AT 6 AT 6 AT
fusing
Mains buffering min. 30 ms min. 30 ms (SDCS-PIN-4) min. 150 ms
min. 300 ms (SDCS-PIN-4b)
Powerfail < 95 VAC < 185 VAC (SDCS-PIN-4) < 140 VDC
< 95 VAC (SDCS-PIN-4b)
275 V
Relay output X96 (DO8)
Isolated by relay (normally open contact)
Contact ratings: AC: 250 V~ / 3 A~ X96:
DC: 24 V- / 3 A- or
115 / 230 V- / 0.3 A-
275 V
6Ω
SS_PIN4_001_in-out_a.ai
R310
SDCS-PIN-4b:
X99 features a hardware filter NTC ϑ
U
F302
3.15 AT
SF_PINF_001_in-output_a.ai
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
96
Frequency 50 Hz / 60 Hz
Cables
Size D1 D2 D3 D4
DC output current 6A 15 A 20 A 25 A
max. cross sectional area 6 mm² 6 mm² 6 mm² 6 mm²
AWG 10 AWG 10 AWG 10 AWG 10
min. cross sectional area 1 mm² 2.5 mm² 4 mm² 6 mm²
AWG 16 AWG 13 AWG 11 AWG 10
Fuse type KTK - 25
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
X12: Armature circuit interface Interface board SDCS-PIN-4 / SDCS-PIN-4b PE U1 V1 W1
IDCM 11,12
X20:
HWCOD3 5 NC D1
HWCDD5 7 NC X30:
R1
AC/DC voltage measuring circuits
5M
UA - 15 X31:
X1: F100
UU 4 X21:
U1
X2: F101
UV 14 V1
X7: F102
VW 16 X23:
W1
16A
UA + 6
X18: 6
X13: K
Distribution 5 1.3
BZP1 1 1
G V13
4
K
3 1.5
BZP2 3 2 V15
G
2 X24:
K C1
1 1.1
BZP3 5 3 V11
G
X15: 14 Field circuit
K
1.6 interface
BZP4 7 4 13 G G
G V16
2.4 2.1
8 X11: K K
K 1 2 3 4
SS_PIN4_002_b.ai X10:1 2
Typical thyristor converter diagram with SDCS-PIN-4 / SDCS-PIN-4b for D1 - D4 converter.
F- F+ C1 (+) D1 (-)
97
Technical data
IDCM
X12:
11,12
Armature circuit interface Interface board SDCS-PIN-4 / SDCS-PIN-4b PE U1 V1 W1 98
Control board X3: 1 T51 P2
SDCS-CON-4 S1
3 N/1
IDC 9,10 X4: S2 P1
Technical data
Armature current measurement 1 T53
25A...275A 1500:1
3 S1 276A...680A 3000:1
N/1
681A...1200A 4500:1
X5: 1 T52 P2 S2 P1
STWA 3 0V
3 S1
GNDI 8,13 N/1
S2 P1
X22: 1 R57
ANTC 2 3
X20:
HWCOD3 5 NC D1
HWCDD5 7 NC X30:
R1
AC/DC voltage measuring circuits
5M
UA - 15 X31:
X1: F100
UU 4 X21:
U1
X2: F101
UV 14 V1
X7: F102
VW 16 X23:
W1
16A
UA + 6
X18: 6
X13: K
Distribution 5 1.3
BZP1 1 1
G V13
4
K
3 1.5
BZP2 3 2 V15
G
2 X24:
K C1
1 1.1
BZP3 5 3 V11
G
X15: 14
K
1.6
BZP4 7 4 13 G G
G V16
2.4 2.1
8 K K
K
1.2
BZP5 9 5 7 G V12
G V24 G V21
2 1.1 1.4
K K K
1.4
BZP6 11 6 1 G V14
SS_PIN4_002_b.ai
C1 (+) D1 (-)
99
X22 X122 X23 X24 X25 V14 V11 V16 V13 V12 V15
G G G G G G
U1
C C C C C C
V1
X413 S
X313 S
X12 S
X13 S
A B C D E F
X12
X12
W1
S2
S1
X113
X213
SDCS-PIN-51
C1
SDCS-PIN-46 / SDCS-PIN-48
B L _ P IN 5 1 _ 0 0 2 _ 2 Q _ a .d s f
X513
X113
X213
X413
X313
X13
X13
D1
X22 X122 X23 X24 X25 V24 V11 V26 V13 V22 V15
C C C C C C
G G G G G G
U1
C C C C C C
T4 T1 T6 T3 T2 F
V1
X413 S
X313 S
X12 S
X13 S
A B C D E F
X12
X12
X213
X113
W1
S2
S1
X113
X213
SDCS-PIN-51
C1
SDCS-PIN-46 / SDCS-PIN-48
B L _ P IN 5 1 _ 0 0 1 _ 4 Q _ a .d s f
X513
X113
X213
X413
X313
X13
X13
D1
270
X1 X2
A B C D E F
X113 X213
SDCS-PIN-4x
conductive supports
BL_PIN4_002_a.ai
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
100
90
3 4 Two PTC
S3 1 2 One PTC
R1 ....... R21
V1 W11 W9 W8 W7 W6
W10 W70 W71 W72 R22
X12
X12S X413S
W1
100
X113
X213
X413
X313
supports
X13
Æ 4.8 SDCS-PIN-51
10
10
7.5 190 297.5
305
B L _ P IN 5 1 _ 0 0 3 _ + h o ld e r _ a .d s f
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
101
R9 18
R10 18
R11 18
R12 18
R13 18
R14 18
R15 18
R16 18
R17 33
R18 68
R19 120
R20 270
R21 560
R22 47
Zero current
R23 47
detection
R24 47
R25 47
R26 100
1 Rated current see the name plate of the converter
Voltage coding
Size D5 D6 / D7 D7
Conv. nom. voltage [V] Y=4 (400 V) Y=6 (600 V) Y=7 (690 V) Y=4 (400 V) Y=6 (600 V) Y=7 (690 V) Y=8 (800 V) Y=10 Y=12
U1 [VAC] 1 Y=5 (500 V) Y=5 (500 V) (1000 V) (>1000 V)
Voltage measurement
500 V 600 V 690 V 500 V 600 V 690 V 800 V 1000 V
scaled by type code or
parameter (97.03)
Measuring board SDCS-PIN-51 see
chapter
W1, 6, 12, 17, 22
Galvanic
W2, 7, 13, 18, 23 isolation
W3, 8, 14, 19, 24
W4, 9, 15, 20, 25
W5, 11, 16, 21, 26
1 Rated voltage see the name plate of the converter TL_PIN51_001_a.ai
The converters can be used at lower mains voltage as specified without hardware modifications, if the mains voltage
connected to the converter is not lower than 45 % for voltages 500 V and not lower than 55 % for voltages 500 V.
Board used as a spare part: Indicates a removed resistor or zero ohm resistor
• Default: all jumpers Wxx, Rxx are in condition.
• Ensure the correct settings before the board is used.
