ABB DCS800 Installation And Start-Up Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. DC Drives
  5. DCS800
  6. Installation and start-up manual

ABB DCS800 Installation And Start-Up Manual

Rebuild kits drives
Hide thumbs Also See for DCS800:
Table of Contents

Advertisement

Quick Links

Download this manual
DCS800
Selection, Installation and Start-Up Manual for Rebuild Kits
DCS800 Drives

Advertisement

Table of Contents
loading

Related Manuals for ABB DCS800

Summary of Contents for ABB DCS800

  • Page 1 DCS800 Selection, Installation and Start-Up Manual for Rebuild Kits DCS800 Drives...
  • Page 2 DCS800 Single Drive Manuals All the documents available for the drive system DCS800 are listed below: Language Public. number DCS800 Quick Guide 3ADW000191 DCS800 Tools & Documentation CD 3ADW000211 DCS800 Converter module Flyer DCS800 3ADW000190 Technical Catalogue DCS800 3ADW000192 Hardware Manual DCS800...
  • Page 3 DCS800 Drives DCS800-R0x Selection, Installation and Start-Up Manual for Rebuild Kits Code: 3ADW000195R0101 Rev A DCS800 Service Manual e a.DOC EFFECTIVE: June 19th, 2006 SUPERSEDES:...
  • Page 4 3ADW000197R0101 DCS800-R Sel e a 3ADW000195R0101 DCS800 Service Manual e a...

  • Page 5: Table Of Contents

    Hardware conditions ....................Drive´s design conditions ..................... Conditions caused by the application................Type coding and accessories..................Hardware Basic components of the DCS800-R kit ............... Housing for main electronics ..................Pre-assembled part ...................... Loose parts........................Optional parts ....................... Dimensions main electronic housing ................
  • Page 6 Points to be observed because of the situation ............Maintenance work ...................... Tools .......................... Measurements with the “old” equipment still working..........Mounting the Kit ......................Wiring the Kit ......................Commissioning the Kit....................Table of contents 3ADW000195R0101 DCS800 Service Manual e a...

  • Page 7: How To Use This Manual

    Start-up gives some general guidelines and cross references how to commission and start up a DC drive system using a Rebuild kit. Associated publications Associated publications see inner page of the jacket of that manual. Introduction 3ADW000xxxR0101 DCS800-R Sel e a...
  • Page 8 Introduction 3ADW000197R0101 DCS800-R Sel e a...

  • Page 9: Basic Selection

    The electronics of the existing converter indicated by the left box above is splitted into 2 boxes in the kit. electronics: electronics: thyristor interface to interface to bridge thyristor bridge Rebuild kit Existing The Rebuild kit can be used for armature bridges in non-regenerative or regenera- Basic Selection 3ADW000197R0101 DCS800-R Sel e a...

  • Page 10: Hardware Conditions

    In such a case, please check if a complete new converter may be more economical. Basic Selection 3ADW000197R0101 DCS800-R Sel e a...

  • Page 11: Drive´s Design Conditions

    - If the existing bridge has been used in a configuration different to 6-pulse , addi- tional engineering is needed. It should be checked at first, if a standard converter DCS800-S0x can be used for such a configuration. Most likely the DCS800-R0x can be designed similar as with a standard converter.

  • Page 12: Type Coding And Accessories

    There is only one mechanical construction for all the different versions of the kit. It basically serves as a cover for that part named DCS800-R0x on the next figure. Ordering of the kit is done with the ordering code shown on the right page. The op- tions available for the Rebuild kit are identical as for a DCS800-S0x converter.
  • Page 13 +xxxx codes according selectable option list for add-on options ≤990V Existing parts Residual current detection a or b QUINT-PS PIN-48 PIN 1x PIN-51 REB-1 REB-2 REB-3 PIN-48 to motor field DCS8-R_sys_ovw.dsf Overview of DCS800-R System Basic Selection 3ADW000197R0101 DCS800-R Sel e a...
  • Page 14 Basic Selection 3ADW000197R0101 DCS800-R Sel e a...

  • Page 15: Hardware

    All other components which may come or may had been ordered together with the kit are described in detail either within the DCS800 Hardware Manual or within their dedicated documentation. Basic components of the DCS800-R kit The kit is ordered according to the type designation at chapter Basic Selection.

