dc drive abb
TRANSCRIPT
III i
DCS Thyristor Power Convertersfor DC drive systems
25 to 5150 A
Technical Data DCS 400DCS 500BDCS 600DCF 500BDCF 600
III ii
How to use the DCS Documentation System
The matrix below indicates all available product documentation and its corresponding order numbers on its left columns as well as all existingDC Drive systems on its top rows. System descriptions, Technical data and Operating instructions (as far as they are available for thecorresponding drive) are the basic documents and will be delivered together with each drive. All other documentation has to be orderedseparately.
DC drive systems System Drive Standard Drive RebuildCubicle Module Cubicle Module
Product documentation DC
A 6
00
DC
A 6
20
DC
S/D
CF
600
Mul
tiDriv
e
DC
S 6
00 C
rane
Driv
e
DC
A 5
00 /
DC
A 5
20
DC
S 5
00 E
asy
Driv
e
DC
S 4
00 E
asy
Driv
e
DC
S 4
00
DC
S/D
CF
500
B
DC
E 4
00
DC
R
System description Language Volume3ADW000066 EN, DE,FR II D x x x3ADW000072 EN, DE II F x x x3ADW000121 ➀ EN II F1 x x3ADW000095 (Manual) ➁ EN,DE,FR,IT,SP II K x x x3ADW000139 EN II F x x3ADW000071 (Flyer) EN, DE x3ADW000152 EN, DE,FR,IT,SP x3ADW000173 (Flyer) EN x
Technical Data Language Volume3ADW000165 EN III x x x
Operating Instructions Language Volume3ADW000055 EN,DE,FR,SP IV A x x x3ADW000080 EN, DE IV F x x x3ADW000091 (Installation) EN, DE IV F1 x x x x
Software description Language Volume3ADW000078 EN V D1 x x x3ADW000076 EN V F x x x3AST000953 ➂ EN x x
Tools Language Volume3AFE61178775 CMT/DCS500 EN - x x xEN 5926915-1 GAD EN - x x x3ADW000048 (Application blocks) EN V A2 x x x3AFY61296123 Drive Window EN - x x x x
Service Instructions Language Volume3ADW000093 EN, DE VI A x x x x x x x3ADW000131 EN VI K x x x
Fieldbus Language Volume3ADW000086 EN - x x x3ADW000097 EN - x x x x
Others Language Volume3ADW000115 12-Pulse operation EN VIII F2 x x3ADW000092 Rebuild manual EN XI H1 x3ADW000128 Paralleling DCS Conv. EN VIII D1 x x x x3ADW000040 12-Puls operation EN, DE VIII A2 x x
Status: 25.March.2002
➀ Covers information of Technical data➁ Covers information of Technical data, Operating Instructions, Software Description➂ Covers information of Operating Instructions, Software Description
avai
labl
e on
ly fo
r: D
CS
500
B /
600
driv
e sy
stem
s
III iii
Contents
III TECHNICAL DATA
1 Quick Guide..................................................................... III 1-11.1 DCS 500B .............................................................................................. III 1-21.2 DCF 500B ............................................................................................... III 1-31.3 DCS 600 ................................................................................................. III 1-41.4 DCF 600 ................................................................................................. III 1-51.5 DCS 400 ................................................................................................. III 1-6
2 Converter modules ......................................................... III 2-12.1 Dimensions .............................................................................................. III 2-22.2 Fuses - installed inside the converter (Size A5, C4) ............................... III 2-82.3 Cross-sectional areas - Tightening torques ............................................. III 2-92.4 Power losses .......................................................................................... III 2-102.5 Power section cooling ............................................................................ III 2-11
3 Control boards ................................................................ III 3-13.1 SDCS-CON-2 ......................................................................................... III 3-1
4 Power supply board ....................................................... III 4-14.1 SDCS-POW-1 .......................................................................................... III 4-1
5 Power interface boards .................................................. III 5-15.1 Power interface board SDCS-PIN-1x .................................................... III 5-15.2 Power interface board SDCS-PIN-20x .................................................. III 5-25.3 Galvanic isolation - T90, A92 ................................................................. III 5-55.4 Power interface board (SDCS-PIN-41 / PIN-5x) .................................... III 5-95.5 Fan current monitoring PW 1003 ......................................................... III 5-135.6 Zero current detection SDCS-CZD-01 ................................................. III 5-155.7 Power signal measuring board SDCS-MP-1 ....................................... III 5-16
6 Digital and analogue I/O boards .................................... III 6-16.1 Digital I/O board SDCS-IOB-2 ............................................................... III 6-26.2 Analogue I/O board SDCS-IOB-3 .......................................................... III 6-46.3 I/O Extension bord SDCS-IOE-1 ............................................................ III 6-8
7 Communication boards .................................................. III 7-17.1 Communication board SDCS-COM-5 .................................................... III 7-17.2 Control and communication board SDCS-AMC-DC .............................. III 7-27.3 DDCS Branchning unit NDBU-95 .......................................................... III 7-6
8 Field exciters .................................................................. III 8-18.1 SDCS-FEX-1 (internal) ........................................................................... III 8-18.2 SDCS-FEX-2 (internal) ........................................................................... III 8-28.3 DCF503A-0050 and DCF504A-0050 (external) .................................... III 8-48.4 DCF505 and DCF506 Overvoltage protection ....................................... III 8-8
9 Accesories ...................................................................... III 9-19.1 Accessories - Power circuit .................................................................... III 9-19.2 Accessories - Field ................................................................................. III 9-69.3 Fan, electronics ...................................................................................... III 9-7
Appendix A ..........................................................................III A-1Optical cables ................................................................................................ III A-1
We recommend to use both, SYSTEM
DESCRIPTION plus TECHNICAL DATA at thesame time in case you are planningand engineering your drive.
You will find all necessary technicalinformation in there to solve yourproblem.
III iv
III 1-1
1 Quick GuideGeneral remarksThe term “DCS thyristor power converter” is a general designation for basic DC converters from ABB. This termcan be found in many parts of the relevant documentation. The precise product name in accordance with thebrief descriptions given below characterizes a specific unit.
Brief description of DCS 500BThe DCS 500B unit range is an enhancement developed from the DCS 500 range.The DCS 500B is an armature converter with the following standard features:• Design and commissioning tools • Monitoring functions • Communication via databus • Human-machineinterface • More than 300 additional functions blocks programmable under Win-dows • Graphical Application Designer • Plain text display • FOR HIGH POWER
Brief description of DCF 500BWith software release 21.232 or higher DCS 500B has a '3-phase field exciter mode'. A DCF 500B is a three-phase field exciter based on the programmable DCS 500B software and the SDCS-CON-2 control board.The interface board PIN-1x is modified; - an overvoltage protection unit DCF 505/506 is required.
Brief description of DCS 600The DCS 600 converter family is based on the hardware developed for the DCS 500B type.Instead of a COM-x board, the SDCS_AMC_DC board is used. PC tools will be connected there, as well asthe APC (Application controller), if the APC is used as a PLC. If a different PLC is used, separate adaptermodules are needed. They must be connected to the AMC-DC board, too. The software code always beginswith S15.xxx for MultiDrive or S18.xxx for Crane drives.
Brief description of DCF 600The DCF 600 unit range is intended to be used for supplying motor fields and is based on the hardware andsystem configuration of the DCS 600 unit. The software is identical to the DCS 600 software. Similar to DCF500B units the DCF 505/506 overvoltage protection unit is required. The same modification is applied to thePIN-1x board, compared to DCF 500B.
Brief description of DCS 400The DCS 400 is the smallest drive in its class. The compact design has been partly achieved by a fully integratedfield exciter based on IGBT technology. A commissioning wizard - available on the control panel and the PCtool - makes start-up of the drive easy. In addition, the DCS 400 contains application macros.
III 1-2
1.1 DCS 500B
This functional overview of DCS 500B componentsmakes it easy to find detailed technical data in thecorresponding chapters.
L1K1
T2
Q1
F2
F3
X12
:
X13
:
X37
:
X1:
X2:
M
T
T
83
85
72
X17
:X
16:
X14
:
PC
+C
MT
/DC
S50
0
DCF 503A / 504A
CO
M 5
CO
N 2
PO
W 1
PIN
1x
PIN
51
DCF 501B / 502B
IOB
2x
IOB
3IO
E 1
PS
5311
X11
:
X33
:
PIN
20x
7 3
8 4
T3
F1
K5
K3
≤ 69
0V
≤ 10
00V
CD
P 3
12
SN
AT
6xx
FE
X 1
FE
X 2
Nxx
x-0x
µPM
DC
S 5
0.B
....
-.1-
21..
...
PIN
41
PIN
41
L3*
+24
V
Pow
ersu
pply
to fi
eldThree-phase field supply
CO
M x
- sh
ort
des
igna
tion
of c
om
pon
ents
anal
og
ue in
pu
t / o
utp
ut
alte
rnat
ive
EM
C f
ilter
Ear
th-f
ault
mo
nito
r
Fie
ld b
us
to th
e P
LC
optical fibre optical fibre
dig
ital
inp
ut /
out
pu
t
Leg
end
7.1
-
deta
ile
d de
scr
ipti
on
se
e c
hapt
er
7.1
see
Tec
hn
ical
Dat
a*
7.1
3.1
4.1
5.1
5.4
6.1
6.2
6.3
6.2
5.2
9.1
9.3
9.2
8.1
8.2
2
8.3
8.4
5.4
5.4
2
III 1-3
1.2 DCF 500B
This functional overview of DCF 500B componentsmakes it easy to find detailed technical data in thecorresponding chapters.
X1:
X2:
X17
:X
16:
CO
M 5
CO
N 2
X11
:
X33
:C
DP
312
µP
83
85
72
IOB
2x
IOB
3IO
E 1
PS
5311
7 3
8 4
Nxx
x-0x
+24
V
L1K3
T2
Q1
F2
X37
:
PC
+D
DC
-Too
l
PO
W 1
PIN
1x
DCF 506
PIN
20x
F1
K5
≤ 69
0V
≤ 50
0V
SN
AT
6xx
M
X12
:
X13
:
CZD-0x
to X
16: D
CS
500
B
(Arm
atur
e co
nver
ter)
to a
dig
ital i
nput
of D
CF
500
B
CO
N x
- sh
ort
des
igna
tio
n o
f co
mpo
nen
ts
anal
og
ue in
pu
t / o
utp
ut
alte
rnat
ive
EM
C f
ilter
Ear
th-f
ault
mo
nito
r dig
ital
inp
ut /
out
pu
t
Leg
end
7.1
-
mod
ified
optical fibre optical fibre
Fie
ld b
us
to th
e P
LC
7.1
3.1
4.1
5.1
6.1
6.2 6.
2
5.2
9.1
9.3
22
8.4
6.3
5.6
III 1-4
1.3 DCS 600
This functional overview of DCS 600 componentsmakes it easy to find detailed technical data in thecorresponding chapters.
DCF 601 / 602
X1:
X2:
X17
:
AM
C-D
C
X11
:
X33
:
DS
P
V260
CH
3
CH
0
CH
2
CO
N 2 µP X
16:
7 3
8 4
X14
:
72IO
E 1
Mo
nit
ori
ng
LE
D b
ar
NL
MD
Pan
elC
DP
312
L1K1
T2
Q1
F2
F3
M
T
T
83
85
PC
+D
rive
sWin
do
w+
FC
B
DCF 503 / 504
PO
W 1
PIN
1x
PIN
51
IOB
2x
IOB
3
PS
5311P
IN 2
0x
T3
F1
K5
K3
≤ 69
0V
≤ 10
00V
-ND
PA
-02
-ND
PC
-12
-NIS
A-0
3 (I
SA
)
FE
X 1
FE
X 2
M
PIN
41
PIN
41
L3N
DB
U95
(PC
MC
IA)
X12
:
X13
:
X37
:
Mul
tiD
rive
sock
etN
DP
I
A92
T90
CO
N x
- sh
ort
des
igna
tio
n o
f co
mpo
nen
ts
anal
og
ue in
pu
t / o
utp
ut
alte
rnat
ive
EM
C f
ilter
Ear
th-f
ault
mo
nito
r
to th
e P
LC
opt
ical
fib
red
igit
al in
put
/ o
utp
ut
Leg
end
7.1
PL
C-A
dvan
t c
on
tro
l
- o
ptio
nal
I/O
- M
aste
r/ F
ollo
wer
Fie
ld B
us
Ad
apte
rM
od
ule
N...
.
to other drives
Rev
D o
r la
ter
12-P
uls
e lin
k
Pow
ersu
pply Three-phase field supply
7.2
3.1
4.1
5.1
5.4
6.1
6.2 6.
2
5.3
5.2
9.1
9.3
9.2
8.1
8.2
2
8.3
5.4
5.4
7.3
6.3
2
8.4
III 1-5
1.4 DCF 600
This functional overview of DCF 600 componentsmakes it easy to find detailed technical data in thecorresponding chapters.
X1:
X2:
X17
:
AM
C-D
C
X11
:
X33
:
DS
P
V26
0
CH
3
CH
0
CH
2
CO
N 2
µP X16
:X
14:
X12
:
X13
:
X37
:
Mo
nit
ori
ng
LE
D b
arN
LM
D
Pan
elC
DP
312
Mul
tiD
rive
sock
etN
DP
I
L1K3
T2
Q1
F2
M
83
85
PC
+D
rive
sWin
do
w+
FC
B
DCS 600
PO
W 1
PIN
1x
DCF 506
IOB
2x
IOB
3
PIN
20x
F1
K5
≤ 69
0V
≤ 60
0V
M
ND
BU
95
-ND
PA
-02
-ND
PC
-12
-NIS
A-0
3 (I
SA
)
(PC
MC
IA)
72IO
E 1
7 3
8 4
CZD-0x
2
CO
N 2
- sh
ort
des
igna
tio
n o
f co
mpo
nen
ts
anal
og
ue in
pu
t / o
utp
ut
alte
rnat
ive
EM
C f
ilter
Ear
th-f
ault
mo
nito
r
to th
e P
LC
opt
ical
fib
red
igit
al in
put
/ o
utp
ut
Leg
end
7.1
-
PL
C-A
dvan
t c
on
tro
l
- o
ptio
nal
I/O
- M
aste
r/ F
ollo
wer
Fie
ld B
us
Ad
apte
rM
od
ule
N...
.
to other drives
mod
ified
Rev
D o
r la
ter
to a
dig
ital i
nput
of D
CF
600
7.2
3.1
4.1
5.1
6.1
6.25.2
9.1
9.3
2
8.4
7.3
6.3
5.6
III 1-6
1.5 DCS 400
Remark:All detailed information about the DCS 400 DC drive you can only find in the DCS 400Manual (documentation no. 3ADW 000 095).
L1K1
Q1
M
T
T
SD
CS
-CO
N-3
A
42
F1
230.
..500
V
µPM
DC
S 4
00
115.
..230
V A
C11
5 / 2
30 V
AC
82
1
RS232
SD
CS
-PIN
-3A
Nxx
x-0x
EM
C f
ilter
Fie
ld b
us
to th
e P
LC
Leg
end
Pow
erS
upp
ly
Thy
rist
or
con
tro
l
PC
+T
ool o
rP
LC
Con
trol
ele
ctro
nics
Field supplySDCS-FIS-3A
Inp
uts
/ Ou
tpu
ts
Serialinterfaces
optical fibre
dig
ital
in-
/ou
tput
, 24
V;
no g
alva
nic
isol
atio
nA
nalo
gue
out
pu
t; 1
1 b
it +s
ign
anal
og
ue in
pu
t; 1
1 b
it +s
ign
Rel
ay o
utp
ut;
250
V A
C, 3
A
Fie
ldco
ntr
ol
Co
ntr
ol p
anel
DC
S40
0PA
N
III 2-1
2 Converter modules
M
L1 L2 L3
F1x
F1x
F1x
F1x
F1x
F1x
DCS 500 / DCS 500B / DCS 600 / DCF 500B / DCF 600Unit range type DCF 500B and DCF 600 for output current of up to max. 520 A available2.1 Dimensions ............................................................................................ III 2-22.2 Fuses - installed inside the converter (Size A5, C4) ............................ III 2-122.3 Cross-sectional areas - Tightening torques ......................................... III 2-142.4 Power losses ........................................................................................ III 2-162.5 Power section cooling .......................................................................... III 2-19
Note:For clearness the type designationin this chapter is shown in the fol-lowing way:
Designation is valid for
DCS 500 DCS 500BDCS 600DCF 500BDCF 600
III 2-2
2.1 Dimensions
Module C1DCS 50x-0025DCS 50x-0050DCS 50x-0075
Dimensions in mmWeight appr. 7.6 kg
Module C1DCS 50x-0100DCS 50x-0110DCS 50x-0140
Dimensions in mmWeight appr. 11.5 kg
Fig. 2.1/1: Dimension drawing C1-Module
Fig. 2.1/2: Dimension drawing C1-Module
(+) (-)
250
Center of hinge
Swinging radius
(+) (-)
Swinging radius
Center of hinge
DCS 500 valid for DCS 500B / DCS 600 / DCF 500B / DCF 600
III 2-3
Module C2DCS 50x-0200DCS 50x-0250DCS 50x-0270DCS 50x-0350
Dimensions in mmWeight appr. 22,8 kg
Module C2DCS 50x-0450DCS 50x-0520
Dimensions in mmWeight appr. 29 kg
Busbars in mm: 25 x 3
Busbars in mm: 30 x 5
Fig. 2.1/3: Dimension drawing C2-Module
Fig. 2.1/4: Dimension drawing C2-Module
DCS 500 valid for DCS 500B / DCS 600 / DCF 500B / DCF 600
(+) (-)
150
250
176 (0200/0250)191 (0270/0350)
Swinging radius
Center of hinge
(+) (-)
150
250
Swinging radius
Center of hinge
III 2-4
Module C2DCS 50x-0680DCS 50x-0820DCS 50x-1000
Dimensions in mmWeight appr. 42 kg
DCS 500 valid for DCS 500B / DCS 600
Fig. 2.1/5: Dimension drawing C2-Module
150
250
Swinging radius
Center of hinge
10
M1266 50
C1 D1
V1U1 W1
Main Connectionsat view from top
III 2-5
Module A5DCS 50x-0903DCS 50x-1203DCS 50x-1503DCS 50x-2003
Dimensions in mmWeight appr. 110 kg
Fig. 2.1/6: Dimension drawing A5-Module
Busbars in mm:DC 80 x 10AC 60 x 5
DCS 500 valid for DCS 500B / DCS 600
510
450
127.5 125 125
U1 V1 W1
55
276
400
461483
102
earthing M12
C1 D1
325.5
65.5 25 50 50 50
Ø 14
17.75
44.5
8069
earthing M12
773
400
85.517 26
for M10
22
Ø 14
1726
34
1005
820
775
III 2-6
Module C4Connection right-handsideDCS 50x-2050-xxRx..DCS 50x-2500-xxRx..DCS 50x-2650-xxRx..DCS 50x-3200-xxRx..DCS 50x-3300-xxRx..DCS 50x-4000-xxRx..DCS 50x-4750-xxRx..DCS 50x-5150-xxRx..