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
102
PE U1 V1 W1
Technical data
T51 P2
X12: X12: Interface board SDCS-PIN-51 S1 4000/1
IDCM 11,12 A3,B3
S2 P1
X23: 1
R25 47R
R24 47R
R23 47R
R22 47R
R26 100R
IDC 9,10 A4,B4 X24: 1 T52 P2
S1 4000/1
2
S2 P1
R16
X25: 1
R18 68R
R17 33R
18R
R15 18R
R14 18R
R13 18R
R12 18R
R11 18R
R10 18R
R9 18R
R8 18R
R7 18R
R6 18R
R5 18R
R4 18R
R3 18R
R2 18R
R1 18R
R21 560R
R20 270R
R19 120R
GNDI 8,13 A5,B2
STWA 3 B7 101 W1 W2 W3 W4 W5
0V 100
UU 4 A7 U1
5M
201 W6 1M W7 1M W8 1M W9 1M W11 1M
200
UV 14 A2 V1
Fast-on
2.4 1.1 2.6 1.3 2.2 1.5 G G
Control board S1
SDCS-CON-4 2.4 K 1.4 K
GA CA GB CB GC CC GD CD GE CE GF CF
1.1 K 2.1 K
BZP2 3 B7 2 A5,B5 A5,B5 A10,B10 F11 F14
BZP3 5 B6 3 A9,B9 A9,B9 A6,B6
R11 V11 R14 V21
BZP4 7 B5 4 A7,B7 A7,B7 A8,B8
C11 C14
BZP5 9 B4 5 A8,B8 A8,B8 A7,B7
C24 C21
BZP6 11 B3 6 A6,B6 A6,B6 A9,B9 R24 R21
G G
A4,B4 A4,B4
*
GNDI 12,14 A2,A3 0V A4,B4 K K
2.6 1.6
General
The SDCS-PIN-4 / SDCS-PIN-4b measures the line voltage and DC voltage via high ohmic resistors.
Typical 5 MOhm for 500 V units of size D1 - D4+.
Line voltages below 100 V must be adapted using smaller resistance and thus the measurement
channel must be rescaled. The rescaling provides improved mains synchronization and a better DC
measurement resolution of small voltages.
The SDCS-SUB-4 provides the needed voltage scaling. The default selection is 1.17 MOhm for a
maximum mains voltage of 120 V. The maximum measurement voltage scale is 200 V. Adjust the
voltage scaling parameter according to the table below.
7 5
Mains voltage Chain RC, RDSetting Size
X 1 0 6 X 1 0 0 X 1 0 2 X 1 0 4 X 1 0 8
X 1 0 9 D (97.03)
W 30 - 120 V about 1.17 MOhm 117 V D1 - D4+
X 1 0 5
Example: chain RC = R109 + R110 + R111
X 1 0 3
V
U
4 0
X 1 0 1
C
X 1 0 7 G N D
B L _ S U B 4 _ 0 0 1 _ a .d s f
X17
SDCS-SUB-4
D
W
X112
V
X12
U
C
GND
X95
SDCS-PIN-4 +
X5 X22
High voltage
Field firing
X11 X4
X3 SDCS-PIN-4b S1 1
X31 2 1-2 = automatic
X2 X7 3 2-3 = 230 V fix
X1
X8 X9 K301
F100
F101
F102
K400
X10
F400 F300
W1 D1 X96 X99
C1 U1 V1
X24 X21 X25 X23 X20
conducting point
Relay Input
output Aux.
(DO 8) supply
Output field
current BL_PIN4_003_SUB4_b.ai
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
104
Technical data
X12: C W V U D :X1 Interface board SDCS-PIN-4 / SDCS-PIN-4b PE U1 V1 W1
IDCM 11,12
Armature circuit interface
3 S1
GNDI 8,13 N/1
S2 P1
X22: 1 R57
ANTC 2 3
HWCOD3 5 NC D1
X20:
HWCDD5 7 NC X30:
R1
AC/DC voltage measuring circuits
5M
UA - 15 X31:
X1: F100
UU 4
U1
F101 X21:
X2:
UV 14 V1
X7: F102 X25:
VW 16
W1
16A X23:
UA + 6
X18: 6
X13:
SDCS-SUB-4
X12
X112
K
5 1.3
BZP1 1 1 Distribution G V13
4
K
3 1.5
BZP2 3 2 G V15 X24:
2
K C1
1 1.1
BZP3 5 3 G V11
X15: 14
SS_PIN4_003_SUB4_b.ai X10:1 2
F- F+ C1 (+) D1 (-)
Typical armature circuit thyristor converter diagram with SDCS-PIN-4 / SDCS-PIN-4b and SDCS-SUB-4
X12: C W V U D :X1 Interface board SDCS-PIN-4 / SDCS-PIN-4b PE U1 V1 W1
IDCM 11,12
Armature circuit interface
X22: 1 R57
ANTC 2 3
HWCOD3 5 NC D1
X20:
HWCDD5 7 NC X30:
R1
AC/DC voltage measuring circuits
5M
UA - 15 X31:
X1: F100
UU 4
U1
F101 X21:
X2:
UV 14 V1
X7: F102 X25:
VW 16
W1
16A X23:
UA + 6
X18: 6
X13:
SDCS-SUB-4
X12
X112
K
5 1.3
BZP1 1 1 Distribution G V13
4
K
3 1.5
BZP2 3 2 G V15
SS_PIN4_003_SUB4_b.ai
C1 (+) D1 (-)
Typical armature circuit thyristor converter diagram with SDCS-PIN-4 / SDCS-PIN-4b and SDCS-SUB-4
Technical data
105
106
Galvanic isolation
Fuse F11 1500 V, 5 A
DC-DC transducer A92 (1) P42000D3-0111 (3ADN260008P0001)
Switch position RG 0 (675 V) 1 (810 V) 2 (945 V) 3 (1080 V) 5 (1350 V) 6 (1620 V)
DC-DC transducer A92 (2) P42001D3 (3ADV050096P0007)
Switch position RG - - - - A (1400 V) B (1600 V)
Fuse F90 1000 V, 10 A
Transformer T90 3ADT745047P0001
Secondary Terminals 2U1 2U2 2U3 2U4 2U5 2U6
2V1 2V2 2V3 2V4 2V5 2V6
2W1 2W2 2W3 2W4 2W5 2W6
2N 2N 2N 2N 2N 2N
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
F90 (1000 V, 10 A)
T90
removed wires
Rx
27,4 k resistors, to be soldered in parallel to the 5 M hybrid; also see table before S
2N PE U1 V1 W1
T51 P2
X12: X12: Interface board SDCS-PIN-51 S1 4000/1
IDCM 11,12 A3,B3
S2 P1
X23: 1
R25 47R
R24 47R
R23 47R
R22 47R
R26 100R
IDC 9,10 A4,B4 X24: 1 T52 P2
S1 4000/1
2
S2 P1 aux. supply
R16
X25: 1
230 V AC
2
R18 68R
R17 33R
18R
R15 18R
R14 18R
R13 18R
R12 18R
R11 18R
R10 18R
R9 18R
R8 18R
R7 18R
R6 18R
R5 18R
R4 18R
R3 18R
R2 18R
R1 18R
R21 560R
R20 270R
R19 120R
GNDI 8,13 A5,B2
STWA 3 B7 Rx W1 W2 W3 W4 W5
0V 100 101
U1
SDCS-POW-4
UU 4 A7
5M
Rx W6 1M W7 1M W8 1M W9 1M W11 1M X99:1
200 201
UV 14 A2 V1
X99:2
Rx W12 W13 W14 W15 W16
AC/DC voltage measurement 300 301
VW 16 A1 W1
ANTC 2 A8 3
Fast-on
2.4 1.1 2.6 1.3 2.2 1.5 G G
Control board S1
SDCS-CON-4 2.4 K 1.4 K
GA CA GB CB GC CC GD CD GE CE GF CF
*
GNDI 12,14 A2,A3 0V A4,B4 K K
2.6 1.6
SR2 4,2 A7,A8 REV A3,B3 A3,B3 A3,B3
HW-coding jumpers
GA CA GB CB GC CC GD CD GE CE GF CF C13 C16
= =
X213: X213: X113: C26 C23
0V R26 R23 20 17 A92
W70 W71 W72 A10,B10 A10,B10 A5,B5
G G
1k5 A5,B5 A5,B5 A10,B10 K K
2.2 1.2
ACOD1 13 B2
A9,B9 A9,B9 A6,B6
820R 1k5 3k3
W80 W81 W82 W83 A7,B7 A7,B7 A8,B8 G V22 G V12
1.5 K 2.5 K
A8,B8 A8,B8 A7,B7 F15 F12
ACOD2 15 B1
A6,B6 A6,B6 A9,B9
1k5 820R 1k5 3k3 8k2
R15 V15 R12 V25
X12: X12: A4,B4 A4,B4 A4,B4
HWCOD3 5 B6 NC C15 C12
A3,B3 A3,B3 A3,B3
C22 C25
HWCDD5 7 B5 R22 R25
A1,B1 A1,B1 A1,B1
W10
HWCIN4 1 B8 A2 A2 SDCS-PIN-4x A2
F11
(1500 V, 5 A)
Typical armature circuit thyristor converter diagram with SDCS-PIN-51 and SDCS-PIN-4x for a 4-Q D5,
Technical data
107
108
10 pF 1 nF Z 15 V
Voltage input Output U/I
SF_WAN_001_A92_a.ai
Power supply
20 - 253 VAC/DC
Data
Selectable voltage gains 675 810 945 1080 1350 1620 VDC
Switch position 0 1 2 3 5 6 -
The voltage gain and frequency response is especially designed for DCS800 converters.
