ABB DCS 400 User manual

II K 1-1
DCS Thyristor power converter
for DC drive systems
20 to 1000 A
9 to 522 kW
Manual
DCS 400

II K 1-2
List of contents
MANUAL
1 DCS 400 - the compact-size DC drive ........ II K 1-3
2 System overview of DCS 400 .................... II K 2-1
2.1 Environmental conditions ............................................. II K 2-2
2.2 DCS 400 power converter modules ............................ II K 2-3
2.3 DCS 400 overload withstand capability ...................... II K 2-4
2.4 Control and Display Units of the DCS 400 ................. II K 2-5
3 Technical Data ............................................ II K 3-1
3.1 Module Dimensions ....................................................... II K 3-1
3.2 Cross-sectional areas - Tightening torques .................. II K 3-3
3.3 Power losses ................................................................. II K 3-5
3.4 Power section cooling ................................................... II K 3-6
3.5 Control board SDCS-CON-3A ...................................... II K 3-7
3.6 Power interface board SDCS-PIN-3A ........................... II K 3-9
3.7 Field exciter SDCS-FIS-3A ......................................... II K 3-10
3.8 Circuit diagrams .......................................................... II K 3-12
4 Overview of software.................................. II K 4-1
4.1 General inormation about application Macros .............. II K 4-2
4.2 Application Macros ........................................................ II K 4-4
4.3 Digital and analogue Inputs/Outputs ........................... II K 4-22
4.4 Drive Logic .................................................................. II K 4-24
4.5 Regulator functions ..................................................... II K 4-27
4.6 Software Structure ...................................................... II K 4-42
4.7 Parameter list .............................................................. II K 4-44
5 Installation ................................................... II K 5-1
5.1 Safety instructions ......................................................... II K 5-2
5.2 EMC Compliant Installation and Configuration for PDS II K 5-4
5.3 Connection Examples ................................................. II K 5-17
6 Operating Instructions ............................... II K 6-1
6.1 Panel ............................................................................. II K 6-2
6.2 Guided Commissioning ................................................. II K 6-7
6.3 Useful hints for commissioning ................................... II K 6-20
6.4 Troubleshooting .......................................................... II K 6-24
7 Serial interfaces .......................................... II K 7-1
7.1 Panel-port ...................................................................... II K 7-6
7.2 RS232-port .................................................................... II K 7-7
7.3 Fieldbus interface .......................................................... II K 7-8
Appendix
AAccessories ....................................................................... II K A-1
Line chokes ................................................................... II K A-1
Fuses ............................................................................. II K A-4
EMC filter ....................................................................... II K A-6
B Declaration of conformity .................................................. II K B-1
C Quick Installation & Commissioning guide ....................... II K C-1
D Examples for basic parameter programming ................... II K D-1
Index
This manual is valid for DCS 400 Rev A including software version 108.0

II K 1-3
1 DCS 400 - the compact-size DC drive
DCS 400 is a new generation of DC drives, which
is rated from 9 to 522 KW and for use on all line
supply voltages from 230 to 500 V.
Total ease of use was the brief given to the drive`s
designers. The result is a DC drive that meets the
needs of machine builders. It is:
I as easy to handle as an analogue drive but with
all the advantages of a digital drive
I easy to design into machine equipment, being
compact and having just the right number of
features
I easy to install and set up
The DCS 400 is an innovative design , using the
latest semiconductor technology together with
an advanced software which helps to reduce
maintenance, increase product reliability and
enables extremely rapid commissioning.
The DCS 400's small size brings substantial space
savings to machine builders, allowing them to
integratemore accessories withinthesame space.
The compact design has been partly achieved by
a fully integrated field exciter, which includes the
field fuse and choke.
Based on new IGBT technology used for the field
exciter, there is no need for a field voltage
adaptation transformer to match the line supply
voltage with that of the motor.
The commissioning wizard -available on the con-
trol panel and the PC tool - makes start up of the
drive extremely easy, by simply guiding the user
through the start up procedure.
In addition, the DCS 400 contains application
macros . By selecting a macro from a menu, the
user can pre-select the software structure and
the I/O connection, thus saving time and elimi-
nating any errors.
The DCS 400 carries the CE Mark and is designed
and produced according to the quality standard
ISO 9001.

II K 1-4
Activation and operator-control
analogue and digital inputs and outputs
fieldbusses
MMC (man-machine communication) via:
Drive Window Light
(start-up and maintenance program) PC pro-
grams can be run under all commonly used
Windows
®
environments (3.1x, 95,98, NT):
 Parameter programming
 Fault detection
 Feedback display and analysis
 Fault logger
DCS400PAN
Removable control and display panel with
plain text display for:
 Guided commissioning
 Parameter programming
 Fault detection
 Reference and feedback display
 Local operation
Unit functions
Drive functions
 Speed ramp function generator (S-ramp,
2 accel / decel ramps)
 Speed feedback via tacho, encoder, EMF
 Speed controlling
 Torque / current reference processing
 External torque limitation
 Current controlling
 Automatic field weakening
 Automatic optimization for armature-circuit
current, field current, speed controller, EMF
regulator, flux adaptation
 Speed monitor
 On/Off control logic
 Remote/local operation
 Emergency stop
 Automatic phase sequence detection
 Motor overload detection
 Internal motor potentiometer function for the
speed reference
 Jog function
 Configuration macros
Monitoring functions
Self-test
Fault logger
Motor monitoring
 Speed feedback error
 Overtemperature (PTC evaluation)
 Overload (I² t)
 Overspeed
 Stalled motor
 Armature-circuit overcurrent
 Armature-circuit overvoltage
 Minimum field current
 Field overcurrent
Power converter protection
 Overtemperature
 Watchdog function
 Mains voltage interruption
Thyristor diagnosis
DCS 400 - the compact-size DC drive