Dimensions in mmWeight appr. 350 kg
Busbars in mm:100 x 10
Fig. 2.1/7: Dimension drawing C4-Module with AC/DC power connection Right-hand side
DCS 500 valid for DCS 500B / DCS 600
(+)/ (-)
(max 654 *)
(310
*)
* for 1000 V units
Holes 14x20
A - A B - B C - C
A A
C C
BB
III 2-7
Module C4Connection left-handsideDCS 50x-2050-xxLx..DCS 50x-2500-xxLx..DCS 50x-2650-xxLx..DCS 50x-3200-xxLx..DCS 50x-3300-xxLx..DCS 50x-4000-xxLx..DCS 50x-4750-xxLx..DCS 50x-5150-xxLx..
Dimensions in mmWeight appr. 350 kg
Busbars in mm:100 x 10
Fig. 2.1/8: Dimension drawing C4-Module with AC/DC power connection Left-hand side
DCS 500 valid for DCS 500B / DCS 600
(+) / (-)
(max 654 *)
(310
*)
* for 1000 V units
Holes 14x20
A - A B - B C - C
A A
C C
BB
III 2-8
Converter type Model Fuse F1 Size Manufacturer / Type Inside calip. [mm]
400 V / 500 VDCS 50x-1203-41/51 A5 700A 690V UR 5 Bussman 170M 6162 110DCS 50x-1503-41/51 A5 1250A 660V UR 5 Bussman 170M 6166 110DCS 50x-2003-41/51 A5 1600A 660V UR 5 Bussman 170M 6169 110DCS 50x-2500-41/51 C4 1700A 1000V UR 8 Bussman 170M 7034DCS 50x-3300-41/51 C4 2200A 1000V UR 8 Bussman 170M 7035DCS 50x-4000-41/51 C4 2500A 660V UR 7 Bussman 170M 7026DCS 50x-5150-41/51 C4 3000A 660V UR 7 Bussman 170M 7028600 V / 690 VDCS 50x-0903-61/71 A5 630A 1250V UR 6 Bussman 170M 6144 110DCS 50x-1503-61/71 A5 1100A 1250V UR 6 Bussman 170M 6149 110DCS 501-2003-61/71 A5 1400A 1000V UR 6 Bussman 170M 6151 110DCS 50x-2050-61/71 C4 1100A 1000V UR 8 Bussman 170M 7031DCS 50x-2500-61/71 C4 1700A 1000V UR 8 Bussman 170M 7034DCS 50x-3300-61/71 C4 2200A 1000V UR 8 Bussman 170M 7035DCS 50x-4000-61/71 C4 2500A 1000V UR 8 Bussman 170M 7036DCS 50x-4750-61/71 C4 2500A 1000V UR 8 Bussman 170M 7036790 VDCS 50x-2050-81 C4 1100A 1000V UR 8 Bussman 170M 7031DCS 50x-3200-81 C4 2200A 1000V UR 8 Bussman 170M 7035DCS 50x-4000-81 C4 2500A 1000V UR 8 Bussman 170M 7036DCS 50x-4750-81 C4 2500A 1000V UR 8 Bussman 170M 70361000 VDCS 50x-2050-91 C4 1500A 1250V UR 9 Bussman 170M 7510DCS 50x-2650-91 C4 1500A 1250V UR 9 Bussman 170M 7510DCS 50x-3200-91 C4 2000A 1250V UR 9 Bussman 170M 7513DCS 50x-4000-91 C4 2100A 1500V UR 10 Bussman 170M 7520
Table 2.2/1: Fuses installed inside the converter
2.2 Fuses - installed inside the converter
Size 5, 6, 11
Size a b c d5 50 29 30 76
5a 50 29 30 76+14*6 80 14 30 76
11 50 29 25 61 * tag for clip-on switch
Size A7 628 909 10510 120
Size 7...10
Remark:Given dimensions may be exeeded insome cases. Please take them only forinformation.
15
4xM10min 10 deep
Ø 3
3
2525
100
67.5
82.5
Ø 11
max 105
Ø 5
6
A8
max
105
max
d
max d108
c11
11
14 17
139
6
b a b
Indicator
Fig. 2.2/1: Fuses size 5, 6, 11
Fig. 2.2/2: Fuses size 7...10
L1 L2 L3
F1x
F1x
F1x
F1x
F1x
F1x
DCS 500 valid for DCS 500B / DCS 600
III 2-9
epyttinU )1MK,1MA(1D,1C )5KA,3KA,1KA(1W,1V,1U EP
]mN[
CDI]-A[
.1
]²mm[
).2(
]²mm[vI
]~A[
.1
]²mm[
).2(
]²mm[ ]²mm[
xx-5200-x05SCD 52 4x1 - 02 4x1 - 4x1 6Mx1 6
xx-0500-x05SCD 05 01x1 - 14 6x1 - 6x1 6Mx1 6
xx-5700-x05SCD 57 52x1 - 16 52x1 - 61x1 6Mx1 6
xx-0010-x05SCD 001 52x1 - 28 52x1 - 61x1 6Mx1 6
xx-0110-x05SCD 011 52x1 - 09 52x1 - 61x1 6Mx1 6
xx-0410-x05SCD 041 53x1 - 411 53x1 - 61x1 6Mx1 6
xx-0020-x05SCD 002 53x2 59x1 361 52x2 59x1 52x1 8Mx1 31
xx-0520-x05SCD 052 53x2 59x1 402 52x2 59x1 52x1 8Mx1 31
xx-0720-x05SCD 072 53x2 59x1 022 52x2 59x1 52x1 8Mx1 31
xx-0530-x05SCD 053 07x2 - 682 05x2 05x1 8Mx1 31
xx-0540-x05SCD 054 59x2 - 763 59x2 - 05x1 01Mx1 52
xx-0250-x05SCD 025 59x2 - 424 59x2 - 05x1 01Mx1 52
xx-0860-x05SCD 086 021x2 - 555 021x2 - 021x1 21Mx1 05
xx-0280-x05SCD 028 051x2 - 966 021x2 - 021x1 21Mx1 05
xx-3090-x05SCD 009 59x4 051x3 437 07x4 59x3 051x1 21Mx2 05
xx-0001-x05SCD 0001 581x2 - 618 051x2 - 051x1 21Mx1 05
xx-3021-x05SCD 0021 021x4 - 979 59x4 021x3 581x1 21Mx2 05
xx-3051-x05SCD 0051 581x4 - 4221 051x4 - 051x2 21Mx2 05
xx-3002-x05SCD 0002 021x8 581x6 2361 042x4 - 042x2 21Mx2 05
xx-0502-x05SCD 0502 021x8 581x6 3761 021x6 051x5 021x3 21Mx4 05
xx-0052-x05SCD 0052 581x7 - 0402 021x8 581x6 021x4 21Mx4 05
xx-0562-x05SCD 0562 581x7 - 2612 021x8 581x6 021x4 21Mx4 05
xx-0023-x05SCD 0023 581x8 - 1162 581x7 - 051x4 21Mx4 05
xx-0033-x05SCD 0033 581x8 - 3962 581x7 - 051x4 21Mx4 05
xx-0004-x05SCD 0004 003x7 - 4623 042x8 - 042x4 21Mx4 05
xx-0574-x05SCD ➀ 0574 003x8 - 6783 003x6 - 003x3 21Mx4 05
xx-0515-x05SCD ➀ 0515 003x8 - 2024 003x6 - 003x3 21Mx4 05
You will find instructions on how to calculate the PEconductor’s cross-sectional area in VDE 0100 or inequivalent national standards. We would remind youthat power converters may have a current-limitingeffect.
2.3 Cross-sectional areas - Tightening torques
➀ Reduced ambient temperature 40°C
Table 2.3/1: Cross-sectional areas - tightening torques
Recommended cross-sectional area to DINVDE 0276-1000 and DINVDE 0100-540 (PE) trefoil arrangement, up to 50°C ambienttemperature.
DCS 500 valid for DCS 500B / DCS 600 / DCF 500B / DCF 600
III 2-10
Converter type y → y=4 (400 V) y=5 (500 V) y=6 (600 V) y=7 (690 V) y=8 (790 V) y=9 (1000V)
x=1 → 2-Q IDC [A] [W] [W] [W] [W] [W] [W]
x=2 → 4-Q 4Q 2Q PV-I PV-U PV-I PV-U PV-I PV-U PV-I PV-U PV-I PV-U PV-I PV-U
DCS50x-0025-y1 25 25 60 30 60 47DCS50x-0050-y1 50 50 123 30 123 47DCS50x-0050-61 50 50 108 46DCS50x-0075-y1 75 75 175 30 175 47DCS50x-0100-y1 100 100 207 50 207 70DCS50x-0110-61 110 100 284 100DCS50x-0140-y1 140 125 311 50 311 70
DCS50x-0200-y1 200 180 488 50 488 70DCS50x-0250-y1 250 225 656 50 656 70DCS50x-0270-61 270 245 781 100DCS50x-0350-y1 350 315 840 50 840 70DCS50x-0450-y1 450 405 1040 70 1040 80 1119 110DCS50x-0520-y1 520 470 1238 70 1238 80DCS50x-0680-y1 680 610 1622 105 1622 140DCS50x-0820-y1 820 740 1986 125 1986 160DCS50x-1000-y1 1000 900 2527 125 2527 160
DCS50x-0903-y1 900 900 4326 617 4326 617DCS50x-1203-y1 1200 1200 3882 202 3882 315DCS50x-1503-y1 1500 1500 4295 202 4295 315 5157 454 5295 617DCS50x-2003-y1 2000 2000 5467 202 5467 315 5205 454 6078 617
DCS50x-2050-y1 2050 2050 8017 503 8017 665 8017 871 7278 1396DCS50x-2500-y1 2500 2500 7611 305 7611 476 7611 685 7611 907DCS50x-2650-y1 2650 2650 10673 1396DCS50x-3200-y1 3200 3200 10287 871 11073 1396DCS50x-3300-y1 3300 3300 10764 305 10764 476 10764 685 10764 907DCS50x-4000-y1 4000 4000 12251 305 12251 476 12914 503 12914 665 12914 871 14430 1396DCS50x-4750-y1 4750 4750 14309 503 14309 665 14309 871DCS50x-5150-y1 5150 5150 15322 305 15322 476
Table 2.4/1: DCS 500 Power losses
2.4 Power losses
The units’ power loss is made up of several differentcomponents:• current-dependent losses PV-I
- of the thyristors- of the fuses- of the busbar system
• voltage-dependent losses PV-U
- snubber circuit of the thyristors
• almost constant losses PV-C
- unit electronics- unit fan- field supply
Depending on what you want to achieve by yourpower-loss study, you must make up your mind on thefollowing points:
• Efficiency calculation for the drive system con-cerned:
For this purpose, all the power-loss compo-nents mentioned above (and additionally thelosses caused, for instance, by the motor fan,line reactor, cabling of network/power convert-er/motor, field supply unit and matching trans-former, etc.) must be added.
• Fan losses can be estimated by 85% of the fanpower consumption (see table 2.5/2).
Remarks on the table• The values stated are “worst case”, i.e. the values
obtained under the most unfavourable conditions.• The losses of the unit electronics can be assumed
to be PV-C = 30 ... 60 W, dependent on the loadinginvolved (SDCS-COMx, number of binary inputs to“1-signal”, pulse encoder used, etc.).
• The current-dependent losses can be convertedas follows for the partial load range:
− − −≈ +
* , *%
* , *%
0 6100%
0 4100%
2
• For the units 1000 A, the losses due to externalsemiconductor busbars, busbar systems/wiringare not included.
DCS 500
DCS 500 valid for DCS 500B / DCS 600 / DCF 500B / DCF 600
III 2-11
naF 2B25NC 341E2W 002E2W 052E2W 061E2D
rofR...D4-P53GR1yLxxxx-x05SCDrofL...D4-P53GR1yRxxxx-x05SCD
]V[egatlovdetaR ~1;032...802 ~1;032 ~1;032 ~1;032 ~1;032~3;004...083 .nnoc-
.nnoc-~3;096...514
]%[ecnareloT 01± 01-/6+ 01-/6+ 01-/6+ 01± 01±
]zH[ycneuqerF 05 06 05 06 05 06 05 06 05 06 05 06
]W[noitpmusnocrewoP 41 31 62 92 46 08 531 581 356 068 0083 0083
]A[noitpmusnoctnerruC 41.0 21.0 21.0 31.0 92.0 53.0 95.0 28.0 05.2 4.3 7.3/5.6 7.3/5.6<
]A[tnerrucgnikcolB 52.0< 2.0< 3.0< 4,0< 7.0< 8.0< 9.0< 9.0< 57.3 5.4 51/72 51/72<
m[gniwolbyleerf,emulovriA 3 ]h/ 651 081 573 044 529 0301 0681 5791 0011 -
m[tniopgnikroW 3 Ata]h/ - - - - -.rppa /0053A3.2 ➁
.rppa /0024A2.3 ➁
]C°[erutarepmettneibma.xaM 06< 58< 57< 06 55< 04<
esaergfoemitefillufesU .rppa °06/h00052 rppa °06/h00054. °06/h00054.rppa h00004.rppa °04/h00004.rppa °04/h00004.rppa
noitcetorP ecnadepmI ➀ :rotcetedrutarepmeT UN I;~V032 N ~A5.2
➀ gniebssalcnoitalusniehtrofelbissimrepnahtrehgih,erutarepmetgnidniwanitlusertonlliwrotordekcolbahtiwtnerrucdesaercnioteudsessoldesaercnI.devlovni
➁ V514tadesusinafehtfi,rewol%02.rppawolfriaehtdnarehgih%02.rppaeblliwtnerrucrotomehT
2.5 Power section cooling
Fan assignment for DCS 500
Fan data for DCS 500
Fan connection for DCS 500
Table 2.5/2: Fan data for DCS 500
Table 2.5/1: Fan assignment for DCS 500
Y
Y
DCS 500 valid for DCS 500B / DCS 600 / DCF 500B / DCF 600
Y
Y
Con-verter
Fan
Phase sequence is differ-ent for L and R type. Seecover of fan terminal box.
epytretrevnoC ledoM noitarugifnoC epytnaF
...1y-5200-x05SCD1y-5700-x05SCD
1C 1 2B25NC
...1y-0010-x05SCD1y-0410-x05SCD
1C 2 341E2W
...1y-0020-x05SCDy-0280-x05SCD
2C 3 002E2W
1y-0001-x05SCD 2C 3 052E2W
...1y-3090-x05SCD1y-3002-x05SCD
5A 4 061E2D
...1y-0502-x05SCD1y-0515-x05SCD
4C 5
rofR...D4-P53GR1yLxxxx-x05SCDrofL...D4-P53GR1yRxxxx-x05SCD
Config. 1
M~
1 2 3X2:
Config. 2
M~ϑ
1 2 3 4 5X2:
Config. 3
M~ϑ
1 2 3 4 5X2:
Config. 4 Config. 5
U1 V1 W1 U2 V2 W2 TK TKPE
M~ϑ
Voltage
380-400 V
415-690 V
Connection
U1-W2V1-U2W1-V2
U2-V2-W2
M~ϑ
2 31 5 6X2: 4
TW TW
III 2-12
Monitoring the DCS 500 power section
detector is used as for (a.) and (b.) above, but itis here not mounted on a heat sink but at theunit’s housing in the upper intake air zone. Thedetector thus measures the power section’sradiated heat and any changes in the cooling airtemperature and volume. Since the cooling airvolume can only be detected indirectly, a differ-ential-pressure switch has been additionally fittedat the unit’s housing.The resistance change proportional to thetemperature is acquired and evaluated in theunit’s software. If the temperature rises above theparameterized value, then first an alarm will beoutputted, and - if the temperature continues torise - an error message. The value to be set forthis parameter must not be more than 10 de-grees above the permissible ambient tempera-ture.The differential-pressure switch compares thepressure inside the unit with the normal atmos-pheric pressure. If the fan has been switched onand the unit door closed (and no unit casingshave been removed), the pressure switch willsignal “Cooling conditions ok”, which means thedrive may be enabled. There is no need to setany specific differential pressure (recommenda-tion: centre setting).
a.The power sections of sizes C1 and C2 aremonitored by an electrically isolated PTC ther-mistor detector, which is installed on the likewiseelectrically isolated heat sink near the thyristors.The resistance change proportional to thetemperature is acquired and evaluated in theunit’s software. If the temperature rises above acertain value predefined by the unit codinginvolved, then first an alarm will be outputted,and - if the temperature continues to rise - anerror message. This means that changes in therated cooling conditions, such as cooling airvolume and temperature, the fan itself, overloaddue to an excessively high load current, etc. aredetected.
b.The size-A5 power section is likewise monitoredby an electrically isolated PTC thermistor detec-tor, which is installed on the non-isolated heatsink in an isolated configuration by means of anadaptor plate and an isolating disk. Evaluation ofthe resistance and the protection effect corre-spond to those mentioned for point (a.) above.
c. The size-C4 power section is not directly moni-tored by an electrically isolated PTC thermistordetector. For this size, the same thermistor
DCS 500 valid for DCS 500B / DCS 600 / DCF 500B / DCF 600
III 3-1
The control board is based on the 80186EM micro-processor and the ASIC circuit DC94L01.
Fig. 3.1/1 Layout of the control board SDCS-CON-2
Fig. 3.1/2 Seven segment display of theSDCS-CON-2
- Digital outputs are forced low.- Programmable analogue outputs are reset tozero, 0V.
Seven segment displayA seven segment display is located on the controlboard and it shows the state of drive.
Memory circuits and the back-upThe program including system and parameter val-ues is stored at Flash PROM D33. Different pro-grams can be downloaded directly to thesePROMs. Application functionallity and parametervalues are saved in the Flash PROM D35.Fault and Alarm messages -the time of their ap-pearance and some other values like the operatinghours and so on- are stored in static RAM circuits.They have a back up capacitor of 1 F, which lastsminimum 8 hours, typically several days. It takesabout 30 minutes to charge the backup capacitor.
ASIC functionASIC = Application Specific Integrated CircuitMost of the measurements and control functions forthe DCS500 are done in the ASIC:
- communication with control panel (RS 485)- communication with field exciters (RS 485)- measurement- watchdog function- A/D and D/A-conversion control- thyristor firing pulse generation
Watchdog functionThe control board has an internal watchdog. Thewatchdog controls the running of the control boardprogram. If the watchdog trips, it has the followingeffects:
- Writing to FPROM is disabled.- Thyristor firing control is reset and disabled.