Dimensions in mm
67,5 118,0
Terminal assignments:
15 Voltage input - 37 38 39 40
23 Voltage input + (3600 V)
27
37 Current output +
38 Voltage output +
39 Current output -
40 Voltage output -
15 23
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
109
Transformer T90
Principle diagram of the transformer T90
1U 2N 2U6 2U5 2U4 2U3 2U2 2U1
1N
S
(3ADT745047)
Data
Selectable transfer ratios Uprim: 500, 600, 690, 800,1000, 1200 VAC rms
Output voltage: 7.3 VAC rms
Insulation voltage: 1200 V
Isolation test voltage: 3500 V
Ambient temperature range: - 10 to + 70 °C
Weight: 2.1 kg
Dimensions in mm Note:
max 116 The terminals on the primary side of the
transformer are a special lug terminal design.
Handling hints:
First turn the screw counter-clockwise to the
end stop, then swing out the shrowding cover.
Put in the cable lug, swing in the shrowding
max 110
3 mm
5.2 x 7.7
130
80
118....120
130
Technical data
3ADW000194R0811 DCS800 Hardware Manual us h
110
See the dimensional drawings of the DCS800 below. The dimensions are in milllimeters.
Size D1 Size D2 Size D3
DCS800-S01-0020 DCS800-S01-0180 DCS800-S01-0315
DCS800-S01-0045 DCS800-S01-0230 DCS800-S01-0405
DCS800-S01-0065 DCS800-S01-0470
DCS800-S01-0090 DCS800-S02-0200
DCS800-S01-0125 DCS800-S02-0260 DCS800-S02-0350
DCS800-S02-0450
DCS800-S02-0025 DCS800-S02-0520
DCS800-S02-0050
DCS800-S02-0075 600 V Units
DCS800-S02-0100
DCS800-S01-0290
DCS800-S02-0140
DCS800-S02-0320
S S
S = 5 mm for size D1
T1 = 150 mm for size D1
S = 10 mm for size D2 - D3
Air flow
top clearance
270
Minimum
225 D
T1
Screw M6 C
10
Fan terminal
43.5
Mounting direction
8.7
48.5
310 for size D1/D2
Signal terminals
A
B
Power connection
T2 = 100 mm for size D1
64.5
10.5
32.5
45
C1 U1 V1 W1 D1
bottom clearance
9
20
Earthing H
86 Screw
Minimum
4 x 45 = 180 E
T2
F
Size A B C D E F G H G
D1 370 350 142 200 67 98 145 M6
D2 370 350 209 267 121,5 163,5 212 M10
D3 459 437,5 262,5 310 147,5 205 252 M10 MG_800_003_D1-D3_a.ai
Size D4
DCS800-S01-0610
DCS800-S01-0740
DCS800-S01-0900
DCS800-S02-0680
DCS800-S02-0820
DCS800-S02-1000
600 V Units
DCS800-S01-0590
DCS800-S02-0650
Weight appr. 38 kg
10 10
250
345
48.5 Fan terminal f. M6 298
8.7
Fan terminal
42
Air flow
644
625
577
U1 C1 V1 D1W1
9
45
Earthing
25
20
M12
107 147.5
150
40 80 195.5
f. M12 240(PIN-4)
52 80 80 287.5(CON-4)
Size D4+
DCS800-S01-1190
DCS800-S02-1190
Weight appr. 55 kg
150 150
Min. side Min. side
clearance clearance
150
Fan terminal clearance 330.8
34
8.7
42
f. M6
Air flow
740.5
623.5
577
9
U1 V1 W1
45
30
C1 D1 Earthing
Min. bottom clearance
30
M12
105.5
25
20
127
150
30 30 30
f. M12 180
37 80 80 291 (PIN-4)
309 (CON-4)
Power terminal: Busbar 60 x 5
Weight appr. 55 kg MG_800_009_D4+_a.ai
Size D5
DCS800-S0x-0900-xxb
DCS800-S0x-1200-xxb Busbars in mm:
DCS800-S0x-1500-xxb DC: 80 x 10
DCS800-S0x-2000-xxb AC: 60 x 5
top clearance
510
400
Minimum
450
250
127.5 125 125 For M10 85.5 17 26
34 26 17
22
U1 V1 W1
55
Ø 14
DCS800
Support Support
> 510
773
min. 480
820
944
775
Earthing M12
Cable tray
with = 40 mm
69
14
height = 39 mm
Fan terminal
Ø
bottom clearance
102
44.5
80
Earthing M12
Minimum
C1 D1
349.5 65.5 25 50 50 50
17.75
400
150
461
325.5
MG_800_005_D5_b.ai
A L-shape support as indicated will allow to place the converter temporarily close to the front end of the support (weight still
taken by a lifting device) and then push it back to the back plate of the cabinet. The upper and lower holes in the back plate
of the converter should be used to fix the converter in that position.