II K 2-1
2 System overview of DCS 400
Fig. 2/1: System overview of DCS 400
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II K 2-2
Planned for 2000
under preparation
2.1 Environmental conditions
Mains supply - power part
Voltage, 3-phase: 230 to 500 V in acc. with IEC 38
Voltage deviation: ±10% permanent
Rated frequency: 50 Hz or 60 Hz
Static frequency deviation: 50 Hz ±2 %; 60 Hz ±2 %
Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz
df/dt: 17 % / s
Mains supply - Electronics supply
Voltage, 1-phase: 115 to 230 V in acc. with IEC 38
Voltage deviation: -15% / +10%
Frequency range: 45 Hz to 65 Hz
Degree of protection
Power converter module: IP 00
Paint finish
Power converter module, cover: RAL 9002 light-grey
housing: RAL 7012 dark-grey
Fig. 2.1/1: Effect of the site elevation above sea level on the
power converter's load capacity
Current reduction to (%) for armature circuit and field supply
Fig. 2.1/2: Effect of the ambient temperature on the converter
module load capacity.
Current reduction to (%) for armature circuit and field supply
Environmental limit values
Permissible ambient temp. with rated current I DC: +5 to +40°C
Ambient temp., power conv. module:+40°C to 55°C; s. Fig. 2.1/2
Alteration in the ambient temp.: < 0,5°C / minute
Storage temperature: -40 to +55°C
Transport temperature: -40 to +70°C
Relative humidity: 5 to 95%, no condensation
Pollution degree: Grade 2
Site elevation:
<1000 m above M.S.L.: 100%, without current reduction
>1000 m above M.S.L.: with current reduct., s. Fig. 2.1/1
Vibration converter module: 0,5 g; 5 Hz to 55 Hz
Noises: Size as module
(1 m distance)
A1 55 dBA
A2 55 dBA
A3 60 dBA
A4 66...70 dBA, dependent on fan
Compliance with standards
The power converter modules and cubicles are designed for industrial applications.
Within the EU, the components satisfy the requirements European guidelines, shown
in the table below.
Standards in North America
In North America, the system components
satisfy the requirements as listed in the
table below.
70
80
90
100
110
30 35 40 45 50 55°C
Please note:
applies for power converter modules only.
50
60
70
80
90
100
1000 2000 3000 4000 5000m
European Union Directive Manufacturer’s Assurance
Harmonized Standards
Converter module
Machinery Directive
89/392/EEC
93/68/EEC
Declaration of
Incorporation
EN 60204-1
[IEC 204-1]
Low Voltage Directive
73/23/EEC
93/68/EEC
Declaration of Conformity
EN 60146-1-1
[IEC 146-1-1]
EN 50178 [IEC --]
see additional
IEC 664
EMC Directive
89/336/EEC
93/68/EEC
Declaration of Conformity.
Provided that all installation
instructions concerning
cable selection, cabling and
EMC filters or dedicated
transformer are followed.
EN 61800-3
¥
[IEC 1800-3]
where limits are under consideration
EN 50081-2 / EN 50082-2 has been supplied
¥ in accordance with 3ADW 000 032
’Installation in accordance with EMC’
The Technical Construction File to which this
Declaration relates has been assessed by
Report and Certificate from ABB EMC
Certification AB being the Competent Body
according to the EMC Directive.
System overview of DCS 400
Safety for Power
conversion Equipment
≤600 V
Standard for module
UL 508 C
Industrial control
Equipment: industrial
products ≤600 V
CSA C 22.2. No.1495