0.7s 0.7s 0.7s
RAM/ROM memory test error
During download sequence
Normal situation
Program is not running
Alarm
Fault
3 Control boards3.1 Control Board SDCS-CON-2
1
S1
R2716
23
222324
1
X4 X5 X6 X710 1 10 1 10 1 8
X310 1
X33
X37 X14
X18
X17
X12
X13
X2
ASIC
X21 X11
CPU
D33
D35
S2A1B1
A1B1
B1A1
21
21
A1B1 2 1 2 1
H1
233.5
247
21
Ch
AI2- X3:7
22-23
n. c. to +10V 22 kΩ ->+10V
23-24
*
5 V 12/24 V
5 V 12/24 V 13 mA
S1
*
123
222324
123
222324
123
222324
123
222324
123
222324
*
*
1 5
X16 B1A1 X1
V260
DDCC+
S2
*
S4 *
*
X34
S4**
247
TxD
RxD
1 562
1 7
82
1 7
82
1 7
82
1 562
1 562
1 7
82
1 562
Back upcapacitor
Jumper coding
default value
Terminal
Input AI2 used for temperature measurement via PTC
single ended:
Characteristics for pulse encoder inputs
All supports are conductiveconnected to GND
differential:
Initialisation with default values; read parameters from D33
Normal start; read parameters from D35 after initialisation
Tacho (+ and -) connected to AITAC; X3:4 connected to GND
Tacho (+ and -) connected to AITAC
Position, if SDCS-IOB-3 is connected
Bootstrap loader (can only be used with additional
hardware and a PC-program)
Position of jumpers 1-2, 3-4 is random;
7-8 is parking position for jumper 5-6
blue
grey
III 3-2
Fig. 3.1/3 Auxiliary power distribution on the board SDCS-CON-2
RS485 serial communication channelsThe control board has two RS485 channels. The firstchannel is used for field exciter control of DCF 501B/502B, DCF 503A/504A or DCF 601/602 (terminalsX16:1...3) and the second for the control panel (CDP)at terminals X33 or X34. The terminals X33 and X34are wired up in parallel internally.
DDCS Channel integratedThe control board SDCS-CON-2 has an integratedDDCS (Digital Drive Control System) channel with atranfer rate up to 4 Mbits/s. This channel (V260) e.g.can be used for fieldbus modules. The terminalsX16:4 and 5 are provided for power supply of themodules.
Fig. 3.1/5 Connection of the DDCS channel withpower supply to the control board SDCS-CON-2
Fig. 3.1/4 Connection for field supply units DCF xxxto the RS485 Communication Interface ofthe SDCS-CON-2 board.
Supply voltage +5 V +15 V -15 V +24 V +48 V1 +48 V2
Undervoltage tripping level +4.55 V +12.4 V - 12.0 V +19 V +38 V +38 V
Test terminals X37: B4 / B5 B10 B8 B11 B12 --------
Supply voltage monitoringThe control board monitors the following voltagelevels:
threshold a trip signal is generated.
In addition to that there is a monitoring function for the5 V level. If +5 V drops under the tripping level, itcauses a master reset by hardware. All I/O registersare forced to 0 and the firing pulses are suppressed.
+48V1
X37X37
+48V2
+24V
+15V
-15V
+5V
X37:A12,B12
A13
A11,B11
A10,B10
A8,B8
B2,B3,B4,B5
B8
A7
Reg.
X2:
SDCS-CON-2SDCS-POW-1
0VAGND
A9,B9
0VGND
A2,A3,A4,A5
X33:1
X34:1
Reg.
B1
Reg.
X16:4Reg.
+24 V for RS-485
+24 V Digital output
-10V /10 mA ref. source
+10V /10 mA ref. source
Watchdog
For Power Interface board andfield exciter
For digital input supply
For SDCS-CON-2 processor and its periferals
26 wireFlatcable Supply for signal
measurments
Powerfail prim. ("0" = o.k.)
Ref.regul.
+24 V for external fieldbus module ≤ 150 mA
Auxiliary power distributionThe electronic power supply board SDCS-POW-1(see separate chapter) generates different levels ofvoltages. Some of them are transferred via theCON-2 board directly to the boards, where they areused, others are manipulated and then transfered.
The electronic power supply system with the differentvoltage levels is monitored in two ways. There is asignal powerfail primary, which monitors the inputpower supply voltage of the POW-1 board and asignal powerfail secondary, which monitors the lowvoltage levels. If one voltage level drops below the
1 5
X16
GND
µTxD/RxD
RS485
RxD
TxD
1 5
X16
GND+24 V/≤ 150 mA
III 3-3
Fig. 3.1/6 Terminal connection of the SDCS-CON-2 board
Digital and analogue I/O connection of the SDCS-CON-2
Reso- Input/output Scaling Power Common Remarkslution values by mode[bit] Hardware range
±90...270 V12 + sign ±30...90 V R 2716/ ±20 V ➀ ➁ ➂ ➃
±8...30 V Software
12 + sign -10...0...+10 V Software ±20 V ➀ ➁ ➂
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂
5 * mA for external use5 * mA e.g. reference pot.
11 + sign -10...0...+10 V Software 5 * mA11 + sign -10...0...+10 V Software 5 * mAanalogue ±3 V fixed 5 * mA 3 V = nom. conv. curr.
Encoder supply Remarks
Inputs not isolatedImpedance = 120 if selectedmax. frequence 300 kHz
Sense lines for GND and supply to correct volt-age drops on cable (only if 5V/12V encoder is inuse)
5V/ 0.25 mA * Selectable on POW-1 board12V/24V 0.2 mA *
Input value Signal definition Remarksby
0...8 V Software = "0" status16...60 V = "1" status
Output value Signal definition Remarksby
50 * mA Software Current limit for all 7 outputs =160 mADo not apply any reversevoltages!
➀ total smoothing time 2 ms➁ -20...0...+20 mA by external 500 resistor➂ 4...20 mA by ➁ + Software function➃ Remove jumper S4:1-2 and 3-4 if SDCS-IOB-3 is used* short circuit proof (but a short-circuit can cause a malfunction of the drive)
The terminal connectors X3: ... X7: and X16: are removable. Whenconnecting the terminal blocks to the CON-2 board, please start withthe left connector at first and make sure, that they will be placed onthe board in the correct sequence and without spaces in between.
AITAC
90-270 V
30-90 V
8-30 V
+24V
AI4
ChA +
ChA -
ChB +
ChB -
ChZ +
ChZ -
GND
0 V
R2716
+10V
S1:23-24
100µ
+48 V/ ≤50 mA
100k1n1n
100n
100k
100k 100k
Power-Source
Sense GND
Sense Power +
0V
AI2
AI3
AI1
-
+
-
+
-
+
-
-
-
+
AO1AO2
+/- I-act
47.5100µ
100n
0V (AOx)
+10V
0V
-10V
DI1
DI2
DI3
DI4DI5
DI6
DI7DI8
47.5k
220n10k
4.75k
DO4
DO5
DO7
DO1
DO2
DO3
DO6
22 K
3
4
5
8
7
6
7
9
X6:1
2
3
4 5
6
7 8
10
4
5
7
1 2
3
6
4
2
3
6
5
9
10
8
9
10
2
4
5
7
2
3
6
8
9
10
8
X3:1
X4:1
X5:1
X7:
Software
+24V 7 8 910 11 12
+24V 13141516 17 18
+24V4 5 6
S1:1 2 3
S1:
GND
1 2
3 456
S4
III 3-4
III 4-1
AC Supply voltage
Supply voltage 115 V AC 230 V ACTolerence -15%/+10% -15%/+10%Frequency 45 Hz ... 65 Hz 45 Hz ... 65 HzPower consumption 120 VA 120 VAPower loss 60 W 60 WInrush current 20 A / 20 ms 10 A / 20 msMains buffering min 30 ms min 30 ms
Supply voltage +5 V * +15 V +24 V +48 V2Test terminals X 5 B X3 A X3 B heat sink T 10
* The 5 volt level can be checked, if 5 volt is selected!
4 Power Supply Board4.1 Power Supply Board SDCS-POW-1
Fig. 4.1/1 Layout of the SDCS-POW-1 board
Output X96-DO8Potential isolated by relay (NO contact)MOV- element (275 V)Contact rating: AC: 250 V~/ 3 A~
DC: 24 V-/ 3 A-or 115/230 V-/ 0.3 A-)
The SDCS-POW-1 board is designed for DCS 500converter modules and is mounted on the elec-tronic support. This board is used for all types ofmodules independant from current or voltagerange.
The SDCS-POW-1 works on a switched mode ba-sis in fly back configuration. It generates all neces-sary DC voltages for the SDCS-CON-2 and allother electronic boards. The input voltage can be
selected via the switch SW1 either to 230 V AC orto 115 V AC. The following figure shows the in-structions for the selection of the AC input voltageand for the selection of the encoder supply voltage.
If an SDCS-CON-2 (without I/O board IOB-3) to-gether with a pulse encoder is used for speedmeasurement, the incremental encoder supply volt-age must be selected by jumpers X5, X4 and X3.
Backup supplyThese two terminals are used to add additional ca-pacitance to the existing ones to increase themains buffering time. More detailed data is avail-able on request via your ABB representative.
SD
CS
-PO
W-1
LNX96 X9923
0 V
115 V
2 1
SW1
-+
X95
M1
1
X3713
1426
X5 X4 X3
AB
15V24V
5 V
AB
15 V
24 V AB
15V24V
AB
AB
15V24V
AB
AB
15V24V
AB
220
135
DO8
X5 X4 X3
230 V
110 V
230 V
115 V
230 V 115 V
T 10
12 V AB
15V24V
AB
AC supply selection
AC supply
Backup supplyfor SDCS-POW-1
Encoder supply selection
Relay output
default value
line potential !
Sense-function
yes
yes
no
no
III 4-2
III 5-1
5 Power interface boards5.1 Power Interface Board SDCS-PIN-1x
The power interface board is used for convertermodules model C1. There are 2 different versionsin use. The used types are:- SDCS-PIN-11 for 25 A, 50 A and 75 A converters
at 500V- SDCS PIN-12 for 50 A converters at 600 V
The SDCS-PIN-1x boards consists of:- firing pulse circuits and pulse transformers- measurement of the armature current via current
transformers- snubber circuit for thyristors protection
(consists of RC circuits and MOV elements)
Fig. 5.1/1 Layout of the SDCS-PIN-1x board.
- AC and DC high ohmic voltage measurement- heat sink temperature measurement via PTC
sensor- scaling for rated current, zero current detection
and HW type coding- If the SDCS-PIN-11 connection board is installed
in a DCF50x-0025...0075 / DCF60x-0025...0075,then the resistors R113, R116 and R119 are notbuild-in
Note:If this PCB is used as a spare part for a DCF.... ,then the resistors R113/R116/R119 (value = 0 )must be removed.
Table 5.1/1 Settings of the SDCS-PIN-1x board if aDCS converter is equipped with it by ABB
Board used as a spare part:- default: all jumpers W10-W82 are
in condition- ensure the correct converter type
related settings
Board type PIN 11 PIN 12Current transformer ratio 1500:1 1500:1Max. rated voltage [V] 500 500 500 600Rated current [A] 25 50 75 50W10 2Q= ; 4Q= ← ← ← ←W15 zero current detectionW17 rated current scalingW18 rated current scalingW80 HW type codingW81 HW type codingW82 HW type coding
T11 T24T14 T21,T13 T26,T16 T23 T15 T22 T12 T25
X12
W18,W17,W15
W10
W81 W80X13
1 8
16
T101 T102 T103
SDCS-PIN-1X
X22
W82
X121(GND)
X122(IACT)
U1 C1 V1 D1 W1 R11
8
R112R115
16
1 8
282
PTC
265
R116 R113R119
XT11 XT24XT14 XT21 XT13 XT26 XT16 XT23 XT15 XT22 XT12 XT25
line potential !
indicates a removed jumper
III 5-2
The power interface board is used for DCS con-verter modules construction type C1 and C2. Thereare different versions in use. The used types are:
- SDCS-PIN-205B for 100 A...1000 A Conv. at 500 V- SDCS-PIN-206B for 110 A...450 A Conv. at 600 V
The SDCS-PIN20xB can replace the SDCS-PIN-20x and PIN-20xA.
The SDCS-PIN-20x board consists of:- firing pulse circuits with pulse transformers- measurement of the armature current- snubber circuit for thyristor protection
(consists of RC circuits in parallel of the thyristorsand RCD network)
- AC and DC high ohmic voltage measurement- rated current scaling with burden resistors, zero
current detection and HW voltage type coding- interface for heat sink temperature measurement
with a PTC sensor- fuses for overvoltage protection and voltage
measuring- the same board will be used without any modifi-
cation at a converter used for three-phase fieldsupply
Fig. 5.2/1 Layout of the SDCS-PIN-20x, 20xA, 20xB board.
Spare partThe protection of the power part is done by usingRC circuits. Snubber circuits are wired up in paral-lel to each thyristor with fuses in between. RCD el-ements are protected by the fuses F 101 to F 103.The AC voltage measurement is taken from behindthe fuse.
Fuse data: Bussmann KTK-R-6A (600V)
The power interface board SDCS-PIN205 can beused as a replacement of SDCS-PIN-21, 22 and25. The board SDCS-PIN-206 can be used as a re-placement of SDCS-PIN-23 and 24, but not vice-versa! In case of a converter with 450 A / 520 A /700 A at 500 V or a converter of 450 A at 600 V ad-ditional actions have to be taken into account.
5.2 Power interface board SDCS-PIN-20x
SDCS-PIN-20X
X121 8
916X131 8
916
T24
T22
T26
T11
T15
T13
T14
T12
T16
T21
T25
T23
X22 X3 X4
X94
X91
X92
X93
X95
123
35
35
123
F101
F102
F103
X121 (IACT)X120 (GND)
U1
V1
W1
C1 D1
28
0
253
PTC
U1 V1 W1
X5X6
W10
W80
W81
W82
R24
8R
249
R25
0R
251
R25
2R
179
R17
8R
177
R17
6R
175
R17
4R
173
R17
2R
171
R17
0R
169
R16
8R
167
R16
6R
165
R16
4R
163
R16
2R
161
R16
0
P126 P127
P123
P122
P125
P124
P131
P130
P128 P129
MOV
R15
1R
149
R15
0
C10
8
P125
P124
X94
C1
C108
C109
linepotential!
III 5-3
Table 5.2/1 Settings of the SDCS-PIN-20xB board for 2-Q converters if a DCS converter is equipped with it by ABB
2-Q Converters
Table 5.2/2 Settings of the SDCS-PIN-20xB board for 4-Q converters if a DCS converter is equipped with it by ABB
4-Q Converters
Bo
ard
use
d a
s a
spar
e p
art:
- de
faul
t: al
l res
isto
rs, r
epre
send
ing
a ju
mpe
r W
xx /
Rxx
are
in
con
ditio
n-
ensu
re th
e co
rrec
t con
vert
er ty
pe r
elat
ed s
ettin
gs
Board type PIN 205B PIN 206BCurrent transformer ratio 1000:1 600:1 3000:1 1000:1 600:1
Rated voltage [V] 500 600Rated current [A] 100 125 180 225 315 405 470 610 740 900 100 245 405
W10 2-Q/4-Q selectionW80 HW type codingW81 HW type codingW82 HW type codingR248 HW type codingR249 HW type codingR250 HW type codingR251 HW type codingR252 HW type codingR149 33 Ω zero current detectionR150 47.5 Ω zero current detectionR151 100 Ω zero current detectionR160 1k Ω rated current scalingR161 1k Ω rated current scalingR162 332 Ω rated current scalingR163 332 Ω rated current scalingR164 332 Ω rated current scalingR165 332 Ω rated current scalingR166 332 Ω rated current scalingR167 47.5 Ω rated current scalingR168 33.2 Ω rated current scalingR169 33.2 Ω rated current scalingR170 33.2 Ω rated current scalingR171 33.2 Ω rated current scalingR172 33.2 Ω rated current scalingR173 33.2 Ω rated current scalingR174 33.2 Ω rated current scalingR175 33.2 Ω rated current scalingR176 33.2 Ω rated current scalingR177 10 Ω rated current scalingR178 10 Ω rated current scalingR179 10 Ω rated current scaling
Board type PIN 205B PIN 206B1000:1 600:1 3000:1 1000:1 600:1
500 600100 140 200 250 350 450 520 680 820 1000 110 270 450
W10 2-Q/4-Q selectionW80 HW type codingW81 HW type codingW82 HW type codingR248 HW type codingR249 HW type codingR250 HW type codingR251 HW type codingR252 HW type codingR149 33 Ω zero current detectionR150 47.5 Ω zero current detectionR151 100 Ω zero current detectionR160 1k Ω rated current scalingR161 1k Ω rated current scalingR162 332 Ω rated current scalingR163 332 Ω rated current scalingR164 332 Ω rated current scalingR165 332 Ω rated current scalingR166 332 Ω rated current scalingR167 47.5 Ω rated current scalingR168 33.2 Ω rated current scalingR169 33.2 Ω rated current scalingR170 33.2 Ω rated current scalingR171 33.2 Ω rated current scalingR172 33.2 Ω rated current scalingR173 33.2 Ω rated current scalingR174 33.2 Ω rated current scalingR175 33.2 Ω rated current scalingR176 33.2 Ω rated current scalingR177 10 Ω rated current scalingR178 10 Ω rated current scalingR179 10 Ω rated current scaling
Rated current [A]
Rated voltage [V]Current transformer ratio
indicates a removed jumper
III 5-4
Fig. 5.2/2 Typical armature circuit thyristor converter diagram with SDCS-PIN-20B boardfor a 2Q/4Q C1/C2 type converter
V11
V24
V21
V14
1.4
2.1
2.4
1.1
2.6
V26
V13
1.3
2.3
1.6
V23
V16
2.2
V22
V15
1.5
2.5
1.2
V25 V12
KG KGG KG K
G KG KG K KG
KGG K
KGG K
X12
:U
1V
1W
1
C1
(+)
D1
(-)
F10
1
3S
TW
A
VW
16
UV
UU
144
0V
5M /
6M
GN
DI
IDC
8,13
9,10
IDC
M11
,12
1X
4:
3
X3:
31
N/1
P1
T51
P2
P2
P1
T53
N/1
W81
AC
OD
1
AC
OD
21513
AN
TC
2
1X
22:
3R
57H
WC
IN4
1W
10 W80
7B
ZP
4
+48
V1
SR
1
GN
DI
SR
2
BZ
P5
BZ
P6
8,61011
12,1
4
4,29
BZ
P2
BZ
P3
BZ
P1
X13
: 3 51
0 V
+ 4
8 V
1
W82
UA
+6
UA
-15
820R
1k5
3k3
1k5
S1
S2
S1
S2
PE
RE
VE
RS
E
FO
RW
AR
D
1 2 3 4 5 6K G KGKKGKGK KGGGKGKG K GKGKG
2.6
1.6
2.5
1.4
2.3
1.2
2.1
1.5
2.4
1.3
2.2
HW
CD
D5
7
HW
CO
D3
5N
C
NC
1.1
F10
2
F10
3
6A
C1W1
V1
U1D1
191731293135331192725X
6:
191731293135331192725X
5:6
x 0.