Size D6
458.2
DCS800-S0x-1900 425
375
DCS800-S0x-2050
250 409 Air outlet
DCS800-S0x-2500
10x20
DCS800-S0x-3000
20
C C
200
D D
225
M12
40
U 50
U
62
200
V
V *
1750
200
1725
W
W
1079.5
759.5
Pressure switch
10x20
63
15
72 100
M10 355
385 MG_800_006_D6_a.ai
445
Air entry
468.2
From the front, right, left and
back
136
Size D7 lefthand
(+P905) 230 530
350 For M10
25
DCS800-S0x-2050-xxL
DCS800-S0x-2600-xxL
DCS800-S0x-3300-xxL
DCS800-S0x-4000-xxL
Electronics are located in
the D7 module (+P905) 200
200
Pressure switch
759.5
Earthing M12
For M10
MG_800_007_D7_a.ai
Busbars in mm:
93
Size D7 lefthand
(+P906) 230 530
350 For M10
25
DCS800-S0x-4800-xxL
DCS800-S0x-5200-xxL
With external control unit
(+P906)
*
225
200
1725
200
Pressure switch
759.5
198
Screen clamp
Earthing M12
For flat cable X12
For flat cable X13
34.8
For M10
40
80
264
270
For M6
225
MG_800_007_D7_a.ai
Busbars in mm:
93
80
10.5
MG_800_002_external_b.ai
M6
Size D7
righthand
(+P905) For M10
25
DCS800-S0x-2050-xxR
DCS800-S0x-2600-xxR
DCS800-S0x-3300-xxR
DCS800-S0x-4000-xxR
Electronics are located
200
in the D7 module
(+P905)
*
Weight appr. 315 kg
225
200
1725
200
Pressure switch
759.5
Earthing M12
For M10
MG_800_007_D7_a.ai
Busbars in mm:
AC and DC: 100 x 10
Size D7
righthand
(+P906) For M10
25
DCS800-S0x-4800-xxR
DCS800-S0x-5200-xxR
With external control unit
(+P906)
200
Weight appr. 315 kg
225
200
1725
200
Pressure switch
759.5
Earthing M12
198
40
80
264
270
For M6
225
MG_800_007_D7_a.ai
Busbars in mm:
AC and DC: 100 x 10
370.5
350
10.5
MG_800_002_external_b.ai
M6
D4+ DCS800-S0x-1190-04/05 UR 900 A / 690 V 2 V11 V24 V13 V26 V15 V22
Branch
D7 DCS800-S0x-3300-04/05 UR 2500 A / 660 V 7 V14 V21 V16 V23 V12 V25
600 V / 690 V
D5 DCS800-S0x-0900-06/07 UR 630 A / 1250 V 6
D5 DCS800-S0x-1500-06/07 UR 1100 A / 1250 V 6
D5 DCS800-S01-2000-06/07 UR 1400 A / 1100 V 6
D6 DCS800-S0x-2050-06/07 UR 700 A / 1250 V ➀ 6
D6 DCS800-S0x-2500-06/07 UR 1000 A / 1250 V ➀ 6
D6 DCS800-S0x-3000-06/07 UR 1100 A / 1250 V ➀ 6
D7 DCS800-S0x-3300-06/07 UR 2500 A / 1000 V 8
D7 DCS800-S0x-4000-06/07 UR 3000 A / 1000 V 8
D7 DCS800-S0x-4800-06/07 UR 3000 A / 1000 V 8
800 V
D6 DCS800-S0x-1900-08 UR 630 A / 1250 V ➀ 6
D6 DCS800-S0x-2500-08 UR 1000 A / 1250 V ➀ 6
D6 DCS800-S0x-3000-08 UR 1100 A / 1250 V ➀ 6
D7 DCS800-S0x-3300-08 UR 2500 A / 1000 V 8
D7 DCS800-S0x-4000-08 UR 3000 A / 1000 V 8
D7 DCS800-S0x-4800-08 UR 3000 A / 1000 V 8
1000 V
D7 DCS800-S0x-2050-10 UR 1800 A / 1250 V 9
D7 DCS800-S0x-2600-10 UR 1800 A / 1250 V 9
D7 DCS800-S0x-3300-10 UR 2500 A / 1250 V 9
D7 DCS800-S0x-4000-10 UR 2500 A / 1250 V 9
1200 V
D7 Data on request - -
Size 2
Size 5, 6 Size 7 - 9
Indicator 15
max 105
4xM10
max d
min 10 deep
11
max 105
c
Ø 56
33
Ø
11
67.5
82.5
14 17
108 max d Ø 11
139
b a b
8 25 25
A
100
Size A [mm]
6
7 62
8 90
9 105
Size a [mm] b [mm] c [mm] d [mm]
5 50 29 30 76
Note:
6 80 14 30 76
The given dimensions may be exceeded in some
cases. Please take them only for information.
Accessories
Measurement channel
IFact 5A
35 A X100: 5 A (+)
Setting of switchable burden X100: 35 A (+)
resistors by rated field current
X101: U1
X101: V1 Field
X101: W1
X100: D1 (-)
SF_FEX4_001_measu-ch_a.ai
2
X1
X110
1
P2 P1
35A
T110
1
T113
5A
Field X100
2
X2
T112
D1
S800
T111
115
X5
D800 U730
S801
U731
R106
S2
1
U1
V110
X71
S1100
V1
X101
2
Mains
R107
W1
X6 X4
2 3
X3
R108 X7
1
BL_FEX4_001_a.ai
Electrical data
Power part
AC input voltage 110 V -15% - 500 V +10%; single or 3-phase
AC input current < DC output current
Frequency Same as DCS converter
AC isolation voltage 600 V
Line reactor External
Line fuses KTK25 for FEX-425-Int; external for DCF803-0016 and DCF803-0035
DC output current * 0.3 A - 16 A = DCF803-0016
0.3 A - 25 A = FEX-425-Int
0.3 A - 35 A = DCF803-0035
Powerloss < 130 W (at rated current)
Auxiliary supply
DC input voltage 24 VDC
DC input current < 200 mA supplied via X51 of SDCS-DSL-4
Buffering 10 ms
Control unit
The control includes the following main blocks:
• Micro controller H8 for current control, synchronization and fault handling.
• 2 channel measurement of actual field current in the DC circuit.
• High ohmic measurement of AC voltage. Residual resistance to ground 1.6 M
• H8 controller for drive-to-drive communication based on CAN standard.
• Driver circuit to fire the half control bridge.
• The firmware is stored in a flash memory and contains:
The PI current controller for the field circuit.
The fault and reset logic.
The synchronization and PLL function.
The setting of the current measurement channel.
All parameters are set from the armature converter via drive-to-drive communication. The field current
reference, actual field current, current control and status bits are cyclic sent via drive-to-drive
communication.
The field exciter is equipped with an autoscaling function of the burden resistors based on the nominal
field current of the motor.
Power part
The power part is a 3-phase half controlled bridge with free-wheeling diode.
The external field exciter DCF803-0016 and DCF803-0035 are 3-phase half controlled bridges
including snubbers based on the SDCS-FEX-4. Line fuses, line reactors and transformers are installed
outside the housing.
The FEX-425-Int (internal field exciter) can be installed in D4+ and D5 converters. The unit is based on
a SCDS-FEX-4. For a D4+ the supply must be connected via line reactors and fuses located outside of
the module.
For a D5 the supply must be connected via line reactors outside of the module. The fuses are installed
in the module.
For single-phase operation connect terminals U and W. For single-phase operation an autotransformer
for voltage adaptation is recommended.
Please see comparison of output voltage ripple between single-phase and 3-phase operation.
0.5
0.25
3-phase, half-controlled
0
0.1 0.4 0.7 1
UDC Field 3-phase, full-controlled
DZ_LIN_014_Spg-well_a.ai
DCSLink communication
The field converter is controlled from armature converter via DCSLink based on CAN hardware.
SDCS-FEX-4
Incoming power Remarks
X1:1 24 V / 200 mA 24 V 200 mA 24 V grounded via X51 of SDCS-DSL-4
2
DSL communication Remarks
X3:1 Bus termination
S1100:1 CANL
2 S1100: 1 = ON 120 Ohm
CANH 1 = OFF No termination
3
Ground termination
GNDB
S1100: 2 = ON 200 kOhm R-C ground termination
S1100:3 S1100:2
3 = ON 0 Ohm ground termination
2, 3 = OFF No termination
Termination 200 kOhm
SF_FEX4_002_DCSLink_a.dsf
Node address is set by: S800 digit 0 (node address 00 is not possible!)
S800 S801 digit 10
Same node address must be selected in the corresponding armature converter.
Example: Node address = 13 ==> S800 = 3 and S801 = 1
S801
Switch_0-9.dsf
RS232-Port
The RS232 interface is used for download the 'Field exciter firmware package'.
More information see RS232 interface.
The firmware download is activated by setting S2:1-2 before the auxiliary voltage is switched ON. Field
exciter mode is S2:3-4 (default).
Diagnostics
All messages are sent to the armature converter and displayed in Signals (9.17) to (9.20). If
communication is broken or node numbers are mixed up the simple fault display on the SDCS-FEX-4
can be used. Therefore the unit is equipped with two small LEDs.