II K 2-3
2.2 DCS 400 power converter modules
Size A2
Size A1 Size A3 Size A4
Sizes
➀ Fan with 115 V/1 ph
available as option
System overview DCS 400
Converter type Line voltage
400 V 500 V
IDC [A] IAC [A] IF [A] P [kW] P [kW]
DCS402.0025 25 20 4 10 13
DCS402.0050 50 41 6 21 26
DCS402.0075 75 61 6 31 39
DCS402.0100 100 82 6 41 52
DCS402.0140 140 114 6 58 73
DCS402.0200 200 163 16 83 104
DCS402.0260 260 212 16 108 135
DCS402.0350 350 286 16 145 182
DCS402.0450 450 367 16 187 234
DCS402.0550 550 448 16 232 290
DCS402.0680 680 555 20 282 354
DCS402.0820 820 669 20 340 426
DCS402.1000 1000 816 20 415 520
Table 2.2/3: DCS 402 unit table
Converter type Line voltage
400 V 500 V
IDC [A] IAC [A] IF [A] P [kW] P [kW]
DCS401.0020 20 16 4 9 12
DCS401.0045 45 36 6 21 26
DCS401.0065 65 52 6 31 39
DCS401.0090 90 74 6 41 52
DCS401.0125 125 102 6 58 73
DCS401.0180 180 147 16 84 104
DCS401.0230 230 188 16 107 133
DCS401.0315 315 257 16 146 183
DCS401.0405 405 330 16 188 235
DCS401.0500 500 408 16 232 290
DCS401.0610 610 498 20 284 354
DCS401.0740 740 604 20 344 429
DCS401.0900 900 735 20 419 522
Table 2.2/2: DCS 401 unit table
Size
A1
A1
A1
A1
A1
A2
A2
A3
A3
A3
A4
A4
A4
Unit table
DCS 401 2-quadrant converter DCS 402 4-quadrant converter
DC voltage characteristic
The DC voltage characteristics are calculated
according to:
 UVN = rated supply voltage, 3-phase
 Voltage tolerance ±10 %
Table 2.2/4: Recommended DC voltage with specified input voltage
➀in case of a 2-Q convert-
er, which is used in rege-
narative mode, please
use 4-Q voltage values
System con- DC voltage
nection voltage (max. Motor voltage)
U
vN
U
d
2Q ➀4Q
230 270 240
380 460 400
400 470 420
415 490 430
440 520 460
460 540 480
480 570 500
500 600 520
Size Current Dimensions Weight Min. Clearances Fan connection Fuses
range H x W x D appr. top/butom/side
[mm] [kg] [mm]
A1 20...25 A 310x270x200 11 150x100x5 - external
A1 45...140 A 310x270x200 11 150x100x5 115/230 V/1 ph external
A2 180...260 A 310x270x270 16 250x150x5 115/230 V/1 ph external
A3 315...550 A 400x270x310 25 250x150x10 115/230 V/1 ph external
A4 610...1000 A 580x270x345 38 250x150x10 ➀ 230 V/1 ph external
Table 2.2/1: Sizes of DCS 400
()
α cos*35.1*%10−=
91G
88
cos a= 0.966 (2-Q)
0.866 (4-Q)

II K 2-4
2.3 DCS 400 overload withstand capability System overview of DCS 400
To match a drive systems components as efficiently as possible to the
driven machines load profile, the power converters can be dimensioned by
means of the load cycle. Load cycles for driven machines have been defined
in the IEC 146 or IEEE specifications, for example.
The characteristics are based on an ambient temperature of max. 40°C and an
elevation of max. 1000 m.
Table 2.3/2: Selection of converter modules according to the corresponding load cycles.
Operating Load Typical applications Load cycle
cycle for converter
DC I IDC I continuous (IdN) pumps, fans
DC II IDC II for 15 min and extruders, conveyor belts
1,5 * IDC II for 60 s
DC III IDC III for 15 min and extruders, conveyor belts
1,5 * IDC III for 120 s
DC IV IDC IV for 15 min and
2 * IDC IV for 10 s
Types of load
Table 2.3/1: Definition of the load cycles
Converter type
2-quadrant converter
DCS 401.0020
DCS 401.0045
DCS 401.0065
DCS 401.0090
DCS 401.0125
DCS 401.0180
DCS 401.0230
DCS 401.0315
DCS 401.0405
DCS 401.0500
DCS 401.0610
DCS 401.0740
DCS 401.0900
4-quadrant converter
DCS 402.0025
DCS 402.0050
DCS 402.0075
DCS 402.0100
DCS 402.0140
DCS 402.0200
DCS 402.0260
DCS 402.0350
DCS 402.0450
DCS 402.0550
DCS 402.0680
DCS 402.0820
DCS 402.1000
Load cycles of driven machines Recommended
Converter type
ð

100%

150% 100%
15 min

150% 100%
15 min
200% 100%
15 min
DC I DC II DC III DC IV
IDC I IDC II IDC III IDC IV
contin- 100 % 150 % 100 % 150 % 100 % 200 %
uous 15 min 60 s 15 min 120 s 15 min 10 s
[A] [A] [A] [A]
2-quadrant applications
20 18 27 18 27 18 36
45 40 60 37 56 38 76
65 54 81 52 78 55 110
90 78 117 72 108 66 132
125 104 156 100 150 94 188
180 148 222 144 216 124 248
230 200 300 188 282 178 356
315 264 396 250 375 230 460
405 320 480 310 465 308 616
500 404 606 388 582 350 700
610 490 735 482 723 454 908
740 596 894 578 867 538 1076
900 700 1050 670 1005 620 1240
4-quadrant applications
25 23 35 22 33 21 42
50 45 68 43 65 38 76
75 66 99 64 96 57 114
100 78 117 75 113 67 134
140 110 165 105 158 99 198
200 152 228 148 222 126 252
260 214 321 206 309 184 368
350 286 429 276 414 265 530
450 360 540 346 519 315 630
550 436 654 418 627 380 760
680 544 816 538 807 492 984
820 664 996 648 972 598 1196
1000 766 1149 736 1104 675 1350