1 µF
6 x
15 Ω
Con
trol
boa
rdA
rmat
ure
cur
rent
mea
suri
ng r
esis
tan
ces
AC
/DC
vol
tage
mea
surin
g ci
rcui
ts
HW
-co
ding
Firi
ng p
ulse
cha
nnel
son
ly in
cas
e of
4-Q
co
nver
ters
see
tabl
efo
r R
1xx
PO
WE
R IN
TE
RF
AC
E B
OA
RD
SD
CS
-PIN
-20x
B
see
tabl
e fo
r R
2xx
III 5-5
5.3 Galvanic isolation - T90, A92
The Galvanic isolation is an option for converters inthe current range 2050...5150 A and rated voltages1000 V. For converters with a rated voltage of1190 V and 12-pulse serial > 2x 500 V the galvanicisolation is a standard equipment. It is used to re-place the high-ohmic resistance voltage measure-ment and gives the advantage of a total isolationfrom power part to electronic part.
The transformer T90 and the DC transducer A92are located outside the converter module. The in-ternal AC and DC voltage measurement channelsare opened and connected to the T90 and A92units.
Hard and software settings:
Voltage coding on measuring board
Construction type C4
Conv. nom. voltage [V] * Y=4 (400V)Y=5 (500V)
Y=6 (600V) Y=7 (690V) Y=8 (790V) Y=9 (1000V) Y=1 (1190V)
Rated mains voltage [V] 220…500 270…600 300…690 350…790 450…1000 530…1190
Value f. conv. nom. voltat SET(TINGS) block *
500 600 700 800 1000 1200
Measuring board SDCS- PIN-52 PIN-51 PIN-51 PIN-51 PIN-51 PIN-51
Resistors W1…W26all resistors are 0 Ω
Galvanic isolation 8680A1/3ADT745047
Resistors Rx onPIN51/52
27.4 kΩ 27.4 kΩ 27.4 kΩ 27.4 kΩ 27.4 kΩ 27.4 kΩ
DC transducer A92 8680A1
Switch position RG * 675 V 810 V 945 V 1080 V 1350 V 1620 V
Transformer T90 3ADT745047
Secondary Terminals * 2U12V12W12N
2U22V22W22N
2U32V32W32N
2U42V42W42N
2U52V52W52N
2U62V62W62N
* 12-pulse serial and sequential have a different selection between Conv. nom. voltage and the scalingof measurement channel. See 12-pulse manual.
III 5-6
Fig. 5.3/1 Typical armature circuit thyristor converter diagram with SDCS-PIN-41 and SDCS-PIN-51 boards for a4-Q C4 type converter with galvanic isolation
*
V1
1
V2
4
V21
V14
1.4
2.1
2.4
1.1
2.6
V2
6
V1
3
1.3
2.3
1.6
V23
V16
2.2
V2
2
V1
5
1.5
2.5
1.2
V25
V12
KG KGG KG K
G K G KG KKG
KGG KKG G K
X12
:X
12:
T90
V1
W1
SD
CS
-PIN
-51
C1
(+)
D1
(-)
R11
C11
C24
F1
1
R13
C13
C26
F1
3
C15
C22
R15
F1
5
C14
C21
F14
R14
F16
C16
C23
R16
F12
C12
C25
R12
1M
B7
3S
TW
A
AN
TC
2A
8
UA
-
UA
+
VW
1516 6
UV
UU
144
B1
A6
A1
A2
A7
0V0V
500
400
501
401
200
300
100
5M
201
301
101
W22
W17
W2
3
W1
8
W6
W12
W1
1MW
7
W1
3
W2
1M
W1
9W
20
W8
W1
41M
W3
W9
W15
W4
R19
GN
DI
IDC
8,1
3
9,1
0
IDC
M11
,12
A5,
B2
560R
A4,
B4
R20
R21 270R
120R
A3,
B3
R10
18RR17
R18 33R
68R
R15
R16 18R
18R
R13
R14 18R
18R
R11
R12 18R
18R
47R
47R
100R 18RR8
R9
18R
18R
R6
R7 18R
18R
R26
R25
47R
47R
R4
R5 18R
18R
R2
R3 18R
18R
R24
R23
R22
1X
22:
3
W2
1
W1
1
W1
6
W5
1M
D1
C1
W1
V1
U1
R57
R1
1X
25:
2
X24
:
21
X23
:
21
GD
W70
W81
HW
CD
D5
HW
CIN
417
AC
OD
1
AC
OD
2
HW
CO
D3
15
X12
: 513
B8
B5
W10
X12
:B
6
B1
NC
B2
W8
0
7B
ZP
4
+48
V1
SR
1
GN
DI
SR
2
BZ
P5
BZ
P6
8,6 1011
12,1
4
4,29
BZ
P2
BZ
P3
BZ
P1
X13
: 3 51
4B
5
0 V
FW
D
+ 4
8 V
1
A5,
A6
A4
A7,
A8
A2,
A3
B4
B3
5 6
B7
B6
X13
:B
8
2 31
W82
W71
W83
W72
0V
A7,
B7
A1,
B1
A2
A8,
B8
A6,
B6
A4,
B4
A3,
B3
X11
3:
A5,
B5
A9,
B9
A10
,B10
A7,
B7
A1,
B1
A2
A6,
B6
A4,
B4
A3,
B3
A8,
B8
A10
,B10
A5,
B5
A9,
B9
X11
3:
GA
2.4
CB
CA
GB
1.1
2.6
GC
CC
1.5
SD
CS
-PIN
-41
1.3
CD
GE
CE
2.2
GF
A8,
B8
A1,
B1
A2
A7,
B7
A9,
B9
A4,
B4
A3,
B3
X21
3:
A10
,B10
A6,
B6
A5,
B5
CF
GD
A2
A4,
B4
A3,
B3
A1,
B1
A6,
B6
A8,
B8
A9,
B9
A7,
B7
A10
,B10
A5,
B5
X21
3:
A2
A4,
B4
A1,
B1
A3,
B3
A6,
B6
A8,
B8
A7,
B7
A9,
B9
A10
,B10
A5,
B5
X21
3:
GA
2.5
CB
CA
GB
1.2
2.3
GC
CC
SD
CS
-PIN
-41
A2
A4,
B4
A3,
B3
A1,
B1
A9,
B9
A7,
B7
A6,
B6
A8,
B8
A5,
B5
A10
,B10
X11
3:
1.4
1.6
CD
GE
CE
2.1
GF
CF
RE
V
R24
R21
R26
R22
R23
R25
W2
4W
25W
26
1k5
820
R1k
53k
3
820
R1
k53k
38k
21k
5
PE T
51P
2
400
0/1
400
0/1
P1
T52
P2
P1
S1
S2
S1
S2
Rx
Rx
Rx
Rx
Rx
109
2017
F11
F90
Rx
sold
ered
resi
stor
s in
par
alle
l to
5 M
Ω h
ybrid
resi
stor
s
rem
oved
wire
s
2NU
1S
A92
12
SD
CS
-PO
W-1
X99
:1
X99
:2
aux.
sup
ply
230
V A
C
==
~=
Con
trol
boa
rd
PO
WE
R I
NT
ER
FA
CE
BO
AR
D
Arm
atu
re c
urre
nt m
easu
ring
re
sist
ors
AC
/DC
vol
tage
mea
surin
g ci
rcui
ts
Firi
ng p
ulse
ch
anne
ls
HW
-cod
ing
jum
per
s
III 5-7
5.3.1 A92 DC-DC transducer (type 8680A1)
Fig. 5.3/2 Principle circuit diagram of the DC-DC transducer 8680A1
112.0
10.0
2.0
100
.0
Side view
76.0
70.0
50.060.0
80.0
7.0
5.0
Sna
p-on
mou
ntin
g on
DIN
462
77 r
ail
Buttom view
Fig. 5.3/3 Dimensions in mm Fig. 5.3/4 Location of terminals
Data
Selectable voltage gains: 675, 810, 945, 1080, 1215, 1350, 1620 V DCOutput voltage: 9,84 V / 5 mAAuxiliary power: 230 V ± 15 %; 50/60 Hz; 3 WClearence in air: Auxiliary power to Output: >13 mm
Input/Output to Auxiliary power: >14 mmInsulation voltage: 2000 VInsulation test voltage: 5000 VAmbient temperature range: - 10 …+ 70 °CWeight: appr. 0.4 kg
The voltage gain and frequency response is especially designed for DCS 500Band DCS 600 converters.
Ωk
Ω6 M17
20OPAMP
TRANSDUCER1 : 1
9
10
10nF
230 V AC
+15V
0V
-15V
0V
1
2
Ω6 M RG
GAIN7 STEPS
POWER SUPPLY
Inputvoltage
Outputvoltage
appr. 3.9
appr. 280nF
20
Gain selector
17
1 2 9 10
RG
III 5-8
5.3.2 T90 Transformer (type 3ADT 745 047)
Fig. 5.3/5 Principle diagram of the transformer 3ADT 745 047
Fig. 5.3/6 Dimensions in mm
RemarkThe terminals on the primary side of thetransformer are in special design (lug ter-minals).Handling hints: First turn the screw conter-clockwise to the end stop, then swing outthe shrowding cover. Put inthe cable lug, swing in thethe shrowding cover andfasten the connection byturning the screw clock-wise.
1U
1V
1W
2N
S
2U12U22U32U42U52U6
2V12V22V32V42V52V6
2W12W22W32W42W52W6
1N
max 116m
ax 1
1013
0
118....120
130
80
5.2 x 7.7
DataSelectable transfer ratios Uprim: 502, 601, 701, 800,1000, 1200 V AC rmsOutput voltage: 7.3 V AC rmsInsulation voltage: 3500 VPartial discharge voltage: 1800 VAmbient temperature range: - 10 …+ 70 °CWeight: 2.1 kg
III 5-9
5.4 Power Interface SDCS-PIN 41/SDCS-PIN-5x
The Power Interface of DCS converter modulesmodel A5 and C4 from 900 A up to 5150 A consistsof two boards - the Measuring board SDCS-PIN-5xand the Pulse transformer board SCDS-PIN-41.There are different versions of the SDCS-PIN-5x:SDCS-PIN-51 for converters with all line voltagesSDCS-PIN-52 for converters with line volt. 500 V
The following figures show the different connec-tions between the SDCS-PIN-41 and SDCS-PIN-5xboard depending on the application 2- or 4-quad-rant and the construction type.Converters, delivered from 1998 on, will beequipped with SDCS-PIN-41A, which is a full re-placement for converters, which alredy in use.
Fig. 5.4/1 2-Quadrant application, no parallel thyristors - Construction type A5/C4
Fig. 5.4/2 4-Quadrant application, no parallel thyristors - Construction type A5
Fig. 5.4/3 4-Quadrant application, no parallel thyristors - Construction type C4
V14
SDCS-PIN-41
U1
SDCS-PIN-5x
SD
CS
-CO
N-x
V1
W1
C1
D1
X22 X122 X23 X24 X25
X1
2 S
X1
3 S
X4
13 S
X3
13 S
X1
3
X5
13
X1
13
X2
13
X4
13
X3
13
S2
S1
T1 T6 T3 T2 T5
X1
13
C
G
C
G
C
G
C
G
C
G
C
G
V11 V16 V13 V12 V15
X2
13
T4
X1
3X
12
X1
2
X113
SDCS-PIN-41
G
C
G
C
G
C
G
C
G
C
G
C
T4 T1 T6 T3 T2
V24
SDCS-PIN-41
U1
SDCS-PIN-5x
SD
CS
-CO
N-x
V1
W1
C1
D1
X22 X122 X23 X24 X25
X1
2 S
X1
3 S
X4
13 S
X3
13 S
X1
3
X5
13
X1
13
X2
13
X4
13
X3
13
S2
S1
T1 T6 T3 T2 T5
X1
13
C
G
C
G
C
G
C
G
C
G
C
G
V11 V26 V13 V22 V15
X2
13
T4
X1
3X
12
X1
2
V25 V12 V23 V16 V21 V14
T5
X2
13
X213
SDCS-PIN-41
G
C
G
C
G
C
G
C
G
C
T1 T6 T3 T2 T5
V23
SDCS-PIN-41
B C D E F
X1
13
C
G
C
G
C
G
C
G
C
G
C
G
V13 V22 V12 V25 V15
X2
13
A
U1
SDCS-PIN-5x
SD
CS
-CO
N-x
V1
W1
C1
D1
X22 X122 X23 X24 X25
X1
2 S
X1
3 S
X4
13 S
X3
13 S
X1
3
X5
13
X1
13
X2
13
X4
13
X3
13
S2
S1
X1
3X
12
X1
2
A
C
G
V24 V14 V21 V11 V26 V16
X1
13
III 5-10
Measuring board SDCS-PIN-5xThis board is always used together with SDCS-PIN-41 board. On this board there are the circuitslocated needed for current, voltage and tempera-ture measuring and for hardware coding.
The current is measured by current transformers atthe AC supply, rectified by a diode bridge andscaled with burden resistors to 1.5 V as rated cur-rent. The current response is adjusted by cuttingout resistors (R1 ... R21) from the board accordingto the coding table. The resistors R22 ... R26 areused for the current equal to zero detection. Theseresistors must be cut off according to a second ta-ble.
Voltages (U1, V1, W1 and C1(+) and D1(-)) aremeasured by using high ohm resistor chains. Scal-ing of AC and DC voltage is done by activating 1
Pulse transformer board SDCS-PIN-41/PIN-41A
Fig. 5.4/5 Layout of the SDCS-PIN-51 board for converters with line volt. >500 V
M resistors (= cutting out short circuit wires, whichare represented by a low ohmic resistance).For the voltage measurement 5 resistor chains areused:U1: W1 to W5V1: W6 to W11W1: W12 to W16C1(+): W17 to W21D1(-): W22 to W26
If there is a need for voltage adaption, all 5 chainsmust be handled in the same way.
When gavanically isolated measurement is needed,please contact your ABB representative.
Note! Actual voltage signals U1, V1, W1, C1(+)and D1(-) of the main circuit are not galvanicallyisolated from the control board.
G4C4
G1C1
G6C6
G3C3
G2C2
G5C5
X113
X1
X213
X2
SDCS-PIN-41
T4 T1 T6 T3 T2 T5
A B C D E F
270
100line potential !
Fig. 5.4/4 Layout of the SDCS-PIN-41/PIN-41A pulse transformer board
The board contains sixpulse transformers withamplifiers.
NoteFor spare part reasons,please use only theSDCS-PIN-51 board!
Figure 5.4/6 Layout of the SDCS-PIN-52 board for converters with line volt. 500 V
X41
3
X31
3
X21
3
X11
3
X51
3
X13
S2 S1
X23 X24 X25
R1 . . . . . . . R21
X22 X122
X12
U1
V1
W1
D1
C1
R22
R26
1 2 2 21 1
SDCS-PIN-52
S3
W10 W70
W80
W71
W81
W72
W82W83
213 4
X12S
X13S
X413S
X313S
X41
3
X31
3
X21
3
X11
3
X51
3
X13
S2 S1
X23 X24 X25
R1 . . . . . . . R21
X12S
X13S
X413S
X313S
X22 X122
X12
U1
V1
W1
D1
C1
W5 W4 W3 W2 W1
W16 W15 W14 W13 W12
W26 W25 W24 W23 W22
W11 W9 W8 W7 W6
W21 W20 W19 W18 W17
W5
R123
R22
R26
1 2 2 21 1
SDCS-PIN-51
S3
W10 W70
W80
W71
W81
W72
W82W83
305
100
213 4
PTC Conductivesupports
Isolatingsupports
One PTCTwo PTC
line potential !see diagrampower part
III 5-11
Table 5.4/1 Settings of the SDCS-PIN-51 board if aDCS converter is equipped with it by ABB
Board used as a spare part:- default: all jumpers Wxx, Rxx are in condition- ensure the correct converter type related settings
2 Q - 4 Q coding2 Q 4 Q
W10
➀ the converters can be used at lower line voltage then specified by the y-value without hardware modifications, ifthe nominal line voltage applied to the converter is not lower than 45% for y=5...9 and not lower than 55% for y=4.
Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω
Rat
ed c
urre
nt s
calin
gZ
ero
curr
ent
dete
ctio
n
Voltage codingConstruction type A5 C4Conv. nom. voltage [V]
Y=4 (400V)Y=5 (500V)
Y=6 (600V)Y=7 (690V)
Y=4 (400V)Y=5 (500V)
Y=6 (600V) Y=7 (690V) Y=8 (790V) Y=9 (1000V)
Value f. conv. nom. volt at SET(TINGS) block
500 600 690 800 1000
Measuring board SDCS PIN-52 PIN-51 PIN-52 PIN-51 PIN-51 PIN-51 PIN-51W1, 6, 12, 17, 22W2, 7, 13, 18, 23W3, 8, 14, 19, 24W4, 9, 15, 20, 25W5, 11, 16, 21, 26
0 = HW type coding
HW type coding
Construction type C4Current [A] 1200 1500 2000 900 1500 2000 > 2000 *Voltage max. [V] 500 500 500 600/690 600/690 600/690W70W71W72W80W81W82W83* see Software description
A5
12
34
indicates a removed jumper
III 5-12
Fig. 5.4/7 Typical armature circuit thyristor converter diagram with SDCS-PIN-41and SDCS-PIN-51 boards for a 4-Q A5 type converter
*
V1
1
V2
4
V21
V14
1.4
2.1
2.4
1.1
2.6
V2
6
V1
3
1.3
2.3
1.6
V23
V16
2.2
V2
2
V1
5
1.5
2.5
1.2
V25
V12
KG KGG KG K
G K G KG KKG
KGG KKG G K
X12
:X
12:
U1
V1
W1
SD
CS
-PIN
-51
C1
(+)
D1
(-)
R11
C11
F1
1
R13
C13
F1
3
C15
R15
F1
5
C14
F14
R14
F16
C16
R16
F12
C12
R12
1M
B7
3S
TW
A
AN
TC
2A
8
UA
-
UA
+
VW
1516 6
UV
UU
144
B1
A6
A1
A2
A7
0V0V
500
400
501
401
200
300
100
5M
201
301
101
W22
W17
W23
W18
W6
W12
W1
1MW
7
W13
W2
1M
W19
W2
0
W8
W14
1M
W3
W9
W1
5
W4
R19
GN
DI
IDC
8,1
3
9,1
0
IDC
M1
1,1
2
A5,
B2
560R
A4,
B4
R20
R21 270R
120R
A3,
B3
R10
18RR17
R18 33R
68R
R15
R16 18R
18R
R13
R14 18R
18R
R11
R12 18R
18R
47R
47R
100R 18RR8
R9
18R
18R
R6
R7 18R
18R
R26
R25
47R
47R
R4
R5 18R
18R
R2
R3 18R
18R
R24
R23
R22
1X
22:
3
W21
W11
W16
W5
1M
D1
C1
W1
V1
U1
R57
R1
1X
25:
2
X24
:
21
X23
:
21
2500
/1
P1
T5
1P
2
P2
P1
T53
2500
/1
GD
W70
W81
HW
CD
D5
HW
CIN
417
AC
OD
1
AC
OD
2
HW
CO
D3
15
X12
: 513
B8
B5
W10
X12
:B
6
B1
NC
B2
W80
7B
ZP
4
+48
V1
SR
1
GN
DI
SR
2
BZ
P5
BZ
P6
8,6 1011
12,
14
4,29
BZ
P2
BZ
P3
BZ
P1
X13
: 3 51
4B
5
0 V
FW
D
+ 4
8 V
1
A5,
A6
A4
A7,
A8
A2,
A3
B4
B3
5 6
B7
B6
X13
:B
8
2 31
W82
W71
W83
W72
0V
A7,
B7
A1,
B1
A2
A8,
B8
A6,
B6
A4,
B4
A3,
B3
X11
3:
A5,
B5
A9,
B9
A10
,B10
A7,
B7
A1,
B1
A2
A6,
B6
A4,
B4
A3,
B3
A8,
B8
A10
,B10
A5,
B5
A9,
B9
X11
3:
GA
2.4
CB
CA
GB
1.1
2.6
GC
CC
1.5
SD
CS
-PIN
-41
1.3
CD
GE
CE
2.2
GF
A8,
B8
A1,
B1
A2
A7,
B7
A9,
B9
A4,
B4
A3,
B3
X21
3:
A10
,B10
A6,
B6
A5,
B5
CF
GD
A2
A4,
B4
A3,
B3
A1,
B1
A6,
B6
A8,
B8
A9,
B9
A7,
B7
A10
,B10
A5,
B5
X21
3:
A2
A4,
B4
A1,
B1
A3,
B3
A6,
B6
A8,
B8
A7,
B7
A9,
B9
A10
,B10
A5,
B5
X21
3:
GA
2.5
CB
CA
GB
1.2
2.3
GC
CC
SD
CS
-PIN
-41
A2
A4,
B4
A3,
B3
A1,
B1
A9,
B9
A7,
B7
A6,
B6
A8,
B8
A5,
B5
A10
,B10
X11
3:
1.4
1.6
CD
GE
CE
2.1
GF
CF
RE
V
R24
R26
W24
W2
5W
26
1k5
820
R1k
53
k3
820
R1k
53k
38
k21k
5
S1
S2
S1
S2
PE
T51
P2
4000
/1
4000
/1
P1
T52
P2
P1
S1
S2
S1
S2
X24
:
21
X23
:
21
Co
ntro
l bo
ard
PO
WE
R I
NT
ER
FA
CE
BO
AR
D
Arm
atur
e c
urre
nt m
easu
ring
re
sist
anc
es
AC
/DC
vol
tage
mea
surin
g ci
rcui
ts
Firi
ng
puls
e ch
anne
ls
HW
-cod
ing
jum
pers
type
s 09
03 to
200
3
type
s 20
50 to
515
0
III 5-13
Data
AC input / output voltage: 1-ph / 3-ph; 400 V phase to phase / 230V phase to neutralAC input / output current: 5 AAC peak current: According to fan starting current; external switching device neededAC isolation voltage: 690 V (supply via autotransformer)Load: three phase AC motors or single phase AC motors with starting capaci-
torFrequency: 50 Hz / 60 HzOutput data: passive device; to be used together with DCS electronics onlyTerminal cross sectional area: X1: power supply; max. 2.5 mm2
X2: to X4: motor connection; 2.5 mm2
Current scaling: burden resistor R100 / R101 / R102; see Fig. 5.5/2Interconnection: X22:1 to X22:3 at SDCS-PIN20x / 5x
X22:3 to X22:1 at SDCS-PIN20x / 5xSystem configuration: PW 1003 can be cascaded via terminal X23: - X123:Jumpers: S1:1 / S1:2 not used
S1:3 / S1:4 adapt the transfer characteristics
5.5.1 PW 1003
This device is designed to be used together withthe DCR kit at any type of rebuild application. Itcan monitor the current of single or three phasefans and it can be cascaded, which means multi-ple devices can be connected to one PTC inputto monitor several fan current. The transfer char-acteristic shown at figure 5.5/2 needs to beadapted to the fan current either by changing theburden resistors or by a software parameter, de-pending on the type of fan already used for theexisting power part.
Fig. 5.5/1 Layout of the PW 1003
X3:
linepotential 1 2
X1
: 1 3 5
X4
: 1 2
X1
23:
1X
2: 1 2
R102
R101
R100
S1
1X
22:
1 3
X23
:1
110
92
2631
33.5
111
5.5 Fan current monitoring
The heatsink temperature of the power part ofsome DCS converters is monitored via a PTC ele-ment. Other DCS converters check the cooling airtemperature and the airflow. The third option is thisone, which measures the fan current being withinlimits. In case the fan current is too low or there isno fan current at all or it is too high, the drive needsto be switched off. The fan current may be too lowbecause- the fan may not be switched on or
- any protection device within the fan supply hasacted or
- a wire is broken or- the propeller became loose or something similarThe fan current may be too high because- the fan may be blocked mechanically or- there is a short circuit in the fan winding or some-
thing similarThe overcurrent during acceleration can be sup-pressed by the software.
III 5-14
0
1
2
3
4
5
6
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
default: 1 = 5 A at 60 Ohms
default + S1: 3 - 4
Transfer characteristic of PW1003
Fig. 5.5/2 is used to adapt the device PW1003 to the fan current. The X-axis isnormalized to 1 and represents the fan current. With a burden resistor of 60Ohms (equal to default) the 1 is equal to 5 A. The Y-axis is scaled in outputvoltage (with external pull-up resistor of 2k2 to 5 V) as the output signal to-wards the converter electronics. Values within 2 V and 3 V are of interest, be-cause these values can be set via software as a threshold, using the tempera-ture setting parameter. The converter generates an error message, if the cur-rent is lower / higher than the intersection -parameter value / -selected curve.
+90°C
+45°C (parameter value)
-15°C
Fig. 5.5/2 Relationship between fan current and output voltage of PW 1003
III 5-15
5.6 Zero current detection SDCS-CZD-01
This board is used for fast zero current detectionespecially for three phase field converter in MotorGenerator application. The board provides a safezero current detection also for other very big loadinductances.
The board is located on SDCS-CON-2 board andplugged on X12, X13 and X17.X17: is only used for mechanical reasons. Theelectrical function (connection to IOE-1) is un-changed.
All DCS/DCF converter are equipped with a zerocurrent detection by monitoring the current signal toa certain level.
X13
:
X12
:
X17
:
MP1
106
47
Fig. 5.6/2 Connection between the SDCS-CZD-01 and SDCS-CON-2 board
The CZD-01 board has in addition a cathode / an-ode voltage measurement of all thyristors. The volt-age measurement provides a sharp detection ofDC load condition.
The requirement for zero current detection is:• actual load current falls below a low treshold• AND upper thristors are blocked (V11,V13,V15..)
OR lower thyristors are blocked (V12,V14,V15..)
The activation of the board must be set in the soft-ware via parameter:
DCF500B 4.19 ZERO CUR DETECTDCF600 43.14 ZERO CUR DETECT
Fig. 5.6/1 Layout of the SDCS-CZD-01 board
X13:
X13:
X23
:
X12:
X12:
X22
:
X17:
X17:
X27
:
Fig. 5.6/3 Principle diagram of SDCSCZD-01
MP1 = '1'-signal no zero currentMP1 = '0'-signal zero current
&
&
MP1
470k to zerocurrent interface
D1 (-) C1 (+)
U1 V1 W1
voltage detection
current detection
III 5-16
5.7 Power signal measurement board SDCS-MP-1
Fig. 5.7/2 Connection between the SDCS-MP-1 and SDCS-CON-2 board
Fig. 5.7/1 Layout of the SDCS-MP-1 board
The power signal measurement board SDCS-MP-1is intended to be used as a service and rebuild(DCR 500 /DCR 600 commissioning) aid. Withoutthis board it is practically impossible to measurewith oscilloscope or with general purpose metersignals between the control board and the powerinterface board(s).
The board is plugged to the control board connec-tors X12, X13 and X17. The ribbon cables normallyconnected to the control board are connected tothe measurement board connectors having thesame name as the respective connector on thecontrol board.Measurement points for following signals are pro-vided:- the three phase to ground voltages UU, UV and
UW
- the three phase to phase voltages UVU, UWV andUUW
- one rectified and filtered phase to phase voltageUAC
- armature voltage UDC with sign filtered- armature current IACT with sign- the six thyristor firing commands BZP1...BZP6- the two current direction commands SR1 and
SR2 (measurement points SR11 and SR21)- the sum of pulse transformer primary currents
can be measured accross measurement pointsSR11-SR12 or SR21-SR22 depending on currentdirection
- the control board ground 0V.
The measurement points are separated from thecontrol board signals either with 10 k resistors orwith operational amplifiers so that accidental shortcircuits between the measurement points do not af-fect the converter operation. Measurement point 0Vis directly connected to control board ground.
SDCS-MP-1X13:
X13:
X23
:
X12:
X12:
X22
:
X17:
X17:
X27
:
SDCS-CON-2
Measurement points
X12X13X17
X23
X22 X
27
SDCS-MP-1
SR
11
BZ
P2
BZ
P3
BZ
P4
BZ
P5
BZ
P6
UW
VU
UW
UA
C
SR
12S
R21
SR
22IA
CT
0V
UV
U
BZ
P1
Measurement points
III 6-1
The converter with a control board SDCS-CON-2can be connected in 4 different ways to a controlunit via analogue/digital links. Only one of the fourchoices can be used at the same time (Description
Analogue I/O´s:standardDigital I/O´s:not isolatedEncoder input:not isolated
Analogue I/O´s:standardDigital I/O´s:all isolated by means ofoptocoupler/relay, the sig-nal status is indicated byLED
Analogue I/O´s:more input capacityDigital I/O´s:not isolatedencoder input:isolatedcurrent source for:PT100/PTC element
Analogue I/O´s:more input capacityDigital I/O´s:all isolated by means ofoptocoupler/relay, the sig-nal status is indicated byLEDcurrent source for:PT100/PTC element
of the I/O's see chapter SDCS-CON-2). In additionto this an extension of I/O´s by SDCS-IOE-1 is pos-sible.
Fig. 6/1 I/O via SDCS-CON-2 Fig. 6/2 I/O via SDCS-CON-2 and SDCS-IOB-2
Fig. 6/3 I/O via SDCS-CON-2 and SDCS-IOB-3 Fig. 6/4 I/O via SDCS-IOB-2 and SDCS-IOB-3
6 Digital and analogue I/O boards
SDCS-CON-2
SDCS-CON-2
SDCS-IOB-2
SDCS-IOB-3
SDCS-CON-2
SDCS-IOB-3
SDCS-CON-2
SDCS-IOB-2
III 6-2
6.1 Digital I/O board SDCS-IOB-2
As described at the beginning of the chapter, there arevarious options for configuring the inputs/outputs.
The board IOB-2x has 8 digital inputs and 8 digitaloutputs.There are three different types existing, which differ atthe input voltage level:
SDCS-IOB-21 24...48V DCSDCS-IOB-22 115 V ACSDCS-IOB-23 230 V AC
The inputs are filtered and galvanically isolated byusing opto couplers. Inputs can form two galvanicallyseparated groups by using either X7:1 or X7:2.
If these boards are in use, they have to be mountedoutside the DCS module. They must be mounted in away, that the conductive supports have a good con-nection to ground of the installation.
Fig. 6.1/1 I/O via SDCS-IOB-2x / IOB-3 and CON-x
Fig. 6.1/2 Layout and jumper settings of the SDCS-IOB-2x board
The cable length between X1:/X1: and X2:/X2: is 1.7m and between X1:/X3: is 0.5 m because of EMCreasons.
SDCS-CON-2
SDCS-IOB-2
SDCS-IOB-3
SDCS-CON-2
SDCS-IOB-2
S8
S7
R1
SDCS-IOB-2x
DI1
R2 R3 R4 R5 R6 R7 R8W1
3
W1
1
W9
W7
W5
W3
W1
W2
W4
W6
W8
W1
0
W1
2
W1
4
W1
5
W1
6
X6X5X4
X1X3
K1 K2 K3 K4 K5 K8
DI2 DI3 DI4 DI5 DI6 DI7 DI8
DO1 DO2 DO3DO4
DO5
DO6 DO7
DO8
1 1 1
X7
1
233.5
97.5
5
4
2ms
10ms
DI 7
DI 8
4 *
70
12
43
12
43
1
2 4
3
1
2 4
3
1
2 4
3
1
2 4
3
5
70
4
time constant
default value
input
supports are conductive
diameter of all supports: 4.3 mm
* this dimension may vary (4/5 mm) depending on revision
Line potential !
III 6-3
Fig. 6.1/3 Terminal connection of the SDCS-IOB-2x board
Note:When the SDCS-CON-2 control board with the SDCS-IOB-2 I/O board isinstalled, terminals X6: and X7: on the SDCS-CON-2 must not be used.
Output value Signal definition Remarksby
K1...K5, K8 Software potential-isolated by relays(NO contact element)Contact ratings:AC: 250 V~/ 3 A~DC: 24 V-/ 3 A- or 115/230 V-/ 0.3 A-)MOV-protected (275 V)
K6,7 Software potential-isolated by optocouplerSwitching capacity: 50 mAexternal voltage: 24 V-
X4:, X5: are screw-clamp terminal types for leads up to 4 mm² cross-sectionalarea.Default values are shown within the software diagrams.The ground potential of the digital outputs may vary within ±100 V to each other.
Input value Signal definition Remarksby
Channel 1...8 potential-isolated by optocouplerIOB-21: (24...48V-) R1...R8 = 4.7 k0...8 V = "0 signal"18...60 V = "1 signal"IOB-22: Software (115V~) R1...R8 = 22 k0...20 V = "0 signal"60...130 V = "1 signal"IOB-23: (230 V~) R1...R8 = 47 k0...40 V = "0 signal"90...250 V = "1 sig."
including tolerance; absolute maxvalues
X6: / X7: are screw-clamp terminal types for leads up to 4 mm² cross-sectionalareaInput resistance: see diagram.Input smoothing time constant: see diagram.Smoothing time constant of channel 7 and 8 can be changed; see layout of theboard.The functionality of the input channels, which will be read, can be defined bysoftware; default values are shown within the software diagramsPower supply for digital inputs: 48V / 50mA; not galv. isolated from the DCSelectronics!
If the inputs are supplied from the internal +48 V (X7:3 and/or X7:4) a connectionmust be done from either X7:1 and/or X7:2 to ground of the DCS 500 modules. Indefault condition ground is identical to the converter's frame.
If the inputs are supplied by any external source (+48 V DC, 115 V AC or 230 VAC) the neutral line / - line must be connected to either X7:1 or X7:2. If the inputsshould be controlled with the same voltage level, but from two different voltagesources, having probably two different ground levels, the first neutral line shouldbe connected to X7:1 and the second to X7:2. In this case the jumpers Wx con-necting the inputs to X7:2, but controlled by the source, connected to X7:1, mustbe cut off.The same method is needed for the other jumpers Wx.
High frequency grounding is done by 100 nF capacitor.
X4:1
2
3
4
5
6
7
8
X5:1
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
2
3
4
5
6
7
8
K1
K2
K3
K4
K5
K8
DOx
66V
66V
DI2
DI4
DI5
DI6
DI7
DI8
3
5
6
8
2
4
W2
W5 W6
W7 W8
W11 W12
X6:1
2
W1
R1100n
681+
- 681
DIx
W3 W4
DI1
DI3
R2
R3
R44
R5
R6
W9 W10
R77
R8
W13 W14
W15 W16
X7:1100n
+48V3
+
Software
+48V
III 6-4
6.2 Analogue I/O board SDCS-IOB-3
As described at the beginning of the chapter, there arevarious options for configuring the inputs/outputs.
The board SDCS-IOB-3 consists of the 5 analogueinputs, 3 analogue outputs, the galvanical isolatedpulse encoder interface and a current source fortemperature measuring devices.
If these boards are in use, they have to be mountedoutside the DCS module. They must be mounted in away, that the conductive supports have a good con-nection to ground of the installation.
The cable length between X1:/X1: and X2:/X2: is1.7 m and between X1:/X3: is 0.5 m because of EMCreasons.
Fig. 6.2/2 Layout and jumper settings of the SDCS-IOB-3 board
Fig. 6.2/1 I/O via SDCS-IOB-2x / IOB-3 and CON-x
SDCS-IOB-3
SDCS-CON-2
SDCS-IOB-3
SDCS-CON-2
SDCS-IOB-2
T1
X3 X4 X5
X1 X2
S2 S3
S1
S10
SDCS-IOB-3
AITACAI1
AI2
S1:1-2S1:3-4
S1:5-6S2
AI3 S1:7-8
Ch
AI4 S1:9-10
1 13
142
12
2223
S4
12
21
11
R110
S51 2
43
3 24
V17
1 1 112 1012
S1:11-12S1:13-14
PTC1.5 mA
PT1005 mA
*
12 V
S4
S5
S1S2S3
24 V 5 V *
*
**
***
*
**
85
233.5
5
4
70
S10*
*
S2
S3S3
5 V 12/24 V
5 V 12/24 V 13 mA
23
12324
22
23
12324
22
23
12324
22
23
12324
2223
12324
22
1
78
2 1
78
2
1357911
24681012
1357911
24681012
1357911
24681012
1 243
1 243
7531
8642
7531
8642
7531
8642
7531
8642
x
x
x
4
5
70
gain = 1
-10V..+10V
gain = 10
-1V..+1V
Sum I ACnot equalto 0
activation of 500 Ω betweeninput terminal
Jumper coding
conductive supports
Characteristics for pulse encoder inputssingle ended:
differential:
Pulse encoder supply
Temperature sensor supply
Functionallity of analogue inputs
default value
III 6-5
Fig. 6.2/3 Terminal connection of the SDCS-IOB-3 board
Note:When the SDCS-CON-2 control board with the SDCS-IOB-3 I/Oboard is installed, the connection through plugs S4:1-2 and 3-4on the SDCS-CON-2 must be severed.Terminals X3:, X4: and X5: on the SDCS-CON-2 must not beused.
Reso- Input/output Scaling Power Common Remarkslution values by mode[bit] Hardware range
12 + sign -10...0...+10 V Software ±20 V ➀ ➁ ➂ ➅
12 + sign -10...0...+10 V Software ±20 V ➀ ➁ ➂
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂ ➃ ➄
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂ ➃ ➄
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂
11 + sign -10...0...+10 V Software 5 * mA
11 + sign -10...0...+10 V Software 5 * mA
analogue -10...0...+10 V R 110 5 * mA gain: 0.5...5
5 * mA for external use5 * mA e.g. reference pot.