V730 = Green
V731 = Yellow
Following messages are displayed:
Both OFF No 24 V supply
Green and yellow continuous No firmware
Green blinking 16 A / 25 A / 35 A output active, waiting for DCSLink
communication
Green continuous 16 A / 25 A / 35 A output active, DCSLink communication OK
Yellow blinking 5 A output active (X100:2), waiting for DCSLink communication
Yellow continuous 5 A output active (X100:2), DCSLink communication OK
Green and yellow toggling:
X times yellow Y times green Warning or Fault
X=1 Y=1 Warning Phase missing, see parameter (45.22) / (45.23)
Y=2 Warning Temperature heatsink
Y=6 Warning Parameters added
Y=7 Warning Parameter up- or download failed
Y=8 Warning Compatibility
Y=9 Warning Parameters restored
X=2 Y=1 Fault DCSLink communication
Y=2 Fault Supply voltage synchronization
Y=3 Fault Overcurrent
Y=4 Fault Fast voltage rise, see parameter (45.01) / (45.15)
Y=5 Fault AC supply voltage < 30 VAC
Y=6 Fault AC supply voltage > 650 VAC
Y=9 Fault Temperature heatsink
Y = 10 Fault Parameter flash read
Y = 11 Fault Compatibility
Y = 12 Fault Auxiliary voltage
Y = 14 Fault General hardware (no reset possible)
Y = 15 Fault General firmware (no reset possible)
F3.1 K3 L3 DCF803-0016 / 35
U1 D1 (-)
SDCS-FEX-4
V1 5 A (+)
W1 16 / 35 A (+)
SF_DCF_003_FEX4_a.ai
F3.2 T3
F3.1 K3 L3 DCF803-0016 / 35
U1 D1 (-)
Supply voltage
max. 600 VAC SDCS-FEX-4
Max. 500 VAC V1 5 A (+)
Single phase
W1 16 / 35 A (+)
SF_DCF_003_FEX4_a.ai
Dimensions
DCF803-0016
3 67
Dimensions in mm 173 36.5
X2
X1 X3
21 S1100 1 3 2 1
S801
S800
For mounting on mounting plate
provide hole with diameter of
min 5 mm for thermal sensor
90
300
320
300
146
16A 5A D1 U1 V1 W1
DCF803-0035
Dimensions in mm
Weight appr. 6 kg
X2
X1 X3
21 321
35A 5A D1 U1 V1 W1
F303 W1 35A(+)
V14
R14 V21
V16
R16 V23
V12
R12 V25
D1 (-)
R21
R23
R25
G
G
K
K
1.4
2.1
1.6
2.3
1.2
2.5
C14
C21
C16
C23
C12
C25
4000/1
PE U1 V1 W1
F14
F16
F12
L1
T52 P2
S2 P1
S1
4000/1
P1
T51 P2
S1
S2
F11
F13
F15
C11
C24
C13
C26
C15
C22
V24
V11
V26
V13
V22
V15
R57
C1 (+)
G
G
K
K
R11
R24
R13
R26
R15
R22
2.4
1.1
2.6
1.3
2.2
1.5
SS_FEX4_001_config_b.ai
R14 V21
V16
R16 V23
V12
R12 V25
D1 (-)
R21
R23
R25
G
G
K
K
1.4
2.1
1.6
2.3
1.2
2.5
C14
C21
C16
C23
C12
C25
4000/1
PE U1 V1 W1
F14
F16
F12
L1
T52 P2
S2 P1
S1
4000/1
P1
T51 P2
S1
S2
F11
F13
F15
C11
C24
C13
C26
C15
C22
V24
V11
V26
V13
V22
V15
R57
C1 (+)
G
G
K
K
R11
R24
R13
R26
R15
R22
2.4
1.1
2.6
1.3
2.2
1.5
SS_FEX4_001_config_b.ai
F3.1 FEX-425-Int
K3 L3 U F301 U1 D1(-) Plus code +S164
F302
SDCS-FEX-4
V V1 5A(+)
W F303 W1 35A(+)
V14
R14 V21
V16
R16 V23
V12
R12 V25
D1 (-)
R21
R23
R25
G
G
K
K
1.4
2.1
1.6
2.3
1.2
2.5
C14
C21
C16
C23
C12
C25
4000/1
PE U1 V1 W1
F14
F16
F12
L1
T52 P2
S2 P1
S1
4000/1
P1
T51 P2
S1
S2
F11
F13
F15
C11
C24
C13
C26
C15
C22
V24
V11
V26
V13
V22
V15
R57
C1 (+)
G
G
K
K
R11
R24
R13
R26
R15
R22
2.4
1.1
2.6
1.3
2.2
1.5
SS_FEX4_001_config_b.ai
R14 V21
V16
R16 V23
V12
R12 V25
D1 (-)
R21
R23
R25
G
G
K
K
1.4
2.1
1.6
2.3
1.2
2.5
C14
C21
C16
C23
C12
C25
4000/1
PE U1 V1 W1
F14
F16
F12
L1
T52 P2
S2 P1
S1
4000/1
P1
T51 P2
S1
S2
F11
F13
F15
C11
C24
C13
C26
C15
C22
V24
V11
V26
V13
V22
V15
R57
C1 (+)
G
G
K
K
R11
R24
R13
R26
R15
R22
2.4
1.1
2.6
1.3
2.2
1.5
SS_FEX4_001_config_b.ai
Further information about line reactors see sections Line reactor (L3) (ND30) and Line reactors type
ND401 - 413 (ND402) in this chapter.
- -
T1 SS_DCF_001_part_b.ai T1
319
1 X10 X111 X112 X113 X114 S1100:5 Baudrate Default = OFF (500 kBd)
X2
X5 S1100:6 Baudrate Default = ON (500 kBd)
1 1
S1100 S1100:7 Bridge reversal ON = extended bridge reversal (+20 ms)
X8 1 T1500
S1100:8 Opermode OFF = reserved; ON = DCS800
S801 SDCS-FEX-8x Line
S800 S2
potential ! S801 node x10 DCSLink node address digit 10
4 3
V731 R902
V730
2 1
R903
3 S800 node 1-9 DCSLink node address digit 0
X71
1 Conductive supports V730 Green Fault and warning display, see chapter Diagnosis
1
X6 1 2
5 X3 V731 Yellow Fault and warning display, see chapter Diagnosis
BL_FEX8_001_+Tab_a.ai
Electrical data
Power part
AC input voltage 110 V -15% – 500 V +10%; single-phase
AC input current < DC output current
Frequency Same as DCS module
AC isolation voltage 690 V
Line reactor (L1) 160 H; 45 – 65 Hz (inside)
DC output current ➀ 50 A 0.3 A – 50 A
DC output current ➀ 60 A 0.3 A – 60 A; forced cooling (2 x fan)
Power loss at I F rated
<180 W (at rated current)
Load condition Always L/R > 100 ms (saturation)
X2 Serial communication
X2: 1 Reserved
X2: 2 Reserved
X2: 3 GNDB, ground of commutation interface
X2: 4 CANL
X2: 5 CANH
X3 Auxiliary voltage
AC input voltage 110 V -15% – 230 V +10%; single-phase
Frequency 45 – 65 Hz
AC input power 15 W; 30 VA
Inrush current < 5 A / 20 ms
Mains buffering Min. 30 ms
X4 Fan supply Only 60 A units
AC input voltage 230 VAC; single-phase
Frequency 45 – 65 Hz
AC input current 0.15 A
➀ If Field weakening is needed, the minimum field current of the motor at top speed must be higher than 0.3 A.
Control unit
The control unit includes the following main blocks:
• Micro controller H8 for control and firing.
• Actual DC current measurement using an AC current transformer.
• High ohmic measurement of AC and DC voltage.
Residual resistance to ground =3.5 M(DCF803)
=1.9 M(DCF804)
• RS485 interface and DCSLink interface to the converter's controller board SDCS-CON-4.
• The firmware of the field exciter is stored in a flash memory and contains:
- The PI current controller for the field circuit.
- The fault and reset logic.
- The synchronization and PLL function.
- The bridge reversal function (only DCF804-0050 / 0060).
All control parameters are set from armature converter via drive-to-drive communication. The field
current reference, actual field current, current control and status bit are cyclic sent via drive-to-drive
communication.
The field exciter is equipped with an autoscaling function of the burden resistors based on the nominal
field current of the motor.
Power part
The DCF803-0050 / 0060 is a half-controlled single-phase bridge. A half controlled bridge does not
need a free wheeling circuit.