II K 2-5
System overview DCS 400
2.4 Control and Display Units of the DCS 400
Fig. 2.4/1: Possibilities of operation
For operation, commissioning, diagnosis and for
controlling the drive, there are different possibil-
ities available.
Panel DCS 400 PAN
Features
 Guided commissioning
(Panel Wizard)
 Drive control
 Parameter programming
 Display of reference and ac-
tual values
 Status information
 Fault reset
 Multilingual
 removable during operation
7-Segment display
Features
 RAM/ROM memory test error
 Program is not running
 Normal situation
 During download sequence
 Alarm
 Fault
440V 368A 1500rpm
1500rpm
OUTPUT MENU AUTO OFF LOC <RUN>
The coupling to an overriding system (PLC) takes
place over a serial interface with a fibre-optic link
to a field bus adapter.
Fieldbus Adapter
Components:
 plastic optical fibre
 field bus adaptor
available Fieldbus adapters:
 PROFIBUS
 AC 31
 MODBUS
 MODBUS+
 CAN-BUS
 DeviceNet
You will find more detailed information on data
exchange in the related documentation for field
bus adapters.
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BUS
TE RM INA T ION
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OFF
RXD
TXD
PE SHF DG D(N) D( P)
X1
X2
PE SHF DG D(N) D( P)SH
XMIT
REC
ERROR
+24V 0V SH
(RS232)
X8:
X6:
V800
Panel
connection
electrical
connection optical fibre
≤10 m
power supply
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II K 2-6
Operation by PC
Components :
 RS232 standard cable, 9-pin sub-D connector,
male-female, non-crossing
Functionality:
 Software package "Drive Window Light"
System requirements/recommendation:
 PC with 386 processor or higher
 hard disk with 5 MB free memory
 VGA monitor
 Windows 3.1, 3.11, 95, 98, NT
 3 1/2" floppy disk drive
Start-up wizard
The start-up wizard makes it easier to parameter-
ize and optimize a drive. It guides the user
through the various sequences involved in a
start-up.
Drive Window Light
Drive Window Light is a PC tool for on-line start-
up, diagnosis, maintenance and troubleshooting.
System configuration display
offers an overview the system.
Drive control
to be used for control of a selected drive.
Parameter programming
to be used to process signals and parameters of
the destination drive.
Trending
monitors the feedback values of the destination
drive.
Fault logger
enables you to view the error memory.
Fig. 2.4/2: Example for a Start-up wizard display
System overview of DCS 400
CAUTION!
To avoid unintentional operating states, or to shut
the unit down in case of any imminent danger
according to the standards in the safety instruc-
tions it is not sufficient to merely shut down the
drive via signals 'RUN', drive 'OFF' or 'Emergency
Stop' respectively 'control panel' or 'PC tool'.

II K 3-1
Technical data
3 Technical Data
3.1 Module dimensions
Module A1
DCS 401.0020
DCS 401.0045
DCS 401.0065
DCS 401.0090
DCS 401.0125
DCS 402.0025
DCS 402.0050
DCS 402.0075
DCS 402.0100
DCS 402.0140
Module A2
DCS 401.0180
DCS 401.0230
DCS 402.0200
DCS 402.0260
Module A3
DCS 401.0315
DCS 401.0405
DCS 401.0500
DCS 402.0350
DCS 402.0450
DCS 402.0550
Dimensions in mm
Fig. 3.1/1: Dimension drawing A1, A2, A3-Module

II K 3-2
Technical data
Module A4
DCS 401.0610
DCS 401.0740
DCS 401.0900
DCS 402.0680
DCS 402.0820
DCS 402.1000
Dimensions in mm
Fig. 3.1/2: Dimension drawing A4-Module
for M12
for M6