1.5 mA Curr. source for PTC5 mA Curr. source for PT100
Encoder supply Remarks
Inputs isolated;Impedance = 120 , if selectedmax. frequence 300 kHz
Sense lines for GND and supply to correct volt-age drops on cable (only if 5V/12V enc. is in use)
5V/ 0.25 A * Incremental encoder power supply12V/24V 0.2 A *
Earth fault protection is based on a sum current transformer where the secondary isconnected through 100 resistor to a diode bridge. Voltage will appear across the resis-tor, if the sum of the 3 phase current is not zero.
Restrictions using jumper S1, S2 or S3:The selection for the burden resistor across the input terminals can be done independentfrom S2 or S3 settings for inputs AITAC, AI1, AI2, AI3 and AI4.If the gain is set to 10 by using S2 or S3 and the 500 burden resistor is activated, theinput signal level is changed to -2 mA...0...+2 mA.For input AI4 there are the following configurations available:- input range ”20mA” , or- input range ”10V”, or- earth fault monitoring by Isum not equal to zero
➀ total smoothing time 2 ms➁ -20...0...+20 mA by setting S1➂ 4...20 mA by ➁ + Software function➃ -1...0...-1 V by setting S2/S3 (CMR ±10 V) -2...0...-2 mA by setting S2/S3 + S1 (CMR ±10 V)➄ designated for PT100 evaluation per software and
hardware➅ If the input is used for tacho feedback and the tachovoltage needs to be scaled, the board PS5311 must beordered separate. If this input is used for feedback sig-nals, there is a need for any additional margin of over-shoot measurements. This margin is set by software andresults e.g. in the 8 to 33 volts at PS5311.* short circuit proof
+10V
0V
-10V
AO1
AITAC
AO2
+/- I-act
AI4
GND
0V
3 V = I NDC
100k1n1n
100k
100k 100k
Power-Source
Sense GND
Sense Power +
0V
AI2
AI1
-
+
-
+
-
+
-
+
500
S11 2
3 4
7 8
9 10
12 141311
100
S1
x
R1100V
0V
1.5 mA5 mA
1 2
3 4
S5
S4
V17
4
5
7
X5:12
3
6
8
9
10
3
4
5
6
7
8
9
10
X4:1
2
11
12
8
7
4
X3:1
2
3
6
5
9
10
11
12
SoftwareSDCS-CON-x
+5 6
~
~
47.5100µ
100n
47.5100µ
100n
100µ
ChA +
ChA -
ChB +
ChB -
ChZ +
ChZ -
+24V 7 8 910 11 12
+24V 13141516 17 18
+24V4 5 6
S101 2 3S10
AI3
-x10
S2
S3
x10
PS5311
TG
+
- 81-270V
25-90V
8-33V
R9X2:3
X2:4
8
7
4
X1:1
2
3
6
5
6
X2:3
4
5
8
7
III 6-6
Fig. 6.2/4 Connections incremental encoder - electronics
0
65535
Forward
Connecting a pulse encoder to theDCS 500B / DCS 600 converterThe connection diagram for a pulse encoder to theelectronics of a DCS converter is quite similar, if theSDCS-CON-2 or the SDCS-IOB-3 is used. The basicdifference between these 2 boards is the galvanicalisolated circuit on the SDCS-IOB-3 board.
Power supply for incremental encoderThere is a galvanically isolated power supply for theincremental encoder on SDCS-IOB-3. The jumper S4on this board is used to select either +5 V, +12 V or+24 V as a supply voltage for the pulse encoder.When LED indicator (V17) is lit, the supply is OK.
The pulses generated by the pulse encoder aretransferred to the pulse receivers via opto couplers.
If the SDCS-CON-2 board is used the supply voltagefor the pulse encoder is selected on the SDCS-POW-1 board (refer to SDCS-POW-1).
In both cases the voltage regulator has a feedbackcontrol with Sense power and Sense GND signals.
Feedback connection is recommended when powersupply level for differential pulse encoder is 5V. If a12 V pulse encoder type is in use the sense functionis also available. The wiring is shown on figure 6.2/4.
Fig. 6.2/5 TACHO_PULSES signal
A
A
B
B
Z
Z
+U
0V
X5:2
X5:1
X5:4
X5:3
X5:6
X5:5
IOB-3
X5:7
X5:10
X5:8
X5:9
GND
ChA+
ChA-
ChB+
ChB-
ChZ+
ChZ-
A
A
B
B
Z
Z
+U
0V
X5:2
X5:1
X5:4
X5:3
X5:6
X5:5
IOB-1/CON-2
X5:10
X5:7
X5:9
X5:8
X5:2
X5:1
X5:4
X5:3
X5:6
X5:5
X5:7
X5:10
X5:8
X5:9
GND
ChA+
ChA-
ChB+
ChB-
ChZ+
ChZ-
X5:2
X5:1
X5:4
X5:3
X5:6
X5:5
X5:10
X5:7
X5:9
X5:8
IOB-3 IOB-1/CON-2
= twisted pair
DIFFERENTIAL
SINGLE-ENDED
Power source
Sense power
Sense GND
Power source
Note:If the drive’s direction of rotation is correct (if ne-cessary, correct by exchanging the field connec-tions), the Tacho error message may appear du-ring start-up.
If with a positive reference the TACHO_PULSESsignal (with software 21.xxx: parameter 12104)does not look like the illustration below, then tracksA and A must be mutually exchanged with enco-ders with inverted signals, and tracks A and B withencoders without inverted signals.
If the TACHO_PULSES signal is missing or non-li-near, the encoder’s pulses are not being read cor-rectly. Possible reasons for this may be the enco-der supply, the encoder itself, or the wiring.
III 6-7
Incremental encoderTwo different incremental encoder connections areavailable.- differential connection; pulse encoders generating
either voltage or current signals can be used- single-ended (push pull) connection; voltage si-
gnals
Restrictions using jumper S1: or S10: dependingon the boardLine termination via S1/S10: 2-3 / 8-9 / 14-15 shouldnot be used at 12 V or 24 V encoders, because of thepower consumption taken from the encoder. If a pulseencoder with a build in current source is used aburden resistor of 120 is activated via jumper S1/S10: 1-2 a.s.o.
Fig. 6.2/6 Pulse encoder connection principles
If a single ended 12 V / 24 V encoder is used S1/S10should be set to 5-6 / 11-12 / 17-18 according to thelayouts of the boards. This setting results in an internalthreshold of appr. 5 V. In case of a single ended 5 Vencoder the jumpers will be set to a neutral position S1/S10: 4-5 / 10-11 / 16-17. To get a threshold lower than 5V each terminal X5:2 / X5:4 / X5:6 / X5:7 must beconnected via a resistor according to the table below.
R 1 k 1.5 2.2 k U thresh 1.2 V 1.8 V 2.3 V
Three differential inputs are reserved for connecting thepulse encoder. CH A and CH B are the normal pulsechannels having nominal 90° phase shift between thechannels.
The channel CH A- (CH B-) is the inversed channel CH A(CH B). CH Z is the zero pulse channel which can beadditionally used if the encoder has an output giving one“zero” pulse per revolution.
The distance between pulse encoder and interface boardis dependent on the voltage drop on the connecting linesand on the output and input configuration of the usedcomponents. If cables are used according to the nexttable the voltage drop caused by the cable can becorrected by the voltage regulator.
Cable length parallel wires for Cable usedpower source & GND
0 ... 50 m 1x 0.25 mm² 12x 0.25 mm²50 ... 100 m 2x 0.25 mm² 12x 0.25 mm²
100 ... 150 m 3x 0.25 mm² 14x 0.25 mm²
-U
+U
CH+
CH-
SDCS-IOB-1/CON-2 / IOB-3
+
+
+24V
X5:1
X5:2S1:
(S10:)1
2
3
4
5
6
differentialsingle ended
III 6-8
SDCS-IOE-1
SDCS-CON-x
4 x
anal
og1
x T
acho
7 x
digi
tal
8 x
digi
tal
2 x
anal
og
Pul
sgeb
er
6.3 Extension board SDCS-IOE-1
The board consists of:7 isolated digital inputs2 analogue inputs1 current source for the supply of PTC or PT 100elements
The board is connected electrically via a 10 pin flatcable to the converter module electronics. The con-nection will be done to the SDCS-CON-x boardfrom terminal row X17 to X17 on SDCS-IOE-1. Ithas to be mounted outside of the converter module.The cable length is 2 m because of EMC reasons.
Mechanical ConstructionThe board is mounted on a plastic housing whichhas foot elements (Phoenix Contact series UMK).The foot elements permit snap-in assembly to astandard DIN EN rail (EN 50022, 50035).The dimensions are including the plastic housing.
Fig. 6.3/2 Layout and jumper settings of the SDCS-IOE-1 board
Fig. 6.3/1 Connection of the SDCS-IOE-1 board andthe SDCS-CON-x board.
X17
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
X2S1 S2 S4S3
H1 H2 H3 H4 H5 H6 H7
AI5
AI6
S1:3-4
S2:3-4S3
ChPTC1.5 mA
PT1005 mA
S3
1 243
1 243
2468
1357
8
21
71 2
431 2
431 2
43
S2:1-2
S1:1-2
2468
1357
146.3
90
X1
3 81 4
gain = 1
-10V..+10V
gain = 10
-1V..+1V
Jumperparking
activation of 500 Ω betweeninput terminal
Temperature sensor supplyFunctionallity of analogue inputs
default value
Pla
stic
hou
sing
Mou
ntin
g fo
r D
IN-r
ail
III 6-9
Fig. 6.3/3 Terminal connection of the SDCS-IOE-1 board
Input value Signal definition Remarksby
0...8 V Software = "0" status16...31 V = "1" status
Two potential isolatedgroups. Max. operatingvoltage between thegroups and the controlboard is 50 V
Filter time constant for allinputs is 2.2 ms
Reso- Input/output Scaling Power Common Remarkslution values by mode[bit] Hardware range
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂
11 + sign -10...0...+10 V Software ±40 V ➀ ➁ ➂ ➃
1.5 mA Curr. source for PTC5 mA Curr. source for PT100
absolute accuracy in-cluding the control-board is 0.7%
➀ total smoothing time 2 ms➁ -20...0...+20 mA by setting S1/S2➂ 4...20 mA by ➁ + Software function➃ -1...0...-1 V by setting S3 (CMR ±10 V) -2...0...-2 mA by setting S3 + S2 (CMR ±10 V)
SoftwareSDCS-CON-x
DI10
DI12
DI13
DI14
DI15
3
5
6
8
X1:1
2
DI9
DI11
4
7
2.2k
47n
2.2k
681
H1 +
10
9
GND
AI5100k
1n1n
100k
100k 100k
AI6
-
+
-
+
500
S13 4
3 4x10
S3
8
7
4
X2:1
2
3
6
5
9
10
S2
1.5 mA5 mA
3 4
S4100µ
0V
0V
1 2
for cable shields
for cable shields
for cable shields
III 6-10
III 7-1
cannot be used together with software versionS21.xxx.Channel 3 is a DDCS channel of up to 4 Mbits/sand is used if a serial link based on PROFIBUShardware, CS31 hardware or MODBUS hardwareshould be realized. If one of these possibilitiesshould be used an adaptation module is needed.Please refer to the documentation which is availa-ble for the link system needed.
Fig. 7.1/1 Connection between SDCS-COM-x and a partner
Fig. 7.1/2 Layout and jumper settings of the SDCS-COM-5 board
This board is used for communications to DCS 500converter modules for commissioning and mainte-nance purposes. It consists of 3 different communi-cation channels. All RxD channels (receiver) haveblue color, all TxD channels (transmitter) have greycolor. If any connections should be made alwaysconnect the same color with each other (plug andsocket) .Channel 1 is a HDLC channel of 1.5 Mbits/s and isused for the communication with a PC. Channel 2
RxD
TxD
SDCS-COM-x
Partner
V3
V4
V1
V2
V5
V6
D8
D11
S1
SDCS-COM-5
X11
CH 3RxD
TxD
CH 1RxD
TxD
CH 2RxD
TxD
D7
1
2
3
4
156.5
83.5
1
3 24
13 2
4
13
2
4
13
2
4
13
24
Coding forchannel 2
Converter number
default value
conductive support
7 Communication boards7.1 Communication board SDCS-COM-5
III 7-2
Fig. 7.2/1 Layout of the SDCS-AMC-DC / SDCS-AMC-DC Classic board / AMC-DC Drive Bus
This board must be used together with a DCS 600module equipped with a SDCS-CON-2 board inclu-ding software S15.xxx.
The board is equipped with an own controller withthe following main functionalities:• The software structure implemented in this board
is divided in two sections. The first section is builtfrom the speed regulator and its additionalfunctions which is producing the torque refe-rence.
• The second section is prepared to be program-med with its own characteristics for control andregulation.
• Evaluation of the received data to produce a tor-que reference to be transmitted to the controller
7.2 Control and communication board SDCS-AMC-DC
board CON-2. Actual values from the CON-2 areread, evaluated and retransmitted to the overri-ding control.
Furthermore the board is equipped with three opti-cal channels (max. data transmission speed is 4Mb for each optical channel):- Channel 0 is used to communicate data from the
overriding control (APC2 or via adapter modulesfrom other controllers) to the DCS600-drive.
- Channel 2 (Master-Follower) is used to operatetwo or more drives dependent on each other.Commands and values needed for this applicati-on are produced on this board.
- Channel 3 is prepared to connect the PC tool forcommissioning and maintenance.
Remark: Only channels with the same compon-ents (e.g. 10 Mb component) may beconnected to each other.
optical Components Channel 0 used for D400 driver current Communication **Ch 0 Ch 2 Ch 3 CHO, CH2, CH3 CH0
SDCS-AMC-DC * 10 Mb 5 Mb 10 Mb other interfaces ICMC1 30 mA DDCS
SDCS-AMC-DC Classic * 5 Mb 10 Mb 10 Mb Fieldbus adapter modules NxxA-0x ICMC1 30 mA DDCS
SDCS-AMC-DC 2 10 Mb 5 Mb 10 Mb other interfaces ICMC2 30/50 mA *** DDCS/Drive Bus
SDCS-AMC-DC Classic 2 5 Mb 10 Mb 10 Mb Fieldbus adapter modules NxxA-xx ICMC2 30/50 mA *** DDCS/Drive Bus
* SDCS-AMC-DC 2, SDCS-AMC-DC Classic 2 are direct replacements of SDCS-AMC-DC and SDCS-AMC-DC Classic** see additional parameter [71.01]
Color of optical components:5 Mb blue maximum 30 mA ***10 Mb dark grey maximum 50 mA ***
The SDCS-AMC-DC and the SDCS-AMC-DC Clas-sic boards are identical except the assembly of opticalcomponents for channel 0 and 2.
D200
SDCS-AMC-DC
X10
CH 3TxD
RxD
CH 2TxD
RxD
CH 0TxD
RxD
D105
156.5
83.5
D400
D100
conductive support
5V o.k.
Prg. running
Fault
green
red
green
III 7-3
Fig. 7.2/2 Connections at Master-Follower mode
Fig. 7.2/3 Module Bus connections to Advant controllers (ring feeder)
Fig. 7.2/4 Drive Bus connections to Advant Controller 80
For more configuration possibilitiessee publication 3AFE 63988235
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
FCIAC70AC80
TxD
RxD
. . .
TB 810
20 m - AMC-DC
30 m - AMC-DC 2
or A
MC
-DC
2
or A
MC
-DC
2
or A
MC
-DC
2
plastic optic fibre
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
. . .
20 m SDCS-AMC-DC30 m SDCS-AMC-DC 2
TxD
RxD
TxD
RxD
TxD
RxD
NDBU-950, 1, 2 ... ...8
TxD
RxD
. . .
AC80
TxD
RxD
Ch0 Drive Bus
or A
MC
-DC
2
or A
MC
-DC
2
or A
MC
-DC
2
30 m plastic optic fibre
plastic optic fibre
D20
0
SD
CS
-AM
C-D
C
X10
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D10
5
D40
0
D20
0
SD
CS
-AM
C-D
C
X10
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D10
5
D40
0
D20
0
SD
CS
-AM
C-D
C
X10
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D10
5
D40
0
10 m - AMC-DC / DC 2
20 m - AMC-DC Classic
plastic optic fibre
III 7-4
Fig. 7.2/5 Connections to higher-level system (APC)
Fig. 7.2/6 Connections to higher-level system (Communication modules)
Fig. 7.2/7 Connections to PC by ring feeder (with control program DriveWindow)
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
YPQ112 B
TxD
RxD
TxD
RxD
TxD
RxD
TxD
RxD
APC
. . .
20 m
or A
MC
-DC
2
or A
MC
-DC
2
or A
MC
-DC
2
plastic optic fibre
NxxA-0xNxxA-0x
TxD
RxD
D20
0
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
SD
CS
-AM
C-D
C C
lass
ic
D20
0
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
SD
CS
-AM
C-D
C C
lass
ic
D20
0
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
SD
CS
-AM
C-D
C C
lass
ic
TxD
RxD
NxxA-0x
TxD
RxD
. . .
. . .
10 m
Fieldbus
or A
MC
-DC
Cla
ssic
2
or A
MC
-DC
Cla
ssic
2
or A
MC
-DC
Cla
ssic
2
plastic optic fibre
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
TxD
RxD
. . .
20 m SDCS-AMC-DC / AMC-DC Classic30 m SDCS-AMC DC 2 / AMC-DC Classic 2
(Laptop)
NISA-03 (PC)NDPC-12NDPA-02
or A
MC
-DC
2or
AM
C-D
C C
lass
icor
AM
C-D
C C
lass
ic 2
or A
MC
-DC
2or
AM
C-D
C C
lass
icor
AM
C-D
C C
lass
ic 2
or A
MC
-DC
2or
AM
C-D
C C
lass
icor
AM
C-D
C C
lass
ic 2
plastic optic fibre
III 7-5
Fig. 7.2/8 Connections to PC by by star-type network (with control program DriveWindow)
For more configuration possibilitiessee publication 3ADW 000100R0201
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
D20
0
SD
CS
-AM
C-D
C
CH
3T
xD
RxD
CH
2T
xD
RxD
CH
0T
xD
RxD
D40
0
TxD
RxD
TxD
RxD
TxD
RxD
. . .
NDBU-950, 1, 2 ... ...8
TxD
RxD
. . .
TxD
RxD
TxD
RxD
TxD
RxD
TxD
RxD
TxD
RxD
TxD
RxD
. . .
. . .