The DCF804-0050 / 0060 is a full-controlled single-phase bridge. During normal operation it is fired in
half controlled mode to reduce the current ripple.
Full controlled bridges require separate freewheeling circuits. The firing control enables the
freewheeling of a thyristor if the DC voltage increases. See also parameters (45.01) / (45.15) in the
armature converter.
A MOV (Metal Oxide Varistor) protects the AC input against voltage spikes from the mains.
Another MOV protects the DC output against voltage surges which can be caused by the field winding
of a DC machine.
The power section is equipped with a line reactor (L1). Thus an external line reactor is not needed.
Single-phase field exciters are typically supplied by autotransformers if the rated field voltage is less
than 60 % of the AC supply voltage.
The AC input current can be estimated like this:
IAC = 1.1* IDC * UDC field / UAC supply.
R902
SDCS-FEX-81 DCF804-0050 / 0060
SDCS-FEX-82 DCF803-0050 / 0060
R903
50 A
60 A
DCSLink communication
The field converter is controlled from armature converter via DCSLink based on CAN hardware.
SDCS-FEX-81 / 82
DSL communication Remarks
X2:3 Bus termination
S1100:1 CANL
4 S1100: 1 = ON 120 Ohm
CANH
5 1 = OFF no termination
GNDB Ground termination
S1100:3 S1100:2 S1100: 2 = ON 200 kOhm R-C ground termination
3 = ON 0 Ohm ground termination
Termination 200 kOhm
2, 3 = OFF no termination
SF_DCF_002_DCSLink_b.ai
Node address is set by: S800 digit 0 (node address 00 is not possible!)
S801 digit 10
S800
Same node address must be selected in the corresponding armature converter.
Example: Node address = 13 ==> S800 = 3 and S801 = 1
S801
Switch_0-9.dsf
RS232-Port
The RS232 interface is used for download the 'Field exciter firmware package'.
More information see RS232 interface.
The firmware download is activated by setting S2:1-2 before the auxiliary voltage is switched ON.
Field exciter mode is S2:3-4 (default).
Diagnostics
All messages are sent to the armature converter and displayed in Signals (9.17) to (9.20). If
communication is broken or node numbers are mixed up the simple fault display on the
SDCS-FEX-81 / 82 can be used. Therefore the unit is equipped with two small LEDs.
V730 = Green
V731 = Yellow
Following messages are displayed:
Both OFF No 24 V supply
Green and yellow continuous No firmware
Green blinking 50 A / 60 A output active, waiting for DCSLink communication
Green continuous 50 A / 60 A output active, DCSLink communication OK
Green and yellow toggling:
X times yellow Y times green Warning or Fault
X=1 Y=1 Warning Phase missing, see parameter (45.22) / (45.23)
Y=2 Warning Temperature heatsink
Y=6 Warning Parameters added
Y=7 Warning Parameter up- or download failed
Y=8 Warning Compatibility
Y=9 Warning Parameters restored
X=2 Y=1 Fault DCSLink communication
Y=2 Fault Supply voltage synchronization
Y=3 Fault Overcurrent
Y=4 Fault Fast voltage rise, see parameter (45.01) / (45.15)
Y=5 Fault AC supply voltage < 30 VAC
Y=6 Fault AC supply voltage > 650 VAC
Y=9 Fault Temperature heatsink
Y = 10 Fault Parameter flash read
Y = 11 Fault Compatibility
Y = 12 Fault Auxiliary voltage
Y = 14 Fault General hardware (no reset possible)
Y = 15 Fault General firmware (no reset possible)
Autotransformer (T3),
Fuses (F3.x).
The firmware on the SDCS-CON-4 provides two field exciter functions, one for motor 1 and one for
motor 2. The communication works using a screened two-wire cable.
For distances see chapter DCSLink wiring.
DCSLink
SDCS-
CON-4
M M
SB_DCF_002_b.ai
Connection example
The DCSLink communication is activated by S1100:8 = ON
The bus setting is made using S1100. The node numbers are set using S800 and S801.
Procedure to change the node number:
• Switch off the electronics supply voltage
• Set the appropriate switch according to chapter DCSLink communication
• Switch on the electronics supply voltage
U1 DCF803- U1 DCF803-
Mains V1 0050 / 0060 Mains V1 0050 / 0060
SDCS- or or
C1 C1
CON-4 DCF804- DCF804-
Field D1
0050 / 0060 Field D1
0050 / 0060
Armature PE PE
SDCS-DSL-4
X2:4 X2:4
CANL X52:2 max. CANL max. CANL
CANH 3 length
X2:5 CANH X2:5 CANH
length
50 m 50 m
CANL X53:2 Field Field
CANH 3 exciter exciter
motor 1 motor 2
X3:1 X3:1
Node Node
Power supply X3:2 see S800, S801 Power supply X3:2 see S800, S801
SB_DCF_001_b.ai
Note:
As standard maximum 2 field exciters can be controlled by one DCS800.
DCF803-0050 / DCF804-0050
PE U1 V1
X3: 2 1 1 4
S10
J 2 3
AC1 AC2
X71:
SDCS-FEX-81 *
SDCS-FEX-82 Parts not mounted at DCF803-0050
* V12 / V14 are diodes at DCF803-0050
P1
P2
P3
P4
FORWARD
REVERSE
X2:
1
2
3
4 CANL
5 CANH
GNDB
S1100:3
S1100:2
SF_DCF_001_50A-60A_b.ai
D1(-) C1(+)
DCF803-0060 / DCF804-0060
X4: 1 2
2 x 115 V PE U1 V1
X3: 2 1 series 1 4
connection
S10
M M
~ ~
J 2 3
AC1 AC2
X71:
SDCS-FEX-81 *
SDCS-FEX-82 Parts not mounted at DCF803-0060
* V12 / V14 are diodes at DCF803-0060
Parts mounted at DCF803-0060 / DCF804-0060
P1
P2
P3
P4
FORWARD
REVERSE
X2:
1
2
3
4 CANL
5 CANH
GNDB
S1100:3
S1100:2
SF_DCF_001_50A-60A_b.ai
D1(-) C1(+)
Dimensions
DCF803-0050
DCF804-0050
Top clearance
Minimum
all for M6
all for M6
A U1
U1
V1
V1
C1
all for M6
C1 (+)
Mounting direction
DCSLink
X3
X800
S800 (aux. voltages)
10
173
V731
V730
1 Aux. power supply terminals X3
5
9
X2
5 Sub-D
1
Bottom clearance
Minimum
all for M6
M6 all for M6
A M6 MG_DCF_001_50A-60A_b.ai
DCF803-0060
Minimum
DCF804-0060
all for M6
Dimensions in mm all for M6
Weight appr. 12 kg X4: U1
U1 Fan
V1
V1
X3: Aux. power supply terminals
3x41=123
C1
all for M6
C1 (+)
Mounting direction
D1
D1 (-)
1
DCSLink
X3
V731
V730
1 Aux. power supply terminals X3
5
9
X2
5 Sub-D
6
1
Bottom clearance
Minimum
all for M6
M6 all for M6
M6 MG_DCF_001_50A-60A_b.ai
DCF505 DCF506
C1(+) X11 C1(+) X11
DCS800-S01 DCS800-S0x
M
D1(-) X12 D1(-) X12
X6:2 9
SF_800_001_DCF_a.ai X4:1 2 SF_800_001_DCF_a.ai
[mm²] [Nm]
2-Q, 500 V
DCS800-S01-0020-04/05
DCS800-S01-0045-04/05 D1 DCF506-0140-51 1x4 1 x M8 13
DCS800-S01-0065-04/05
DCS800-S01-0090-04/05
DCS800-S01-0180-04/05 D2
DCS800-S01-0315-04/05 D3 DCF506-0520-51 1 x 10 1 x M8 13
DCS800-S01-0405-04/05
DCS800-S01-0610-04/05 ➁ D4
4-Q, 500V
DCS800-S02-0025-04/05
DCS800-S02-0050-04/05 D1 DCF506-0140-51 1x4 1 x M8 13
DCS800-S02-0075-04/05
DCS800-S02-0100-04/05
DCS800-S02-0200-04/05 D2
DCS800-S02-0350-04/05 D3 DCF506-0520-51 1 x 10 1 x M8 13
DCS800-S02-0450-04/05
DCS800-S02-0680-04/05 ➁ D4
Inductive load supply for Overvoltage Protection
other applications
4-Q, 500V
DCS800-S02-1200-04/05 DCF506-1200-51 1 x 25 1 x M8 13
DCS800-S02-1500-04/05
4-Q, 690V
DCS800-S02-0900-07 DCF506-1500-71 1 x 25 1 x M8 13
DCS800-S02-1500-07
➀ Only these converter types are allowed to be used as large field exciters. A 10 % current de-rating
is strongly recommended.