II K 3-3
Technical data 3.2 Cross-sectional areas - Tightening torques
❶You 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. This can lead to other values than recommend-
ed.
Table 3.2/1: Cross-sectional areas - tightening torques DCS 400
3.2.1 Recommended cross-sectional area to DIN VDE 0276-1000 and DIN VDE 0100-540 (PE), trefoil arrangement, up to 40°C
ambient temperature and a 90°C operating temperature of the conductor.
❶
Definition of the recommended cables above:
H07V: DIN-VDE 0281-1; Polyvinyl chloride insulated cables
NSGAFÖU: DIN-VDE 0250-602; Special rubber-insulated single-core cables
N2XY: DIN-VDE 0276-604; Power cable with special fire performance
Unit type C1, D1 U1, V1, W1 PE
1 x M.. [Nm]
IDC
[A-]
HO7V
[mm²]
NSGA
FÖU
[mm²]
N2XY
[mm²]
Iv
[A~]
HO7V
[mm²]
NSGA
FÖU
[mm²]
N2XY
[mm²]
HO7V
[mm²]
NSGA
FÖU
[mm²]
N2XY
[mm²]
DCS 401.0020 20 1 x 2.5 1 x 1.5 1 x 1.5 16 1 x 2.5 1 x 1.5 1 x 1.5 1 x 2.5 1 x 1.5 1 x 1.5 M6 6
DCS 401.0045 45 1 x 10 1 x 6 1 x 6 36 1 x 6 1 x 6 1 x 4 1 x 6 1 x 6 1 x 4 M6 6
DCS 401.0065 65 1 x 16 1 x 10 1 x 10 52 1 x 16 1 x 10 1 x 6 1 x 16 1 x 10 1 x 6 M6 6
DCS 401.0090 90 1 x 25 1 x 16 1 x 16 74 1 x 25 1 x 16 1 x 16 1 x 16 1 x 16 1 x 16 M6 6
DCS 401.0125 125 1 x 35 1 x 25 1 x 25 102 1 x 35 1 x 25 1 x 25 1 x 16 1 x 16 1 x 16 M6 6
DCS 401.0180 180 1 x 70 1 x 50 1 x 50 147 1 x 50 1 x 50 1 x 35 1 x 25 1 x 25 1 x 16 M10 25
DCS 401.0230 230 1 x 95 1 x 70 1 x 70 188 1 x 70 1 x 70 1 x 50 1 x 35 1 x 35 1 x 25 M10 25
DCS 401.0315 315 2 x 50 1 x 95 1 x 120 257 2 x 50 1 x 95 1 x 95 1 x 50 1 x 50 1 x 50 M10 25
DCS 401.0405 405 2 x 70 2 x 50 1 x 150 330 2 x 70 2 x 50 1 x 120 1 x 70 1 x 50 1 x 70 M10 25
DCS 401.0500 500 2 x 120 2 x 70 2 x 70 408 2 x 95 2 x 70 2 x 70 1 x 95 1 x 70 1 x 70 M10 25
DCS 401.0610 * 610 2 x 150 2 x 95 2 x 95 498 2 x 150 2 x 95 2 x 70 1 x 150 1 x 95 1 x 70 M12 50
DCS 401.0740 * 740 2 x 240 2 x 150 2 x 150 604 2 x 185 2 x 120 2 x 95 1 x 185 1 x 120 1 x 95 M12 50
DCS 401.0900 * 900 2 x 240 2 x 185 2 x 185 735 2 x 240 2 x 150 2 x 150 1 x 240 1 x 150 1 x 150 M12 50
DCS 402.0025 25 1 x 2.5 1 x 2.5 1 x 2.5 20 1 x 2.5 1 x 2.5 1 x 1.5 1 x 2.5 1 x 2.5 1 x 1.5 M6 6
DCS 402.0050 50 1 x 10 1 x 6 1 x 6 41 1 x 10 1 x 6 1 x 4 1 x 10 1 x 6 1 x 4 M6 6
DCS 402.0075 75 1 x 16 1 x 10 1 x 16 61 1 x 16 1 x 10 1 x 10 1 x 16 1 x 10 1 x 10 M6 6
DCS 402.0100 100 1 x 25 1 x 16 1 x 25 82 1 x 25 1 x 16 1 x 16 1 x 16 1 x 16 1 x 16 M6 6
DCS 402.0140 140 1 x 50 1 x 35 1 x 35 114 1 x 35 1 x 25 1 x 25 1 x 16 1 x 16 1 x 16 M6 6
DCS 402.0200 200 1 x 70 1 x 50 1 x 70 163 1 x 70 1 x 50 1 x 50 1 x 35 1 x 25 1 x 25 M10 25
DCS 402.0260 260 1 x 120 1 x 70 1 x 95 212 1 x 95 1 x 70 1 x 70 1 x 50 1 x 35 1 x 35 M10 25
DCS 402.0350 350 2 x 70 1 x 120 1 x 120 286 2 x 50 1 x 120 1 x 95 1 x 50 1 x 70 1 x 50 M10 25
DCS 402.0450 450 2 x 95 2 x 70 2 x 70 367 2 x 70 2 x 70 2 x 50 1 x 70 1 x 70 1 x 50 M10 25
DCS 402.0550 550 2 x 120 2 x 95 2 x 95 465 2 x 120 2 x 70 2 x 70 1 x 120 1 x 70 1 x 70 M10 25
DCS 402.0680 * 680 2 x 185 2 x 120 2 x 120 555 2 x 150 2 x 120 2 x 95 1 x 150 1 x 120 1 x 95 M12 50
DCS 402.0820 * 820 2 x 240 2 x 150 2 x 150 669 2 x 240 2 x 150 2 x 120 1 x 240 1 x 150 1 x 120 M12 50
DCS 401.1000 * 1000 2 x 300 2 x 185 2 x 185 816 2 x 240 2 x 150 2 x 150 1 x 240 1 x 150 1 x 150 M12 50
* Busbar connection 5 x 40 mm is recommended