TxD
RxD
TxD
RxD
20 mSDCS-AMC-DCSDCS-AMC-DC Classic
30 mSDCS-AMC-DC 2SDCS-AMC-DC Classic 2
max. 30 m
. . .NDBU-950, 1, 2 ... ...8
NDBU-950, 1, 2 ... ...8
(Laptop)
NISA-03 (PC)NDPC-12NDPA-02
HCSSilicat
max. 200 m
Plasticopt. fibre
Branchingunit
Branchingunit
Plastic opt. fibre
Branchingunit
Plasticopt. fibre
PC
boa
rd
or A
MC
-DC
2or
AM
C-D
C C
lass
icor
AM
C-D
C C
lass
ic 2
or A
MC
-DC
2or
AM
C-D
C C
lass
icor
AM
C-D
C C
lass
ic 2
or A
MC
-DC
2or
AM
C-D
C C
lass
icor
AM
C-D
C C
lass
ic 2
max. 30 m
or 200 m HCS
III 7-6
DDCS Branching Unit (DBU) is used (only for DCS600/DCF 600) to implement the star topology ofDDCS link. This allows a slave unit to fail or becomeunpowered without disabling the communication. TheNDBU receives messages from the master (PC) andsends them to all the slave units simultaneously. Eachslave unit has an individual address and only theaddressed slave unit sends a reply message to themaster. It is also possible to use NDBU thus enablingpeer-to-peer communication.
7.3 DDCS Branching unit NDBU-95
NDBU-95 DDCS Branching Unit has nine outputchannels where messages from the master are sent.The reply message sent by one slave unit is deliveredto the master and it can be delivered also to otherslaves if necessary. Several NDBU-95s can be usedin parallel, in series or in any combination of these.The maximum distance between the master andNDBU-95 as well as between two NDBU-95s, seemanual 3ADW000100R0201.
Technical specifications
Optical links:Master channels 1 DDCS input and 1 DDCS out-
putSlave channels 9 DDCS inputs and 9 DDCS
outputsData rate 1 - 4 MBd, programmable
Driving current 20 mA, 30 mA, 50 mA + chan-nel disabling, programmable
Monitoring a green LED for each channel,switched on when NDBU is re-ceiving messages
Transmission device 10 Mb component for eachchannel
Power supply:Input voltage +24 VDC ± 10%Input current 300 mAMonitoring a green LED switched on when
the output voltage is normal
Operating temperature: +0 ... +50 °CPCB dimensions: s. diagram beside
For further information see Appendix D in theDriveWindow User's Manual.
Fig. 7.3/1 Layout of the NDBU-95 branching unit
NoteFor addressing and automatic node numbering ofthe drives and branching units see DriveWindowdocumentaion.
264
V120
V119
V118
V117
V116
V115
V114
V113
V112
V111
V110
V109
V108
V107
V106
V105
V104
V103
V102
V101
X1
8
1
RXD
24 V DC
S1
NDBU-95DDCS BRANCHING UNIT, 8+1 CH
1
2 0 V
TXD
RXD
TXD
RXD
TXD
RXD
TXD
RXD
TXD
RXD
TXD
RXD
TXD
RXD
TXD
TXD
RXD
TXD
RXD
+5V OK
X2-X11
TRANSMSETTING
DISLONG
MEDIUMSHORT
1 0
ADDRESS
++
++
++
++
X12++
++
++
++
1 2 4
MBIT/S
41
94
DBU
Remark: Only channels with the same compon-ents (e.g. 10 Mb component) may beconnected to each other.
III 8-1
8 Field exciters
8.1 SDCS-FEX-1 (internal)The Diode Field Exciter board SDCS-FEX-1 is asingle phase diode rectifier for an AC input voltageup to 500 V and a DC output current of 6 A. Theboard has to be mounted inside the armature con-verter module. The excitation current is defined bythe DC output voltage (line voltage multiplied by0.9) and the resistance of the field winding. By us-ing an external resistor in series with the field wind-ing the field current can be adapted slightly.If the SDCS-FEX-1 board isn't already installed itmust be mechanically fixed beside the electronicpower part SDCS-POW-1 and connected via a flatcable to the SDCS-CON-x by using terminal X14.
8.1.1 Electrical data of FEX-1
AC input voltage: 110 V -15%...500 V +10%max. DC output current: 6 A; IF rated
DC output curr. monitoring: 20 mA...6 APower loss at IF rated : 10 WAC Isolating voltage: 600 VTerminals X1:Cross sectional area 2,5 mm²
Fig. 8.1/3 Output voltage with inductive or resistiveload - High-signal at X14:B3
Fig. 8.1/2 Diode field exciter with field lossmonitoring
Fig. 8.1/1 Layout of the SDCS-FEX-1 field exciterboard
The DCS 500 system has different options for thefield supply. There are one and three phase fieldexciters available, which can be either integrated(diode field exciter SDCS-FEX-1 and half controlledfield exciter SDCS-FEX-2) or externally mounted(half controlled DCF503-0050 with the SDCS-FEX-32 board and fully controlled DCF504-0050 with theSDCS-FEX-31 board).
Three phase field exciters DCF 50xB/60x are con-verter modules themselves, similar to the DCS501B/601 or DCS 502B/602 additionally a overvol-tage protection unit is needed see chapter 8.4.
The AC share of the output DC voltage is meas-ured with a capacitor and an auxiliary rectifier andused for current monitoring.Transistor relay is closed when the DC current isflowing (>0.02 A).
Fig. 8.1/4 Output voltage without loadLow-signal at X14:B3
X1:X14:
V1
-
+
SDCS-FEX-1
1
5
3
7
F-
F+ 80
130
Fixed isolating supports (15 mm)
linepotential !
S DC S -FE X -1
X1: 3
F+ F-
5
X1: 1 7SDCS-CON-x
X14:9
3
+ -X14:A4
B3
+ 15 V
CONVERTER MODULE
t
U
U
t
III 8-2
The field exciter board SDCS-FEX-2 / FEX-2A con-sists of a power part and a control board,whichconnects all components electrically and mechani-cally to each other. This arrangement has to bemounted inside the armature converter module be-side the electronic power supply SDCS-POW-1.This is intended to be done for DCS modules oftype C1, C2 and A5, not for C4!
The power part is build up with two power modules.Each of the modules consists of one diode and onethyristor, so they are wired up and controlled like ahalf controlled bridge.
Fig. 8.2/1 Layout of the SDCS-FEX-2 field exciter board
8.2.1 Electrical data of SDCS-FEX-2 / FEX-2AAC input voltage: 110 V -15%...500 V +10%; single phaseAC input current: output currentAC isolation voltage: 600 VFrequency: same as DCS converter moduleDC output current: ➀ 0.3 A...8 A for armature converter module from 25 A to 75 A
0.3 A...16 A for armature converter mod. from 100 A to 2000 APower loss at IF rated : 40 WOutput IACT: Uout = 4 V *Iact / Ilim; Ilim = 3A, 5A, 7A, 9A, 11A, 13A, 15A, 17ATerminal X1:Cross sectional area 4 mm²
➀ If Field weakening is needed, actual field current of the motor at top speed must behigher than 0.3 A
The control is based on a fully digital system. Theµ-processor reads all information from the powerpart, is supplied with all needed voltage levels andcontrol signals via the flat cable X14 by the SDCS-CON-x and generates the firing pulses for the pow-er part.
The range of the single phase rated AC input volt-age is 110 V to 500 V, the maximum current capa-bility is 16 A. If this field exciter is used for smallerfield current, the control unit automatically selects alower current range between 3 A to 16 A to get thebest resolution.
8.2 SDCS-FEX-2 (internal)
1
5
10
6
V11
V13
X1:
X14:T11
T13
T1X20
D37
SDCS-FEX-21 8
1
5
3
7
F-
F+
IACTGND
90
240
Conductive supportFixed isolating supports (15 mm)
linepotential !
III 8-3
8.2.2 Control unitThe control unit includes the following main blocks:
- Micro controller 80C198 for controlling and firing- Actual DC current measurement with an AC
current transformer.- RS485 interface to the converter's controller
board SDCS-CON-x.
The software for the field current control is stored inthe ROM memory of the 80C198. The control isdone by using a PI structure for the current control-ler. All parameters needed for the control or forscaling reasons (selection of burden resistors) arestored in the non-volatile memory of the armatureconverter and transferred to the field controller dur-ing each initializing process via the RS485 link.The Node number is always fix coded to Nodenumber = 1.
The output Iact represents the actual field current,which is measured via the AC transformer, thenrectified and transferred into a voltage signal withburden resistors. The burden resistors, as men-tioned before, are adapted by the board itself de-pending on the setting of the nominal field currentof the motor (see list before). The resulting burdenvoltage can be measured at test terminals besideX14:. The 2.2 K resistor allows a short circuit atthe terminals; the external measuring device shouldhave an internal resistance higher than 1M.
The terminal row X20: is used for test purposes.
8.2.3 Power sectionTwo diode-thyristor modules are arranged as ahalf-controlled single-phase rectifier. The anodes ofthe two diodes are not connected directly to eachother as usual; they are now connected to the endsof the four turn primary winding of the current trans-former. The centre tap is the negative output of therectifier. Thus it is possible to measure the DC cur-rent with an AC current transformer.
A MOV (Metal Oxide Varistor) protects the AC inputagainst voltage spikes from the external source.Another MOV protects the DC output against volt-age surges which can be caused by the field wind-ing of a DC machine.
Fig. 8.2/2 Block diagram of the field exciter SDCS-FEX-2
Synchronisation
T1
2k2
burden adjustment
AC Input DC Output
Power supply voltages+48V, +15V, -15V, +5V, 0V
Control unit
from SDC S-CON-xvia X14:
RS 485Serial link
III 8-4
The half controlled field exciter unit DCF503A-0050 consists of the SDCS-FEX-32A board, twothyristor/diode power modules and auxiliaries (po-wer supply, line choke). The full controlled fieldexciter unit DCF504A-0050 consists of the SDCS-FEX-31A board, four anti-parallel thyristor/ thyristor
Fig. 8.3/2 Layout of the DCF504A-0050 field exciter unit
Fig. 8.3 /1 Different versions of power section of the DCF50xA-0050
power modules and the same auxiliaries.The control is structured similar to the SDCS-FEX-2 field supply. A micro controller is used for control-ling and firing. The DC current is measured by us-ing an AC current transformer (same configurationthan at SDCS-FEX-2).
8.3 DCF503A-0050 and DCF504A-0050 (external)
8.3.1 Electrical data of DCF50xA-0050Power partAC input voltage: 110 V -15%...500 V +10%; single phaseAC input current: output currentFrequency: same as DCS converter moduleAC isolation voltage: 690 VLine reactor: 160 H; 45-65 HzDC output current: ➀ 0.3...50 APower loss at IF rated : 180 WAuxiliary voltage (X3:1-2)AC input voltage: 110 V -15%...230 V +10%; single phaseFrequency: 45 ... 65 HzAC input power: 15 W; 30 VAInrush current: <5 A / 20 msMains buffering: min 30 msTerminal row X2:X2: 1 RS 485 serial link to X16: 1 at SDCS-CON-1 / CON-2X2: 2 RS 485 serial link to X16: 2 at SDCS-CON-1 / CON-2X2: 3 Ground B grounded via cable screen and / or grounded via S2X2: 4 not usedX2: 5 not used
➀ If Field weakening is needed, actual field current of the motor at top speed must be higher than 0.3 A
C1 (+)
D1 (-)
U1
1
5
X6
X2
1
5
V23, V24
V11, V12 V13, V14
V21, V22
X123 X124 X121 X122
X111 X112 X113 X1141
X70
7
X501
1
X208
X5
SDCS-FEX-31A (4-Q)SDCS-FEX-32A (2-Q)
X12 X11
V1
275
330
S11 342
S21 3
42
69
1X80010LED
1 2X3
6
T1
Sub-D
GNDBarea
S2: 1-3 *S2: 1-2 S2: 3-4
GNDB isolatedGNDB grounded via RC circuitGNDB direct grounded
Jumper CodingGrounding of RS485 Transmission driver
* Default value
CPU mode
S1: 1-2 S1: 3-4 *
Firmware downloadField exciter mode
X101
X100
Commutationchoke
Conductive supports
Isolating supports
Linepotential !
1
23456789
10
Node no. 1 serial link CON-2
not used
Field exciter modeBridge reversal time:4 cyclesSerial link to CON-1, CON-2
Node no. 2 serial link CON-2
not used
Test modeextended; Bridgereversal timeNot used - don’t select
Setting X800 Switch OFF * ON
* Default value for all switchesThe settings are read during initialization.
T1 T1
+
-
+
-
ACsupply
DCoutput
ACsupply
DCoutput
III 8-5
8.3.2 Electronic power supplyThere is a power supply unit on the board. Supplyis connected at terminal X3. The rated AC voltages115 V and 230 V can be applied without any modifi-cation.The power supply unit provides the DC voltages 30V, 15 V, 5 V and -15 V to the control electronics.Voltages can be measured by means of a multime-ter from the terminal X70 (see the layout).In addition the power supply generates 5 V for gal-vanic isolated RS485 communication drivers. Thisvoltages can be measured at terminals X100/X101.
Measured Terminal Ground voltage positive
+5V X70:1 X70:2 (GND)+30V X70:3 X70:5 (GND)+15V X70:4 X70:5 (GND)-15V X70:6 X70:5 (GND)+ 5V X100 X101:1 (GNDB)
8.3.3 Control unitThe control unit includes the following main blocks:- Micro controller H8 for control and firing- Actual DC current measurement with an AC
current transformer.- RS485 interface to the converter's controller
board SDCS-CON-x.
The software for the field current control is stored inthe FlashPROM memory. This software contains a
PI current controllerFault/reset logicSynchronization and PLL functionBridge reversal function (only DCF 504A)
The setting and updating of all control parametersare set from armature converter via RS485 inter-face. Actual current, field current reference, controland status bit are cyclic sent via RS 485 communi-cation.
The field exciter is equipped with an auto-scalingfunction of burden resistor based on the nominalfield current of the motor.
The output Iact represents the actual field current,which is measured via the AC transformer, thenrectified and transferred into a voltage signal withburden resistors. The burden resistors -scaled tomeasurement range- are adapted by the board its-elf depending on the setting of the nominal motorfield current. The current signal can be measuredUCursig at X20:3-X70:2 and is scaled to
4 V *Iact / IScale
IScale = 3A, 5A, 7A, 9A, 11A, 13A, 15A, 17A, 21A,27A, 33A, 39A, 45A, 51A
8.3.4 Power sectionIf a DCF503A-0050 is in use two diode-thyristormodules are arranged as a half-controlled single-phase rectifier. If a DCS504A-0050 is in use fourthyristor-thyristor modules are arranged as a full-controlled single-phase rectifier. The anodes of thetwo diodes (anodes / cathodes of the thyristors) arenot connected directly to each other as usual; theyare connected to the ends of the primary winding ofthe current transformer. The centre tap is the nega-tive output of the rectifier. Thus it is possible tomeasure the DC current with an AC current trans-former.
A MOV (Metal Oxide Varistor) protects the AC inputagainst voltage spikes from the external source.Another MOV protects the DC output against volt-age surges which can be caused by the field wind-ing of a DC machine. The free wheeling functionneeded e.g. during network failure is ”build in” be-cause of the diodes, if the half-controlled version isin use. If the full-controlled version is used the freewheeling function is realized by using the thyristorsin diode mode, triggered by a fast voltage rise.
8.3.5 RS232-PortThe RS232 interface is used for download the'Field exciter firmeware package'.
The default settings of this interface are as follows:
Signal level: RS232 (+12V / -12V)Data format: UARTMessage format: Modbus-ProtocolTransmission method: half-duplexBaudrate: 9.600 BaudNumber of Data bits: 8Number of Stop bits: 1Parity-Bit: odd
The programming procedure is activated by settingS1:1-2 during auxiliary voltage is switched ON. Set-ting for field exciter mode is S1:3-4 (default).
1
9
5
6
X6: Description
1 not connected2 TxD3 RxD4 not connected5 SGND Signal ground6...9 not connected
Fig. 8.3/3 Pin assignment of RS232-Port
8.3.6 DiagnosisThe aramarure converter receivesvia serial link the sum of all faultsin "Fex status bit". A more detailederror code is given on the sevensegment display of DCF 503A/DCF 504A.
8
F82 Hardware fault
F83 Software fault
F88 Mains undervoltage < 40 V AC
F89 Mains overvoltage > 620 V AC
F90 Mains synchron. fault < 40Hz; > 70 HzF91 Load overcurrent above 125% of actual selected
measurment range
F92 Fast voltage rise (parameter 44.04 / 44.10 / 13.10 / 13.07)
all faults are reset with the next command to the armatue converter
Boot sequence or empty FlashPROM
III 8-6
Fig. 8.3/6 Serial communication cable connection
Fig. 8.3/5 Serial communication cable connection and address setting for Node 1and field exciter Node 2, using SDCS-FEX-2 and DCF50xA-0050
8.3.7 Field exciter configurationsThe data exchange between the SDCS-CON-x andthe field exciter SDCS-FEX-2 or the DCF503A/504A-0050 is done via a RS485 serial link, whichcan be configured as a bus structure. This link isused to transfer references, actual values and set-tings for up to two field exciter units.
The drive software located on the SDCS-CON-xboard consists of two field supply functions, firstfield exciter and second field exciter. The first fieldexciter is already connected to the EMF controllerto control the motor in all points of the motor dia-gram. The second field exciter is accessible via thefield current reference.
The RS485 interface works with a screened two-wire cable. The allowed length is 5 m. The wireshave to be connected to the terminals X2:1 andX2:2 and the screen to X2:3.
Typical application of this kind is two DC motorsconnected to one converter. The load sharing canbe done by means of adjusting the excitation cur-rent of the second DC-motor.
There are two possible configurations for two Nodenumbers of the field exciters:- one SDCS-FEX-2 and one external field exciter
(DCF503A-0050, DCF504A-0050 or 3-phasefield exciter) or
- two external field exciter units (DCF503A-0050,DCF504A-0050 or 3-phase field exciter).
If a SDCS-FEX-2 is used, it will be always recogni-zed as the field exciter Node 1 by the software.If a DCF503A/504A-0050 is used as Node 1 orNode 2 it must be coded according to the table be-low. Node 2 is operating with a cycle time of 100ms.
Fig. 8.3/4 Typical application example with two fieldexciter units and one converter (withoutfield weakening).
Procedure for field exciter Node changing of the DCF503A/504A:• Switch off the units voltage supply• Set the appropriate switch according to the table• Initialization through switch on the electronics supp-
ly voltage
M M
D C F503-0050
D C F503-0050
SD C S-C O N-x
1 . 2 .
