ABB DCS800 Installation and operation manual

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

DCS800 Single Drive Manuals
All the documents available for the drive system DCS800 are listed below:
Language
Public. number E D I ES F CN
DCS800 Quick Guide 3ADW000191 x p p p p
DCS800 Tools & Documentation CD 3ADW000211 x
DCS800 Converter module
Flyer DCS800 3ADW000190 x x p x p p
Technical Catalogue DCS800 3ADW000192 x x x x p x
Hardware Manual DCS800 3ADW000194 x x p p p p
Firmware Manual DCS800 3ADW000193 x p p p p p
Installation according to EMC 3ADW000032 x
Technical Guide 3ADW000163 x
Service Manual DCS800 3ADW000195 x p
Planning and Start-up for12-Pulse converters 3ADW000196 p
CMA-2 Board 3ADW000136 p
Flyer Hard - Parallel 3ADW000153 p
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 CoDeSys CoDeSys_V23 x x x
61131 DCS800 target +tool description - Application Program 3ADW000199 x
Winding with the DCS 800XXXXX 3ADW000058
Winder application description
Flyer magnetic application
Magnetic application description
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
System description DCS800-A 3ADW000198 p p
Installation of DCS800-A 3ADW000091 p p
DCS800-R Rebuild System
Flyer DCS800-R 3ADW000007 p p
DCS800-R Manual 3ADW000197 p
DCS500/DCS600 upgrade manual
Extension Modules
RAIO-01 Analogue IO Extension 3AFE64484567 x
RDIO-01 Digital IO Extension 3AFE64485733 x
AIMA R-slot extension 3AFE64661442 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 01.2007
DCS800 Drive Manuals-List_c.doc

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:

3ADW000195R0101 DCS800 Service Manual e a
3ADW000197R0101 DCS800-R Sel e a

3
Table of contents
3ADW000xxxR0101 DCS800-R Sel e a
Table of contents
Introduction
How to use this manual .................................................................................................. 0H5
Contents of this manual.................................................................................................. 1H5
Associated publications.................................................................................................. 2H5
Basic Selection
Technical preconditions and limits ................................................................................. 3H7
Selecting the suitable Rebuild kit ................................................................................... 4H7
Hardware conditions .................................................................................................... 5H8
Drive´s design conditions ............................................................................................. 6H9
Conditions caused by the application........................................................................... 7H9
Type coding and accessories..................................................................................... 8H10
Hardware
Basic components of the DCS800-R kit ....................................................................... 9H13
Housing for main electronics ........................................................................................ 10H13
Pre-assembled part ...................................................................................................... 11H14
Loose parts................................................................................................................... 12H14
Optional parts ............................................................................................................... 13H15
Dimensions main electronic housing............................................................................ 14H16
Environmental conditions ............................................................................................. 15H17
Pulse transformer board SDCS-PIN-48........................................................................ 16H19
Wiring ......................................................................................................................... 17H19
Measurement board SDCS-PIN-51 .............................................................................. 18H20
Wiring ......................................................................................................................... 19H22
Fastening ................................................................................................................... 20H22
PTC temperature sensor............................................................................................ 21H22
HW type coding.......................................................................................................... 22H22
Voltage coding ........................................................................................................... 23H23
Nominal current coding .............................................................................................. 24H23
Additional settings ...................................................................................................... 25H25
Interface board SDCS-REB-1....................................................................................... 26H26
Power supply.............................................................................................................. 27H27
Functionality ............................................................................................................... 28H28
Fastening ................................................................................................................... 29H28
Diagram...................................................................................................................... 30H29
Interface board SDCS-REB-3....................................................................................... 31H30
Firing pulses............................................................................................................... 32H30
Signal flow and Thyristor designation ........................................................................ 33H30
Design hints ............................................................................................................... 34H32
Signal handling........................................................................................................... 35H32
Plug connectors X1113: and X2113:.......................................................................... 36H33
Interfacing the Electronics and Thyristors
Connection for 2-quadrant application – No parallel Thyristors ................................. 37H35
Connection for 4-quadrant application – No parallel Thyristors ................................. 38H36

4
Table of contents
3ADW000195R0101 DCS800 Service Manual e a
Connection for 4-quadrant application - parallel thyristors......................................... 39H37
Connection for 2-quadrant application - parallel thyristors......................................... 40H38
Installation
Background for the figures of this chapter ................................................................. 41H39
Hints for Cabling......................................................................................................... 42H51
Safety Instructions
What this chapter contains ........................................................................................... 43H53
To which products this chapter applies ........................................................................ 44H53
Use of warnings and notes ........................................................................................... 45H53
Installation and maintenance work ............................................................................... 46H54
Grounding................................................................................................................... 47H55
Mechanical installation ................................................................................................. 48H56
Operation...................................................................................................................... 49H56
Start-up
What this chapter contains ........................................................................................... 50H59
Safety Instructions...................................................................................................... 51H59
Points to be observed because of the situation ......................................................... 52H59
Maintenance work ...................................................................................................... 53H60
Tools .......................................................................................................................... 54H60
Measurements with the “old” equipment still working................................................. 55H60
Mounting the Kit ......................................................................................................... 56H61
Wiring the Kit.............................................................................................................. 57H61
Commissioning the Kit................................................................................................ 58H62