II K 3-4
Technical data
•The DCS 400 should be installed in an enclosure
that is minimum 150% of the dimensions of con-
verter.
•The DCS 400 is suitable for use in a circuit capable
of delivering not more than 18 kA rms Symetrical
amperes, 500 V AC maximum. Recommended
fuses must be used to provide short circuit protec-
tion.
Table 3.2/2: Cross-sectional areas for UL installations of DCS 400
3.2.2 Cross-sectional areas for UL installations
Note: 60°C wire up to 100 A, 75°C wire over 100 A
Note: Use UL listed ring terminals for connections to drives
Unit type C1, D1 U1, V1, W1 PE
1 x M.. [Nm]
IDC
[A-]
Wire
size
[AWG or
MCM]
Iv
[A~]
Wire
size
[AWG]
Wire
size
[AWG]
DCS 401.0020 20 1 x 10 16 1 x 14 12 M6 6
DCS 401.0045 45 1 x 4 36 1 x 6 10 M6 6
DCS 401.0065 65 1 x 3 52 1 x 4 8 M6 6
DCS 401.0090 90 1 x 1/0 74 1 x 2 8 M6 6
DCS 401.0125 125 1 x 2/0 102 1 x 2/0 6 M6 6
DCS 401.0180 180 1 x 4/0 147 1 x 4/0 6 M10 25
DCS 401.0230 230 1 x 350 188 1 x 300 4 M10 25
DCS 401.0315 315 2 x 3/0 257 2 x 3/0 3 M10 25
DCS 401.0405 405 2 x 250 330 2 x 250 2 M10 25
DCS 401.0500 500 2 x 400 408 2 x 350 2 M10 25
DCS 401.0610 610 * 498 * 0 M12 50
DCS 401.0740 740 *604* 0M1250
DCS 401.0900 900 * 735 * ??? M12 50
DCS 402.0025 25 1 x 8 20 1 x 12 10 M6 6
DCS 402.0050 50 1 x 4 41 1 x 6 10 M6 6
DCS 402.0075 75 1 x 2 61 1 x 3 10 M6 6
DCS 402.0100 100 1 x 1/0 82 1 x 1 8 M6 6
DCS 402.0140 140 1 x 2/0 114 1 x 2/0 6 M6 6
DCS 402.0200 200 1 x 250 163 1 x 250 6 M10 25
DCS 402.0260 260 2 x 2/0 212 1 x 400 4 M10 25
DCS 402.0350 350 2 x 4/0 286 2 x 4/0 3 M10 25
DCS 402.0450 450 2 x 300 367 2 x 300 2 M10 25
DCS 402.0550 550 2 x 500 465 2 x 400 1 M10 25
DCS 402.0680 680 *555* 0M1250
DCS 402.0820 820 * 669 * 2/0 M12 50
DCS 401.1000 1000 * 816 * ??? M12 50
* Busbar connection 5 x 40 mm required
Under preparation
Under preparation

II K 3-5
Technical data 3.3 Power losses
Converter type Power losses PL [W]
Load
IDC [A] 25% 50% 75% 100%
DCS401.0020 20 10 22 35 49
DCS401.0045 45 25 57 95 145
DCS401.0065 65 38 80 128 181
DCS401.0090 90 48 103 166 236
DCS401.0125 125 65 138 220 311
DCS401.0180 180 96 210 341 490
DCS401.0230 230 116 254 413 594
DCS401.0315 315 163 339 526 726
DCS401.0405 405 218 444 697 969
DCS401.0500 500 236 513 830 1188
DCS401.0610 610 312 653 1025 1427
DCS401.0740 740 380 799 1259 1758
DCS401.0900 900 467 993 1578 2222
DCS402.0025 25 13 28 46 65
DCS402.0050 50 28 65 109 162
DCS402.0075 75 44 95 152 217
DCS402.0100 100 53 116 188 270
DCS402.0140 140 73 157 252 357
DCS402.0200 200 108 238 389 562
DCS402.0260 260 133 293 481 696
DCS402.0350 350 182 265 591 818
DCS402.0450 450 237 499 785 1096
DCS402.0550 550 262 573 933 1342
DCS402.0680 680 349 736 1160 1622
DCS402.0820 820 423 895 1416 1986
DCS402.1000 1000 522 1116 1786 2527
Table 3.3/1: DCS 400 Power losses of armature circuit
Remarks on the table
•The values stated are are maximum values ob-
tained under the most unfavourable conditions.
2-Quadrant4-Quadrant
DCS 400 armature circuit
DCS 400 field supply
Fig. 3.3/1: DCS 400 Power losses of field supply
0
50
100
150
200
01234567891011121314151617181920
440V
350V
150V
50V
[W]
[A] I
e
PL