  • Page 16: Pre-Assembled Part

    CON-4). This board needs to be feed by a 2-phase AC line voltage, either 115 V or 230 V - Drive-to-drive interfacevia SDCS-DSL-4 board - Control panel DCS800 CP - Flat cable interconnection board SDCS-CCB4 Hint: The older version of the electronic power supply SDCS-POW-1 can be used as a spare part for the actual one, SDCS-POW-4.

  • Page 17: Optional Parts

    Depending on the overall configuration and the needs caused by the application itself it may be necessary to add other options. These options should be selected based on the overview of the DCS800-R system shown at the end of chapter Basic Selection.

  • Page 18: Dimensions Main Electronic Housing

    Because of that it is important to mount the housing as shown on the figure before and to make sure the convection is not blocked. Dimensional drawing of the DCS800-R Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 19: Environmental Conditions

    CE and other markings. Remark: This chapter with exactly the same lay-out is used for all subsets of the system DCS800. Because of this only headlines without (*) are applicable to the product DCS800-R ! System connection Environmental limit values 230 to ≤...
  • Page 20 • or on request >600 V to 990 V EN / IEC xxxxx see table above. EN / IEC types: on request Available for converter modules in- (for details see table above) cluding field exciter units. Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 21: Pulse Transformer Board Sdcs-Pin-48

    1 m. The cables have to be shortened and have to be equipped with the plug connector, demanded by the thyristor type in use. Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 22: Measurement Board Sdcs-Pin-51

    121.5 X22 X122 Two PTC ..R21 One PTC W10 W70 X12S X413S W 83 X13S X313S Isolating supports SDCS-PIN-51 ∅4.8 182.5 100.7 SDCS-PIN-51 board and card holder Hardware 3ADW000197R0101 DCS800-R Sel e a...
  • Page 23 Typical rebuild connection with controller board, SDCS-PIN-48 and SDCS-PIN-51 boards Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 24: Wiring

    It can be used without further modification; just leave the jumpers as they are. They will not be read by the converter´s software and therefore not taken into calculation. Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 25: Voltage Coding

    The value has to be used instead of dNDCR peak at all the next equations! • The scaling for nominal current will be done by the resistors R1 to R21, which are connected in parallel. Hardware 3ADW000197R0101 DCS800-R Sel e a...
  • Page 26 DCS800-R volt & curr coding.dsf Hint: In case a DCS800-R0x will be used to replace a DCR500B or DCR600 keep the coding of the SDCS-PIN-51 board as done in the past and set parameter 97.02 exactly to that value the SDCS-PIN-51 board was coded.

  • Page 27: Additional Settings

    S ConvScaleVolt (97.03) xxx (V) as coded power stack S MaxBrdgTemp (97.04) 60 (°C) temperature monitoring 2-Q or 4-Q mode S BlockBridge2 (97.07) at 2-Q power part at 4-Q power part Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 28: Interface Board Sdcs-Reb-1

    X713. Thyristors in old bridges are often differently positioned on the heat sink than in modern converter modules. At the bigger standard DCS800 modules firing com- mands are arranged on the pulse transformer board SDCS-PIN-48. In this way three channels are used for forward bridge and three channels for re- verse bridge.

  • Page 29: Power Supply

    V58 is not lit and the transistor switch connected to X2 is open. Normally V58 should be lit and the transistor switch is closed. - the transistor output rating is 60 V DC/ max. 50 mA; the output is isolated; see figure above Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 30: Functionality

    (one of the 2 inputs, which have a fast update time) of the DCS800-R0x electronics (as indicated above) to handle the COASTING function of the converter. If the supply voltage is o.k. the converter can be released by the PLC.

  • Page 31: Diagram

    6x 0k5 BZP2 BZP3 BZP4 BZP5 BZP6 470pF X613 22nF X713 +48V 22nF X613 separated potential range Diagram of the SDCS-REB-2 board ∅ 4.5 Card holder for SDCS-REB-2 SDCS-REB-2 218.5 Layout of the SDCS-REB-2 board Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 32: Interface Board Sdcs-Reb-3

    B, D, F. These are controlled by two current direction signals. The next figure shows the routing of the firing pulses and the activation of the two groups for three different configurations, used with the bigger standard DCS800- S0x modules.
  • Page 33 & SR_xACE SR_xBDF SR_1ACE & SR_1 SR_1BDF & SR_2 SR_2ACE & SR_2BDF (reverse) SDCS-PIN-48 to thyristor & & & SR_xACE SR_xBDF & & DCS8-R RB_sign.dsf & Signal flow of firing pulses and thyristor designation Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 34: Design Hints