Field exciter Node 1 Field exciter Node 2
Unit type Setting X800 Unit type Setting X800
SDCS-FEX-2 --- --- ---DCF 503A/504A X800:1 = OFF --- ---SDCS-FEX-2 --- DCF 503A/504A X800:1 = ONDCF 503A/504A X800:1 = OFF DCF 503A/504A X800:1 = ON
U1
V1
C1
D1
PE
X2:1X2:2X2:3
X3:2
X16:1X16:2X16:3
DCF503A-0050
SDCS-CON-2
X3:1
X14
SDCS-FEX-2
X14
AC INPUT
DC OUTPUT
Power supply
Total lengthmax 5 m
Armaturecontroller
FieldexciterNode 2
field exciter Node 1
Node 2X800:1=ON
X2:1X2:2X2:3
X3:2
X16:1X16:2X16:3
DCF503-0050
SDCS-CON-x
X3:1
X2:1X2:2X2:3
X3:2
DCF503-0050
X3:1
U1
V1
C1
D1PE
U1
V1
C1
D1PE
AC INPUT
DC OUTPUT
Power supply
Total lengthmax 5 m
Armaturecontroller
AC INPUT
DC OUTPUT
Power supply
Total lengthmax 5 m Field
exciterNode 2
FieldexciterNode 1Node 1X800:1=OFF
Node 2X800:1=ON
III 8-7
External field exciterDCF 503A-0050DCF 504A-0050
Dimensions in mmWeight appr. 10 kg
8.3.8 Dimensions
Fig. 8.3/7 Dimension drawing of DCF 503/4A
U1
V1
C1
D1
U1
V1
C1 (+)
D1 (-)
1
9
5
6
X80
0
M6
173
3x41
=12
3
M6
X6
X2
X800
LED
Sub-D
1
10
X2:
Sig
nal
term
ina
lsS
eria
l lin
k
X3:
Aux
. po
wer
su
pply
term
ina
ls
all for M6
all for M6
all f
or M
6
Direction of air flow
Min
imum
Top
cle
ara
nce
all for M6
Min
imum
Bot
tom
cle
aran
ce
all for M6
Mou
ntin
g d
irect
ion
Signal terminalsSerial link(aux. voltages)
Aux. power supply terminals
A
A
Note: In case of vibrating environments use fixing holes A
III 8-8
The three-phase field supply converter DCF 501B/502B and DCF 601/602 need a separate active Over-voltage Protection unit DCF 505 and DCF 506 forprotection the power part against inadmissibly highvoltages.
The protection unit operates by switch on a free-wheeling circuit between the F+ and F- connectors ifa overvoltage occurs. The DCF 505/506 consists of a
8.4 DCF505 / DCF506 Overvoltage Protection
trigger unit and a free-wheeling thyristor (two in anti-parallel at DCF 506). Thyristor firing is caused by a1400 V (FEP1 - 500 V) and 1800 V (FEP2 - 690 V)trigger diode.
The DCF 506 consist of a relay output for signallingthe field supply converter that the overvoltage protec-tion is active. The output is active in the free-wheelingprocess until the current is less than appr. 0.5 A.
Fig. 8.4/1: Simple load with DCF 501B/601 and 2-QOvervoltage Protection DCF 505
Fig. 8.4/2: Motor field supply with DCS 50xB/DCF 60xand 4-Q Overvoltage Protection DCF 506
Assignment Field supply converter to Overvol-tage protection unit
Field supply converter Overvoltage Protectionfor motor fields
2-Q, 500 VDCF501B/601-0025-51 ... DCF506-0140-51DCF501B/601-0140-51
DCF501B/601-0200-51 ... DCF506-0520-51DCF501B/601-0520-51
4-Q, 500VDCF502B/602-0025-51 ... DCF506-0140-51DCF502B/602-0140-51
DCF502B/602-0200-51 ... DCF506-0520-51DCF502B/602-0520-51
Inductive load supply Overvoltage Protectionfor other applications
4-Q, 500VDCS502B/602-0900-51 DCF506-1200-51DCS502B/602-1200-51 DCF506-1200-51DCS502B/602-1500-51 DCF506-1500-51
4-Q, 690VDCS502B/602-0900-71 DCF506-1500-71DCS502B/602-1500-71
Table 8.4/1: Assignment converter to OvervoltageProtection unit
For motor field supply units DCF 501/601 (2-Q),DCF 502B/602 (4-Q) it is always overvoltage pro-tection unit DCF 506 required.
The overvoltage protection unit DCF 505 is suitablefor 2-Q converters DCF 501B/601 with simple non-motoric inductive load.
DCF 501BDCF 601
C1(+)
D1(-)
DCF 505X11
X12
Field supply Converter
Overvoltageprotection
MDCF 501B/502BDCF 601/602
DCF 506
X6:2 9X4:1 2
C1(+)
D1(-)
X11
X12
Field supply Converter
Overvoltageprotection
III 8-9
Diagram
Fig. 8.4/3: Overvoltage Protection DCF 505 / DCF 506
F-
A1
X2:3
X1:1
G1
A
K1
X2:2
X1:3
X2:1
G2 K2
X3:1
X3:2
X4:1 X4:2
KR3
F+
X11 X12
1 2AK
1 2
1 2
1 2R1
R4
R2
V1
X1:2
SDCS-FEP-1 (500 V)SDCS-FEP-2 (690 V)
MJEM 4 mm2 for 25-140 A
MJEM 10 mm2 for 250-520 AMJEM 25 mm2 for 1200-1500 A
parts not used for 2-Q unit
red
grey
red
grey
III 8-10
Overvoltage ProtectionDCF 505-0140/0520-51DCF 505-1200-51DCF 506-0140/0520-51
Dimensions in mmWeight appr. 8 kg
Dimensions
Overvoltage ProtectionDCF 506-1200-51DCF 506-1500-51DCF 506-1500-71
Dimensions in mmWeight appr. 20 kg
X11 (F+)
X12 (F-)
12
16 75 33.5
935
011 7
342
M8
X3 X1
X4 X212
SDCS-FEP-1 (500 V)SDCS-FEP-2 (690 V)
42 145
8.5
355
145
f. M6M84032
35
8.5
482
20 135
X11
X12
III 9-1
Manufacturer/ Type Resistance [m] Fuse F1 Size Fuse holder Caliper [mm]
Bussman 170M 1564 6 50A 660V UR 0 OFAX 00 S3L 78.5Bussman 170M 1566 3 80A 660V UR 0 OFAX 00 S3L 78.5Bussman 170M 1568 1,.8 125A 660V UR 0 OFAX 00 S3L 78.5Bussman 170M 3815 0,.87 200A 660V UR 1 OFAX 1 S3 135Bussman 170M 3816 0,.59 250A 600V UR 1 OFAX 1 S3 135Bussman 170M 3817 0,.47 315A 660V UR 1 OFAX 1 S3 135Bussman 170M 3819 0,.37 400A 660V UR 1 OFAX 1 S3 135Bussman 170M 5810 0,.3 500A 660V UR 2 OFAX 2 S3 150Bussman 170M 6811 0,.22 700A 660V UR 3 OFAS B 3 150Bussman 170M 6813 0,.15 900A 660V UR 3 OFAS B 3 150Bussman 170M 6166 0,.09 1250A 660V UR * 170H 3006 110
Table 9.1/1: Fuses and fuse holders
9.1.1 Fuses and fuse holders (Converter size C1, C2)
9 Accessories9.1 Accessories - Power circuit
Main dimensions of fuse holders
Fuse HxWxDholder [mm]
OFAX 00 S3L 148x112x111OFAX 1 S3 250x174x123OFAX 2 S3 250x214x133OFAS B 3 250x246x136
Table 9.1/2: Fuse holders
Fig. 9.1/2: Fuse holder OFAX ... Fig. 9.1/3: Fuse holder OFAS B 3
Dimensions [mm] Size 0...3
Size a b c d e0 78,5 50 35 20,5 151 135 69 45 45 202 150 69 55 55 263 150 68 76 76 33
Remark:Given dimensions may be exeededin some cases. Please take themonly for information.
Fig. 9.1/1: Fuses size 0...3
L1 L2 L3
F1
a
d e
2
10
c
6
b
Indicator
OFASB 3
W D
H
W D
H
Fig. 9.1/4: Fuse holder 170H 3006
M10
110
A
A
M8
27
205
180
64 77
M8
A-A
60
85
Ø 9
M10
40
* drawing see chapter 2.2
III 9-2
Type Choke rated Weight Power loss recommendedL Irms Ipeak Voltage Fe Cu for armature
[H] [A] [A] [UN] [kg] [W] [W] converter type
ND 01 512 18 27 500 2.0 5 16 DCS...-0025ND 02 250 37 68 500 3.0 7 22 DCS...-0050ND 03 300 37 68 600 3.8 9 20 DCS...-0050ND 04 168 55 82 500 5.8 10 33 DCS...-0075ND 05 135 82 122 600 6.4 5 30 DCS...-0110ND 06 90 102 153 500 7.6 7 41 DCS...-0140ND 07 50 184 275 500 12.6 45 90 DCS...-0250ND 08 56.3 196 294 600 12.8 45 130 DCS...-0270ND 09 37.5 245 367 500 16.0 50 140 DCS...-0350ND 10 25.0 367 551 500 22.2 80 185 DCS...-0520ND 11 33.8 326 490 600 22.6 80 185 DCS...-0450ND 12 18.8 490 734 500 36.0 95 290 DCS...-0820 (2-Q)ND 13 18.2 698 1047 690 46.8 170 160 DCS...-0820 (4-Q)ND 14 9.9 930 1395 500 46.6 100 300 DCS...-1200ND 15 10.9 1163 1744 690 84.0 190 680 DCS...-1500ND 16 6.1 1510 2264 500 81.2 210 650 DCS...-2000
Line chokes type ND 01...ND 16
Table 9.1/3: Data of line chokes
Type a1 a b c d e f gmm²
ND 01 120 100 130 48 65 116 4 8 6ND 02 120 100 130 58 65 116 4 8 10ND 03 148 125 157 63 80 143 5 10 10ND 04 148 125 157 78 80 143 5 10 16ND 05 148 125 157 78 80 143 5 10 25ND 06 178 150 180 72 90 170 5 10 35
Line chokes type ND 01...ND 06
to mains
to converter
9.1.2 Line chokes
Fig. 9.1/4: Line choke type ND 01...ND 06
A, B, C 3001000
X, Y, Z
b
a
a1
c
A
X
B
Y
C
Z
A
B
C
X
Y
Z
3
A, B, C
X, Y, Z
d
e
g
f
Line chokes for use in industrial environment (minimum requirements), lowinductive voltage drop, deep commutation notches.
III 9-3
Type A B C E F G H I KND 07, 08 285 230 86 250 176 65 80 9x18 385ND 09 327 250 99 292 224 63 100 9x18 423ND 10, 11 408 250 99 374 224 63 100 11x18 504ND 12 458 250 112 424 224 63 100 11x18 554
Line chokes type ND 07...ND 12
Line chokes type ND 15, 16Line chokes type ND 13, 14
Fig. 9.1/5: Line chokes type ND 07...ND 12
Fig. 9.1/6: Line chokes type ND 13, ND 14 Fig. 9.1/7: Line chokes type ND 15, ND 16
C ±1
B ±1
F ±0.3
H ±2
15
3AST 478223 D5
3AFE 10014603
0.0188 mH
490 A
I max 734 A
15K
I (6x
)
G ±
4A
±2
E ±
2
A-A
E±2
7
±0.3F
A
A
min
30
∅ w
ithou
t var
nish
for
cond
uctio
n to
the
mou
ntin
g p
late
A A
A-A
18x1
3(3x
)
ø13
(3x)
100
±2140
45 45
±415
4±2
342
±2150 40
50
±2123
10
±1290
100
30
±0.3
224
min
30
∅ w
ithou
t var
nish
for
cond
uctio
n to
the
mou
ntin
g p
late
(6x)
10x
18
±2151
45
90
±517
6±2
440
±2181
147
10
48
15
80
40(1
2x)
ø13
30140
±1390
14030
20
100
10
A A
A-A
147 13
±0.3
316
18
min
30
∅ w
ithou
t var
nish
for
cond
uctio
n to
the
mou
ntin
g p
late
Don't use choke terminalsas cable or busbar support!
Don't use choke terminalsas cable or busbar support!
III 9-4
Table 9.1/4: Data of line chokes type ND4
Line chokes type ND 401...ND 402
Fig. 9.1/8: Line choke type ND 401...ND 402
Table 9.1/5: Dimensions of line chokes type ND 401...ND 402
Type Choke rated Weight Power loss Load LoadL Irms Ipeak Voltage Fe Cu DC curr. 1 DC curr.2
[H] Line AC [A] [A] [UN] [kg] [W] [W]
ND 401 1000 18.5 27 500 3.5 13 35 22.6 18ND 402 600 37 68 500 7.5 13 50 45 36ND 403 450 55 82 500 11 42 90 67 54ND 404 350 74 111 500 13 78 105 90 72ND 405 250 104 156 500 19 91 105 127 101ND 406 160 148 220 500 22 104 130 179 143ND 407 120 192 288 500 23 117 130 234 187ND 408 90 252 387 500 29 137 160 315 252ND 409 70 332 498 500 33 170 215 405 324ND 410 60 406 609 500 51 260 225 495 396ND 411 50 502 753 500 56 260 300 612 490ND 412 40 605 805 500 62 280 335 738 590ND 413 35 740 1105 500 75 312 410 900 720
Type A B C D E F Ø G Ø HND 401 160 190 75 80 51 175 7 9ND 402 200 220 105 115 75 200 7 9
Line chokes type ND 401...ND 413
Line chokes for use in light industrial/residential environment, high inductivevoltage drop, reduced commutation notches.
These chokes are designed for drives which usual operate in speed control mode.The maximum average DC load current depends on the operation point.DC curr. 1 = maximum continuous current for Urated supply = 400 VDC curr. 2 = maximum continuous current for Urated supply = 500 V
A X B Y C Z
170
D
B
F±1ø G+5
E ±2
C
ZYX
BA C
Terminals: WAGO Type 202 UL File E45172
ø H
A
ø G
tin-coated
III 9-5
Fig. 9.1/9: Line choke type ND 403...ND 408
Fig. 9.1/10: Line choke type ND 409...ND 413
Line chokes type ND 403...ND 408
Line chokes type ND 409...ND 413
Type A B C D E F Ø G Ø H Ø KND 403 220 230 120 135 100 77.5 7 9 6.6ND 404 220 225 120 140 100 77.5 7 9 6.6ND 405 235 250 155 170 125 85 10 9 6.6ND 406 255 275 155 175 125 95 10 9 9ND 407 255 275 155 175 125 95 10 9 11ND 408 285 285 180 210 150 95 10 9 11
Type A B C D E F Ø G Ø H Ø KND 409 320 280 180 210 150 95 10 11 11ND 410 345 350 180 235 150 115 10 13 14ND 411 345 350 205 270 175 115 12 13 2x11ND 412 385 350 205 280 175 115 12 13 2x11ND 413 445 350 205 280 175 115 12 13 2x11
Connecting AL terminalssee also relevant standards
Connecting AL terminalssee also relevant standards
B
A
F ±2
104550
ø H
tin-coated
E ±2
C
D
ø G+5
A
X
B
Y
C
Z
øK AL
B
A
F ±2
12
ø H
tin-coated
øG+6
E ±2C
D
A
X
B
Y
C
Z
A B C
X Y Z
øK AL
III 9-6
9.2 Accessories - Field
Type for Field curr. Transformer Weight Power loss Fuse F3IF Isek [kg] PV [W] [A]
Uprim
= 500 V; 50/60HzT 3.01 6 A 7 A 15 65 10T 3.02 12 A 13 A 20 100 16T 3.03 16 A 17 A 20 120 25T 3.04 30 A 33 A 36 180 50T 3.05 50 A 57 A 60 250 63
Uprim = 690 V; 50/60HzT 3.11 6 A 7 A ➀ 15 80 10T 3.12 12 A 13 A ➀ 20 125 16T 3.13 16 A 17 A ➀ 30 150 20T 3.14 30 A 33 A 60 230 50T 3.15 50 A 57 A 60 320 63
➀ 690 V transformer input cannot be used for the field converters SDCS-FEX-1 and SDCS-FEX-2 (isolation only 600 V max.)
Table 9.2/1: Autotransformer data
9.2.1 Autotransformer T3
9.2.2 Line choke L3 for SDCS-FEX-2
F 3
T 3
Type A B C D h e GT 3.01 / T 3.11 210 110 112 75 240 10x18 95T 3.02 / T 3.12 210 135 112 101 240 10x18 95T 3.03T 3.13 230 150 124 118 270 10x18 95T 3.04 260 150 144 123 330 10x18 95T 3.14 295 175 176 141 380 12x18 95T 3.05 / T 3.15
F 3
T 3
Fig. 9.2/1: Autotransformer T3
4.5 Ø
2
max
70
max 80
37
52
1000
1 3 4
1
3
2
4
55
Fig. 9.2/2: Line choke L3
Type line choke data L3 Weight PowerL Irms Ipeak loss
[H] [A] [A] [kg] [W] [mm²]
ND30 2x >500 16 16 1,1 8 2
Table 9.2/2: Data of line choke for field exciter
III 9-7
9.3 Fan, electronics
Type Power Weight Fuse F2 Power loss
[VA] [kg] [A] [W]
T2 460 13 6 20
Table 9.3/1: Data supply transformer T2
Input voltage: 380...690 V/1~; 56 / 60 HzOutput voltage: 115/230 V/1~
9.3.1 Supply transformer T2 for electronics and fan
F2
T2
150
106
125
128
148
100 +-5
35
0 115
230
0 380
400
415
450
500
525
575
600
660
690
Fig. 9.3/1: Transformer T2
III 9-8
Appendix AOptical cables
For the bus communication of the DCS convertersthere are different optical cables available.
Kind of cable Connector cable length Ident. no. Fig.
plastic fibre optic single cable plug 0.5...20 m 3ADT 693324 1plastic fibre optic double cable plug 0.5...20 m 3ADT 693318 2HCS silica (double) without plastic jacket plug 30...50 m 3ADT 693355 3HCS silica (double) with plastic jacket plug 50...200 m 3ADT 693356 4Glass fibre optic (double) reinforced FSMA 10...100 m 3ADV 300002 5
blue
black
black
blue
L
blue black
L
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
for
DC
S 4
00D
CS
500
DC
S 6
00
for
DC
S 6
00 s
elec
ted
ch
ann
els.
see
man
ual
ND
BU
3A
DW
000
100
R02
01fo
r D
CS
500
+ Y
PC
115
L
orange
black
orange
black∅ 5 mm
L
blue
red
blue
red∅ 8 mm
L
green
red
green
red
III A-1
III 9-9
Notices
III A-2
III 9-10
Since we aim to always meet the latest state-of-the-art standards with our products, we are sure youwill understand when we reserve the right to alterparticulars of design, figures, sizes, weights, etc. forour equipment as specified in this brochure.
3AD
W 0
00 1
65 R
0101
RE
V A
04_2
002
ABB Automation Products GmbHPostfach 118068619 Lampertheim • GERMANYTelefon +49(0) 62 06 5 03-0Telefax +49(0) 62 06 5 03-6 09www.abb.com/dc
*165R0101A2130000*