II K 3-6
Technical data 3.4 Power section cooling
Fan assignment for DCS 400
Fan data for DCS 400 (data per fan)
Fan connection for DCS 400
Configuration 3
Configuration 2
Configuration 1
Table 3.4/2: Fan data for DCS 400
Table 3.4/1: Fan assignment for DCS 400
Monitoring the DCS 400 power section
The power sections are monitored by an electrically
isolated PTC thermistor detector. First an alarm will
be outputted, and - if the temperature continues to
rise - an error message. This will switch off the unit
in a controlled manner.
12 3X99: 45
L N
9DF
12 3X99: 45
L N
9DF
M
~
12 3X99:
M
~
45
M55 M56
M
~
12 3X99:
M
~
45
M55 M56
M
~M ~
M57 M58
12 3X99: 45
L N
9DF
12 3X99: 45
L N
9DF
M55
M
~
12 345X99:
LN
L N
HLWKHU9DF
RU9DF
Converter type Size Fan type Configuration
DCS 40x.0020...DCS 40x.0025 A1 no Fan -
DCS 40x.0045...DCS 40x.0140 A1 2x CN2B2 1
DCS 40x.0180...DCS 40x.0260 A2 2x CN2B2 1
DCS 40x.0315...DCS 40x.0350 A3 2x CN2B2 1
DCS 40x.0405...DCS 40x.0550 A3 4x CN2B2 2
DCS 40x.0610...DCS 40x.0820 A4 1x W2E200 (230 V) 3
DCS 40x.0610. 2...DCS 40x.0820. 2 A4 1x W2E200 (115 V) 3
DCS 40x.0900...DCS 40x.1000 A4 1x W2E250 (230 V) 3
DCS 40x.0900. 2...DCS 40x.1000. 2 A4 1x W2E250 (115 V) 3
Fan type CN2B2 W2E200 W2E200 W2E250 W2E250
Rated voltage [V] 115; 1~ 230; 1~ 115; 1~ 115; 1~ 230; 1~
Tolerance [%] ±10 +6/-10 +6/-10 ±10 +6/-10
Frequency [Hz] 50 60 50 60 50 60 50 60 50 60
Power consuption [W] 16 13 64 80 64 80 120 165 135 185
Current consumption [A] 0.2 0.17 0.29 0.35 0.6 0.7 1.06 1.44 0.59 0.82
Stall current [A] < 0.3 < 0.26 < 0.7 < 0.8 <1.5 <1.8 <1.8 <1.8 <0.9 <0.9
Air volume, freely blowing [m3/h] 156 180 925 1030 925 1030 1835 1940 1860 1975
Noise levelt [dBA] 44 48 59 61 59 61 66 67 68 70
Max. ambient temperature [°C] < 60 < 75 < 75 60 60
Useful lifetime of fan appr. 40000
h/60°
appr. 45000
h/60°
appr. 45000
h/60°appr. 40000 h appr. 40000 h
Protection Stall Overtemperature

II K 3-7
Technical data 3.5 Control Board SDCS-CON-3A
Control functions (Watchdog)
The control board has an internal watchdog. The
watchdog trip has the following effects:
- Thyristor firing control is reset and disabled.
- Digital outputs are forced to '0 V'.
Fig. 3.5/1 Layout of the control board SDCS-CON-3A
Fig. 3.5/2 Seven segment display of the SDCS-CON-3A
Seven segment display
A seven segment display is located on the control
board and it shows the state of drive.
If +5 V drops under the tripping level, it causes a
master reset by hardware. All I/O registers are forced
to 0 and the firing pulses are suppressed.
If mains monitor trips, firing pulses are forced to
inverter stability limit.
Supply voltage monitoring
Supply voltage +5 V Mains
Undervoltage tripping level +4.50 V £97 VAC
Serial interfaces
The control board SDCS-CON-3A has three serial
communication channels:
•X7: is a serial communication channel which is
used for
- DCS 400 PAN
- Adapter (3AFE 10035368)
•X6: is a standard RS232 serial communication
channel. It is a 9-pin D-Sub female connector
•V800 is an integrated channel and can be used
for Fieldbus Adapter by using optical fibre
1
2
1
2
3
10
11
12
13
4
2
X1 X2 X3 X4 X5 X8
S4

S2

S1

5
6
R115
X6
S5

X7
X12X13
41 91 81 101 5 1 2
233.5
190

6
6
6

5
6
5
6
1
2
311 12
10 1
2
311 12
10
1
2
311 12
10 1
2
311 12
10
5 V 24 V
5 V 24 V
13
42
13
4
2
6
RS232
DDCS
V800

S5:5-6 int.Micro-controller Flash Prom
S5:1-2 Boot Mode
+10V
S1:
-
+
22 K
4
X2:3
56PTC
5GND
15
6
2
1
2
1
2

12
78
12
78
-XPSHUFRGLQJ
default value
AI2 used for temp.
measurement via PTC
single ended:
Tacho and PTC
All supports are conductive
connected to GND
differential:
Pulse encoder
Tacho signal
connected to GND
AI2 as ref input
Firmware download via RS232
Note: change Jumper position only if electronics is switched off
Firmware download
Normal operation
For firmware download via RS232
S5:1-2 and 5-6 have to be jumpered
Meas. point
IA act
'RQRWFKDQJH
MXPSHUVHWWLQJRI6
*
Tacho signal not
connected to GND
(park position only)
-
-
-
+
4
2
3
X1:1
GND
1
S1
T
-
+2
34
0.7s 0.7s 0.7s
RAM/ROM memory test error
Normal situation
Program is not running
Alarm
Fault