    - Thyristor Vx26 has been assigned to signal 6 - Thyristor Vx26 belongs to current direction 2 (SR_2) - Channel D has been assigned to group SR_BDF - Channels B and F are then likewise assigned to current direction 2 Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 35: Plug Connectors X1113: And X2113

    In this variant, REB-1 and REB-2 are dispensed with, with the result that only two anti-parallel thyristor bridges can be controlled. Hardware 3ADW000197R0101 DCS800-R Sel e a...
  • Page 36 SR ACE SR BDF SR BDF SR ACE SR ACE SR BDF SR BDF SR ACE SR ACE SR ACE SR BDF SR BDF SR BDF ∅4.5 conuctive supports 221.5 Layout of the SDCS-REB-3 board Hardware 3ADW000197R0101 DCS800-R Sel e a...

  • Page 37: Interfacing The Electronics And Thyristors

    V24 V13 V26 V15 (L1) U1 (L2) V1 (L3) W1 V21 V16 V23 V12 DCS800 u i meas val.dsf I actual actual actual to SDCS-PIN-51 Arrangement of thyristors in an anti parallel bridge Connection for 2-quadrant application – No parallel Thyristors...

  • Page 38: Connection For 4-Quadrant Application - No Parallel Thyristors

    L2 and for the thyristors, connected to phase L3 (see figure Arrangement of thyristors in an anti parallel bridge) SDCS-PIN-48 X22 X122 X23 SDCS-PIN-51 SDCS-PIN-48 4q_c4a_b.dsf Firing pulse assignment Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800-R Sel e a...

  • Page 39: Connection For 4-Quadrant Application - Parallel Thyristors

    +48VEXT +24VEXT 0VEXT 0VEXT SDCS-PIN-41 SDCS-REB-2 SDCS-PIN-41 X713 SDCS-PIN-41 X613 SDCS-PIN-48 RB_4q_4p_a.dsf X22 X122 X23 SDCS-PIN-51 SDCS-PIN-41 SDCS-REB-1 SDCS-PIN-41 SDCS-PIN-41 SDCS-PIN-48 Forward bridge pulse transformer boards 4-quadrant application, parallel thyristors. Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800-R Sel e a...

  • Page 40: Connection For 2-Quadrant Application - Parallel Thyristors

    The figure below shows the configuration for a 2-quadrant bridge with 4 parallel connected thyristors. +48VEXT +24VEXT 0VEXT 0VEXT SDCS-REB-2 X713 X613 RB_2q_4p_a.dsf X22 X122 X23 SDCS-PIN-51 SDCS-PIN-41 SDCS-PIN-41 SDCS-PIN-41 SDCS-REB-1 SDCS-PIN-48 Forward bridge pulse transformer boards 2-quadrant application, parallel thyristors. Interfacing the Electronics and Thyristors 3ADW000197R0101 DCS800-R Sel e a...

  • Page 41: Background For The Figures Of This Chapter

    F igure 10 and the following ones will show the mechanical possibilities. • Part 3 shows the main DCS800-R0x electronics with the electronic power sup- ply SDCS-POW-4 and the microprocessor system SDCS-CON-4. All other op- tions which can be connected to the controller boards are left out for easier reading.
  • Page 42 Figure 2: Electrical drawing: 1 thyristor stage Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 43 Figure 3: Electrical drawing: 2 Thyristor stages in parallel Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 44 Figure 4: Electrical drawing: 3 Thyristor stages in parallel Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 45 Figure 5: Electrical drawing: 4 Thyristor stages in parallel Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 46 X12S One PTC ..Two PTC X122 X613 X713 + + - - + + - - DCS8_reb_card_Layout_mechan_reb2.dsf to SDCS-PIN-48 Figure 6: Mechanical suggestion Part 2 without SDCS-REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 47 Figure 7: Electr. drawing: 3 Thyr. stages in parallel w. REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 48 Figure 8: Electr. drawing: 4 Thyr. stages in parallel w. REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 49 B D F A C E B D F A C E B D F A C E X113 X213 X313 X413 X513 X613 X713 X813 DCS8_reb_card_Layout_mechan_reb3_1.dsf to SDCS-PIN-48 Figure 9: Mechanical suggestion 1 for Part 2 with REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 50 B D F A C E B D F A C E X413 X113 X213 X313 X413 X513 X613 X713 X813 X313 DCS8_reb_card_Layout_mechan_reb3_2.dsf to SDCS-PIN-48 Figure 10: Mechanical suggestion 2 for Part 2 with REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 51 B D F A C E B D F A C E B D F A C E X113 X213 X313 X413 X513 X613 X713 X813 DCS8_reb_card_Layout_mechan_reb3_3.dsf to SDCS-PIN-48 Figure 11: Mechanical suggestion 3 for Part 2 with REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 52 50 mm SDCS-REB-2 X513 X513 X613 X113 X113 X713 X213 X213 X413 X313 + + - - + + - - DCS8_reb_card_Layout_mechan_reb3_4.dsf Figure 12: Mechanical suggestion 4 for Part 2 with REB-3 Installation 3ADW000197R0101 DCS800-R Sel e a...