➁ Limited to 520 A due to overvoltage protection.
Diagram
A1
X11 X12
F+
F-
R2 R1
1 2 1 2
X2:1 red
X2:2 grey
X1:3
V1
G2 K2
A
SDCS-FEP-1 (500 V)
SDCS-FEP-2 (690 V) R3
K AK 1 2
K1 G1
X1:1 red
X1:2 grey
X2:3
X3:1
R4
X3:2 1 2
X4:1 X4:2
SS_DCF_002_FEP_a.ai
Output X4:1-2
X1 X3
Potential isolated by relay (NO contact)
Contacts no protected
SDCS-FEP-1/FEP-2
line potential !
X2 X4
BL_FEP_001_a.ai
Dimensions
16 75 33.5 342
Overvoltage protection
9
DCF506-0140-51
DCF506-0520-51
Dimensions in mm 1
X4
Weight appr. 8 kg X3
X1 X2
1
350
X11 (F+)
M8
X12 (F-)
2 1
MG_DCF_004_506_140-520_a.ai
11
Weight appr. 20 kg
2 1
X4 X2
SDCS-FEP-1 (500 V)
SDCS-FEP-2 (690 V)
482
X3 X1
X11
8.5
35
X12
MG_DCF_005_506_1200-1500_a.ai
32 40 M8 f. M6
Dimensions of fuses
Size a b c d e
Size 0 - 3 [mm] [mm] [mm] [mm] [mm]
Indicator 0 78,5 50 35 21 15
1 135 69 45 45 20
2 150 69 55 55 26
3 150 68 76 76 33
a c
b
10
2
6
Fuse1_a.dsf
d
e
Size 4 Indicator
30
11
76
11
14 17
108 76
139
29 50 29
6
fuse2_a.dsf
A
27
OFAX 2 S3
60
H A
205 85
180
9
Ø
40
170H3006_a.dsf
W D M10
Dimensions
Order # Fig. A B C D E F G H J
FWP-5B-30B 1 2.87 0.563 1.855 2.477 2.477 0.25 0.405 0.063 0.25
FWP-35B-60B 1 4.375 0.813 2.75 3.708 3.312 0.344 0.725 0.125 0.542
FWP-70B-100B 1 4.406 0.947 2.594 3.625 3.563 0.344 0.75 0.125 0.375
FWP-125A-200A 1 5.09 1.5 2.84 4.19 3.5 0.41 1 0.25 0.75
FWP-225A-400A 1 5.09 2 2.84 4.28 3.53 0.41 1.5 0.25 0.78
FWP-450A-600A 1 7.09 2.5 2.84 5.72 4.19 0.53 2 0.38 1.3
FWP-700A-800A 1 6.63 2 2.844 5.562 5.062 0.625 1.5 0.25 0.875
Dimensions in inches.
Fig. 1: 5-800 Amp Range Fig. 2: 900-1000 Amp Range Fig. 3: 1200 Amp Range
3
A X
B Y X, Y, Z
C Z A, B, C
A B C
60 0
A, B, C 0 100
X Y Z X, Y, Z
c
a
a1 b
d
Line reactor a1 a b c d e f g
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm2]
e
H ± 2
I (6 x )
C ± 1
1 5
conduction to the mounting plate
± 4
F ± 0 .3
G
L C 1
E ± 2
E ± 2
A ± 2
K
3 A S T 4 7 8 2 2 3 D 5
3 A F E 1 0 0 1 4 6 0 3
0 .0 1 8 8 m H
4 9 0 A
I m a x 7 3 4 A
A
7
A -A
M E _ D R O _ 0 0 2 _ N D 7 -1 2 _ a .d s f
1 5
F ± 0 .3
B ± 1
140 ±2
18x13(3x)
100 100
45 45
30
154 ±4
224 ±0.3
A-A
10
342 ±2
123 ±2
ø1 3
4 0
50
1 5
290 ±1 150 ±2 40
A A
M E _ D R O _ 0 0 3 _ N D 1 3 -1 4 _ a .d s f
20
18
176 ±5
40 ø13
3 1 6 ± 0 .3
A-A
440 ±2
13
147
15 ø1 3
3 0
6 0
80
1 5
30 140 147 48
A A
(6x) 10x18
181 ±2
390±1
M E _ D R O _ 0 0 4 _ N D 1 5 -1 6 _ a .d s f
8 0
2 0 4 0 2 0
2 0
4 0
ø 1 4
t i n v - p e l r a z t i en d n t
M E _ D R O _ 0 0 5 _ N D 1 7 _ a .d s f
øH
tin-coated
X Y Z
A
A B C
øG ø G+5
F±1 E ±2
B C
ME_DRO_006_ND401-402_a.ai
øH
tin-coated
X Y Z
øK AL
A
A B C
ø G+5
50 10 E ±2
F ±2 C
D
ME_DRO_007_ND403-408_a.ai
øH
tin-coated
A B C
X Y Z
øK AL
A
A B C
X Y Z
øG+6
12 E ±2
F ±2 C
D
ME_DRO_008_ND409-413_a.ai
Unit Type Line Reactor for Config. A Line Reactor for Config. B
1.5% Imp. 5% Imp.
2Q Converters 4Q Converters
500 Vdc
DCS800-S01-0020-05 DCS800-S02-0025-05 KLR21BTB KLR21CTB
DCS800-S01-0045-05 DCS800-S02-0050-05 KLR45BTB KLR45CTB
DCS800-S01-0065-05 DCS800-S02-0075-05 KLR80BTB KLR80CTB
DCS800-S01-0090-05 DCS800-S02-0100-05 KLR110BCB KLR110CCB
DCS800-S01-0125-05 DCS800-S02-0140-05 KLR130BCB KLR130CCB
DCS800-S01-0180-05 DCS800-S02-0200-05 KLR200BCB KLR200CCB
DCS800-S01-0230-05 -- KLR200BCB KLR200CCB
-- DCS800-S02-0260-05 KLR250BCB KLR250CCB
DCS800-S01-0315-05 DCS800-S02-0350-05 KLR300BCB KLR300CCB
DCS800-S01-0405-05 -- KLR360BCB KLR360CCB
DCS800-S01-0470-05 DCS800-S02-0450-05 KLR420BCB KLR420CCB
-- DCS800-S02-0520-05 KLR480BCB KLR480CCB
DCS800-S01-0610-05 DCS800-S02-0680-05 KLR600BCB KLR600CCB
DCS800-S01-0740-05 DCS800-S02-0820-05 KLR750BCB KLR750CCB
DCS800-S01-0900-05 -- KLR750BCB KLR750CCB
-- DCS800-S02-1000-05 KLR850BCB KLR850CCB
DCS800-S01-1200-05 DCS800-S02-1200-05 KLR1100BCB KLR1100CCB
DCS800-S01-1500-05 DCS800-S02-1500-05 KLR1250BCB KLR1250CCB
600 Vdc
DCS800-S01-0290-06 -- KLR250BCB KLR250ECB
-- DCS800-S02-0320-06 KLR300BCB KLR300ECB
DCS800-S01-0590-06 DCS800-S02-0650-06 KLR600BCB KLR600ECB
DCS800-S01-0900-06 DCS800-S02-0900-06 KLR750BCB KLR750ECB
DCS800-S01-1500-06 DCS800-S02-1500-06 KLR1250BCB KLR1250ECB
Note:
Configuration A: For most installations.