5
Introduction
3ADW000xxxR0101 DCS800-R Sel e a
Introduction
How to use this manual
The purpose of this manual is to provide you with the information
necessary to select the right rebuild kit with all the necessary or
available options, to install it, do the start-up and operate it as a DC
drive system. Depending on the kit's configuration, different func-
tionality and different options concerning the user interface are
available. As long as the hardware needs to be named or cross-
referenced to in a very general way, the term Rebuild kit will be
used.
Contents of this manual
Introduction describes how to use this manual and the boundary
conditions applying.
Basic Selection provides the information about the types of the
Rebuild kits, their type designations and options.
Hardware description provides the information about the boards
and components
Interfacing the Electronics and Thyristors provides the informa-
tion about the configurations and functions of drives and examples
of the whole circuit diagram.
Installation provides the information about required ambient condi-
tions, space requirements, cabling and wiring and how to install a
rebuild system.
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.

6
Introduction
3ADW000197R0101 DCS800-R Sel e a

7
Basic Selection
3ADW000197R0101 DCS800-R Sel e a
Basic Selection
Technical preconditions and limits
If an electrical drive is in operation for several years, most often discussions will be
started about items like:
-better factory automation based on latest technology
-decrease of standstill time of production
-availability of spare parts
-increase of productivity; perhaps an enlargement of the whole installation using
both types of drives, DC and AC drives
-and other arguments
These wishes can be turned into real life by:
-upgrading the drive itself completely
-upgrading only the converter, which had controlled the DC motor
-upgrading the converter´s electronics only
-upgrading a part of the converter´s electronics.
For a final solution, all the benefits described by:
• higher production • more accurate control
• design of state of the art • others
will be compared with the disadvantages of revamping described by:
• standstill time of production • hardware cost • training etc.
If this comparison is based on an upgrade of the converter´s electronics the Re-
build kit, which is described within this document, may be a solution. Before the fi-
nal decision is made to use a Rebuild kit, the configuration of the existing drive
needs to be checked more in detail to make sure the kit fulfills all demands.
Selecting the suitable Rebuild kit
The basic structure of a converter to control a DC motor looks like this:
The electronics of the existing converter indicated by the left box above is splitted
into 2 boxes in the kit.
The Rebuild kit can be used for armature bridges in non-regenerative or regenera-
Rebuild kit
electronics:
interface to
PLC
electronics:
interface to
thyristor
bridge
thyristor
bridge
Existing
Converter control electronics
with interface to:
- thyristor bridge
- PLC
thyristor
bridge

8
Basic Selection
3ADW000197R0101 DCS800-R Sel e a
tive mode with maximum 4 thyristors in parallel. In case there are more than 4 thy-
ristors in parallel per current direction there is no standard kit prepared; please con-
tact your local ABB organization.
To selecting the Rebuild kit, first the HARDWARE CONDITIONS must be checked
to become aware of critical limitations. If this is not a problem the DRIVE´S
DESIGN CONDITIONS will give some guidelines for the overall design. After that a
decision must be made for the functionality of the interface between the kit and the
Programmable Logic Controller. Depending on that, the Rebuild kit´s type code
can be fixed by using the type designations listed on the next pages. Afterwards
please check if all conditions are fulfilled as listed in CONDITIONS CAUSED BY
THE APPLICATION.
Hardware conditions
If a Rebuild kit is taken into consideration, the items listed afterwards will give
some help to decide whether a Rebuild kit or a converter module / enclosed con-
verter is the better solution.
-Before an existing DC power part is upgraded by the Rebuild kit, it should be
checked if a brand new module may be easier to install or may be a more reli-
able solution (tested power stack).
-The existing power bridge should be build up by max. 4 thyristors in parallel per
current direction (solution for more thyristors in parallel on request). It doesn't
matter whether the bridges have the same number of thyristors in parallel.
-The supply voltage used for the existing thyristor bridge has to be lower than
990 V because of the devices used to interface the electronics to the thyristors
(higher mains voltages on request).
-The thyristors actually used should be of a disk type. One single thyristor
bridge should be capable of running around 1000 A or more, if the converter is
built up by more than one bridge in parallel. If a single bridge cannot give this
current a brand new converter is probably the more economical solution.
-The ratio between reverse / forward blocking voltage of the thyristors and the
nominal line voltage should be factor 3 or higher the blocking voltage has to be
measured on a thyristor test stand if the actual blocking voltage gives a lower
ratio the thyristor(s) need to be replaced. In such a case, please check if a
complete new converter may be more economical.