  • Page 53: Hints For Cabling

    2...8 cables per kit; 5 m long GNT 6093268R6 2 cables per kit; 0.5 m long 1x Resistor 2.21 k Ω DCA 0020531P1 cable type: AWG20, UL10203,T DCA 0021154R0001 Adapters for different gate connections Installation 3ADW000197R0101 DCS800-R Sel e a...
  • Page 54 Figure 13: Principles of cabling Installation 3ADW000197R0101 DCS800-R Sel e a...

  • Page 55: Safety Instructions

    To which products this chapter applies This chapter applies to the whole range of the product DCS800, the converter modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the re- build kit DCS800-R0x. Use of warnings and notes There are two types of safety instructions throughout this manual: warnings and notes.

  • Page 56: Installation And Maintenance Work

    220 V or 230 V) may be present on the terminals of relay outputs SDCS-IOB-2 and RDIO. • DCS800 with enclosure extension: Before working on the drive, isolate the whole drive from the supply. Safety Instructions 3ADW000197R0101 DCS800-R Sel e a...

  • Page 57: Grounding

    • As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required. Safety Instructions 3ADW000195R0101 DCS800 Service Manual e a...

  • Page 58: Mechanical Installation

    These notes are intended for all who install the drive. Handle the unit carefully to avoid damage and injury. • DCS800 sizes D4...D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back.
  • Page 59 To stop the drive using the control panel, press the LOC/REM key and then the stop key Safety Instructions 3ADW000195R0101 DCS800 Service Manual e a...
  • Page 60 Safety Instructions 3ADW000197R0101 DCS800-R Sel e a...

  • Page 61: Start-Up

    Start-up What this chapter contains This chapter describes the commissioning procedure for a DCR kit. This is done based on the procedure used for DCS800-S0x converters. Only the actions and steps, which are different, are listed here. Safety Instructions The rebuilt kit together with the power part and other components being reused will form a converter and a drive system very similar as a new converter module or a new cubicle with a converter module built-in.

  • Page 62: Maintenance Work

    Start-up 3ADW000197R0101 DCS800-R Sel e a...

  • Page 63: Mounting The Kit

    • if the place of V11/V24 is found, but the orientation is not clear and the thyristor is not visible take one pair of pulse firing leads (one of them is Start-up 3ADW000197R0101 DCS800-R Sel e a...

  • Page 64: Commissioning The Kit

    The complete commissioning of a DC drive consisting of the motor and the thyris- torized power part equipped with a rebuild kit is based on the manuals used for the converter type DCS800-S0x. Only a few additional steps are recommended and will be listed afterwards.
  • Page 65 When the gate connections are done and current is flowing in a controlled manner set the minimum firing angle position to default, the bridge changeover time to val- ues necessary and go on with the other steps necessary to get the drive into op- eration. Start-up 3ADW000197R0101 DCS800-R Sel e a...
  • Page 66 Individually factory load tested 230 … 1,200 V Detailed documentation IP21 – IP54 DCS800-E series DCS800 module with all necessary accessories mounted and fully cabled on a panel Pre-assembled drive-kits Very fast installation and commissioning Squeezes shut-down-times in revamp projects to a …...

This manual is also suitable for:

Dcs800-r

Table of Contents