Configuration B: For installations that require compliance with EN 61-800-3 or when AC and DC drives
are on the same line.
See Chapter “Planning the Electrical Installation” for additional information.
Recommended AC Line Reactors are available directly from TCI.
For information, see their web page www.transcoil.com.
Autotransformer (T3)
Autotransformer Field current Secondary current Weight Power losses Fuse F3.2
(T3) [A] [A] [kg] [W] [A]
U1 = 500 V 10 %, 50 / 60 Hz
T3, 01 IF ≤ 6 ≤7 15 65 10
T3, 02 IF ≤ 12 ≤ 13 20 100 16
T3, 03 IF ≤ 16 ≤ 17 20 120 25
T3, 04 IF ≤ 30 ≤ 33 36 180 50
T3, 05 IF ≤ 50 ≤ 57 60 250 63
U1 = 690 V 10 %, 50 / 60 Hz
T3, 11 IF ≤ 6 ≤7① 15 80 10
T3, 12 IF ≤ 12 ≤ 13 ① 20 125 16
T3, 13 IF ≤ 16 ≤ 17 ① 30 150 20
T3, 14 IF ≤ 30 ≤ 33 ① 60 230 50
T3, 15 IF ≤ 50 ≤ 57 60 320 63
➀ The 690 V autotransformer input cannot be used for the field converters DCF803-0016, FEX-425-Int and
DCF803-0035 (maximum isolation voltage is 600 V)
F3.2 F3.2
T3 T3
E
S F _ D R O _ 0 0 2 _ T 3 _ a .d s f
C D F
B
ME_TRA_001_T3_b.ai
Autotransformer A B C D E F ØG
(T3) [mm] [mm] [mm] [mm] [mm] [mm] [mm]
T3, 01 / T3, 11 210 110 112 75 240 10 * 18 95
T3, 02 / T3, 12 210 135 112 101 240 10 * 18 95
T3, 03
T3, 13 230 150 124 118 270 10 * 18 95
T3, 04 260 150 144 123 330 10 * 18 95
T3, 14 / T3, 05 295 175 176 141 380 12 * 18 95
T3, 15
2 1 3 4
Input voltage: max. 500 V
Frequency: 50 / 60 Hz
1 0 0 0
1 2
3 4
m a x 7 0
4 .5 Ø 5 5 3 7
m a x 8 0 5 2
M E _ D R O _ 0 0 9 _ N D 3 0 _ a .d s 4
Connection example
L3
1 2 2
3 4
SB_SIC_004_b.ai
230 V 115 V 0V
S F _ D R O _ 0 0 1 _ T 2 _ a .d s f
6 .3 m m F a s to n
1 5 0
5
0
0
0
5
0
0
5
5
0
0
0
1 1
0
2 3
0
3 8
4 0
4 1
4 5
5 0
5 2
5 7
6 0
6 6
6 9
3 5
1 0 6 1 2 8
1 2 5 1 4 8
M E _ T R A _ 0 0 2 _ T 2 _ a .d s f 1 0 0 + -5
230 V 115 V 0V
S F _ D R O _ 0 0 1 _ T 2 _ a .d s f
500 V
600 V
460 V
530 V
400 V
460 V
500 V
600 V
460 V
530 V
400 V
460 V
500 V
600 V
460 V
530 V
400 V
460 V
Input voltage: 500 / 460 VAC or 600 / 530 VAC ±15 %, 3-phase
Input frequency: 50 to 60 Hz
Output voltage: 400 VAC or 460 VAC 3-phase
SA_TRA_001_T8_a.ai
U1 V1 W1
M
~
SA_TRA_002_ErP_a.ai
Dimensions
226
245
114 R4
,50
4
91
7,50
167
T8 autotransf.dsf
The DCS800 together with a SDCS-IOB-3 and a specially designed current transformer (CT), big
enough to feed through all the cables / busbars of the three phases are prepared to detect residual
current. This option can only be used at grounded networks.
S1
11 12
X3:11
12 13 14 AI4
Iact Jumper
IOB
Cp
I L1
I L2
M
I L3
SF_800_004_cur-detect_b.dsf
30
M4*8
P2
P1 S1 S2
25
89
84,5
30 30
40
25 CT 33
25 223 40
No busbars are
273±0,5 allowed within this
area around the CT
ME_TRA_004_PWS10004_b.ai
30
P2 M4*8
P1 S1 S2
55
198
max
190
30 30
30
55 CT
50
55 340 55 30
No busbars are
450
allowed within this
area around the CT
ME_TRA_003_PWS33001_b.ai
Mechanical mountings
The current transformers do not include mountings. There are mountings available for both types. Due
to CT‘s constructions a left and a right mounting is necessary.
Drilling pattern
left mounting Holes for M6
18
CT ME_TRA_004_PWS10004_b.ai
468
Drilling pattern
left mounting
Holes for M6
69.
ME_TRA_003_PWS33001_b.ai
CT
Comissioning hints
After all parts are installed, make sure:
- Jumper S1 on the SDCS-IOB-3 is in position 11 - 12 and 13 - 14.
- No cables are connected to terminals X3:9 and X3:10 on the SDCS-IOB-3.
- Select AI4 for this monitoring function via parameters.
- Activate the monitoring function via parameters.
- Define the threshold in amps via parameters.
- If necessary delay the fault message via parameters to avoid actions caused by disturbance or
similar.
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 optic fibre single cable plug 0.5 to 30 m 3ADT693324 1
Plastic optic fibre double cable plug 0.5 to 30 m 3ADT693318 2
HCS silica (double) without plastic jacket plug 30 to 50 m 3ADT693355 3
HCS silica (double) with plastic jacket plug 50 to 200 m 3ADT693356 4
Figure 1
L
blue black
Figure 2
L
blue black
black blue
Figure 3
L
orange orange
5 mm
black black
Figure 4
blue blue
Other cables
DCSLink cable
SDCS-DSL-4: X51
X1: DCF803-0016
DCF803-0035
FEX-425-Int
Dismantle for
DCF803-0035
DCF803-0060
DCF804-0050
DCF804-0060
X3: DCF803-0016
X2: DCF803-0050
shield grounding
FEX-425-Int
30 mm 10 mm 40 mm
Screen 10 mm
wire Cable
red netting Tinfoil sheath red 1
1 1 1
2 black black 2 2
2
3
white white 3 3 5
3
blue blue
2 2 2 2 4
black black
1 1 Two cable pairs 1 1 3
screen 20 mm 20 mm screen
not twisted
SDCS-DSL-4: X52/X53
0.54 / 2 / 4 / 10 / 20 m
ME_KAB_001_DCSLink_b.ai
P u ll ta b
( fo r c a b le m a r k in g )
M E _ K A B _ 0 0 3 _ IO B 2 -3 -u n s c re e n e d _ a .d s f
1 .4 / 3 .2 / 4 m
S c r e e n la id o p e n
P u ll ta b P u ll ta b
( fo r c a b le ( fo r c a b le
m a r k in g ) m a r k in g )
S D C S -IO B -2 S D C S -C O N -4
S D C S -IO B -3
M E _ K A B _ 0 0 2 _ IO B 2 -3 -s c re e n e d _ a .d s f
ABB
ABB Automation Products
Wallstadter Straße 59
D-68526 Ladenburg
Germany
Telefon: +49(0)6203-71-7608 *194R0811A5040000*
Telefax: +49(0)6203-71-7609 *194R0811A5040000*
www.abb.com/motors&drives