II K 3-8
Technical data
Fig. 3.5/3 Terminal connection of the SDCS-CON-3A board
Digital and analogue I/O connection of the SDCS-CON-3A
Reso- Input/output Scaling Load Common Remarks
lution values by mode
[bit] Hardware range
±90...270 V
11 + sign ±30...90 V R 115/ ±20 V ➀ ➁
±8...30 V Software
11 + sign -11...0...+11 V Software ±20 V ➀ ➁
11 + sign -11...0...+11 V Software ±40 V ➀ ➁
£10* mA for external use
£10* mA e.g. reference pot.
11 + sign -11...0...+11 V Software £5 * mA
11 + sign -11...0...+11 V Software £5 * mA
Encoder supply Remarks
Inputs not isolated
max. frequency £300 kHz
5V/ 24V £200 mA* Selectable with jumper S2: 10-12
Input value Signal definition Remarks
by
0...+5 V Software ^ = "0" status
+15...+30 V ^ = "1" status
Output value Signal definition Remarks
by
50 * mA Software Current limit for all 4 outputs =
160 mA
➀ total smoothing time £2 ms
➁ -20...0...+20 mA by external 500 Wresistor
* short circuit proof
The terminal connectors X1: ... X5: are removable. They cannot be
interchanged
Note
Unless otherwise stated, all signals are
referenced to a 0 V potential. On all PCBs,
this potential is firmly connected to the
unit's casing by means of plating-through
at the fixing points.
AITAC
90-270 V
30-90 V
8-30 V
+24V
ChA +
ChA -
ChB +
ChB -
ChZ +
ChZ -
GND
0 V
R115
+10V
S1:
100µ
+24 V/ ≤50 mA
100k
1n
1n
47n
100k
100k 100k
Power-Source
AI1
-
+
-
+
-
-
-
+
AO1
AO2
47.5
100µ
100n
+10V
0V
-10V
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
470k
22n
10k
4.75k
DO4
DO1
DO2
DO3
22 K
5
6
7
4
3
8
9
X4:1
2
3
4
5
6
7
8
10
4
5
1
2
3
4
2
3
2
X2:1
9
4
5
7
2
3
6
8
X1:1
X3:1
X5:
6'&6&21 Software
GND
3
4
2
1
S1
AI2
+5/+24V
123
120 Ω
+5/+24V
456 120 Ω
+5/+24V
789 120 Ω
S2
+5V +24V
10 11 12
56
A

II K 3-9
Technical data
3.6 Power Interface Board SDCS-PIN-3A
The power interface board SDCS-PIN-3A is used
for all converter modules model A1...A4.
Functions:
- firing pulse circuits
- measurement of the armature current
- snubber circuit
- AC and DC voltage measurement
- heat sink temperature measurement
Fig. 3.6/1 Layout of the SDCS-PIN-3A board.
- power supply for complete converter electronics
- fuses for field supply. Fuse data F100...F102:
Bussmann KTK-15A (600V)
Output X98:1-2 (DO5)
Potential isolated by relay (N.O. contact)
MOV- element (275 V)
Contact rating: AC: £250 V~/ £3 A~
DC: £24 V-/ £3 A-
or £115/230 V-/ £0.3 A-)
AC Supply voltage (X98:3-4)
Supply voltage 115...230 V AC
Tolerence -15%/+10%
Frequency 45 Hz ... 65 Hz
Power consumption 120 VA
Power loss £60 W
Inrush current 20 A/10 A (20 ms)
Mains buffering min 30 ms
X6
T24 T22 T26 T11 T15 T13
X14 X11
X100
X15
X16
X22
T1
X12X13
T14 T12 T16 T21 T25 T23
F100 F101 F102
X10
X24
X21
X23
X20
X98
1234
PTC
12
C1 U1 V1 W1 D1
258
225
F+
'2
F-
T2
X1
X2
X7
X3 X4 X5
Electronic
supply
115...230 V
to motor field

II K 3-10
Technical data
The DCS 400 converter has an build-in three-phase
field exciter with the following features:
•smoothed field voltage
- better commutation of the motor
- increased brush life
•less heat generation in the motor
•less effort of cabling Fig. 3.7/1 Layout of the SDCS-FIS-3A field exciter
board
3.7 Field exciter SDCS-FIS-3A
Electrical data of SDCS-FIS-3A
AC input voltage: 230 V...500 V ±10%; three-phase
DC output voltage 50...440 V programmable
AC input current: £output current
AC isolation voltage: 600 V
Frequency: same as DCS converter module
DC output current: 0.1 A...4 A for armature converter modules from 20 A to 25 A
0.1 A...6 A for armature converter mod. from 45 A to 140 A
0.3 A...16 A for armature converter mod. from 180 A to 550 A
0.3 A...20 A for armature converter mod. for ³610 A
Power loss see chapter 3.3
Terminal X10:1,2 on SDCS-PIN-3A
Cross sectional area 4 mm²
Fig. 3.7/2 Diagram of the field exciter unit
Remark:
The DC link capacitor of the IGBT based field exciter
serves as an overvoltage protection for the armature
converter.
Overloading of the DC link capacitor is prevented by
the connected motor field winding.
The energy of glitches caused by the commutation of
the armature converter is no longer waste energy but
is used by the field exciter.
The overvoltage protection only works if a field wind-
ing is connected.
Therefore DCS400 can not be used with discon-
nected field.
X5
X3
X4 X6
X7 X2 X1
X14
T100
SDCS-FIS-3A
145
45
U1
V1
W1
SDCS-CON-3A X1 X2 X7
X10:2 X10:1
SDCS-PIN-3A SDCS-FIS-3A
X12: X12:
26
1
26
1
FPWM
8
IFM 9
8
9GND
3
3
X14: X14:
X11:2
3
X100:1-2 X6:1-3
X6X4X3
Converter
DC Output
(for motor field)
low level
control