dcs thyristor power converters for dc drive...
TRANSCRIPT
II F i
DCS Thyristor Power Convertersfor DC Drive Systems
25 to 5150 A
System DescriptionDCS 600 MultiDrive
II F ii
List of contents
II F SYSTEM DESCRIPTION1 DCS 600 MultiDrive - the power converter II F 1-1
2 DCS 600 MultiDrive components overview II F 2-12.1 Environmental conditions .............................................. II F 2-32.2 DCS 600 power converter modules .............................. II F 2-42.3 DCS 600 overload withstand capability ........................ II F 2-72.4 Field Supply .................................................................. II F 2-92.5 Options for power converter modules ......................... II F 2-11
In-/output signals ....................................................... II F 2-12Serial interfacesOperation by the panel .............................................. II F 2-13Panel (control and display panel) .............................. II F 2-14Operation by the PC .................................................. II F 2-15Drive control ............................................................... II F 2-15
2.6 Options ........................................................................ II F 2-17Line reactors for armature (DCS600) andfield (DCF600) supply ................................................ II F 2-17Aspects of fusing for armature circuits and fieldsupplies of DC drives .............................................. ...II F 2-20Fuses and fuse holders for armature and field supplyII F 2-22Transformer for field supply ....................................... II F 2-22Line reactor ................................................................ II F 2-23Electronic system / fan supply ................................... II F 2-23Auxiliary transformer .................................................. II F 2-23Earth fault monitor ..................................................... II F 2-23EMC filters ................................................................. II F 2-24
3 Overview of Software (Vers. 15.xxx) ......... II F 3-13.1 Basic structure of DCS 600 MultiDrive .......................... II F 3-13.2 Control modes ............................................................... II F 3-13.3 Start, Stop and Fault reactions ..................................... II F 3-23.5 Torque control ............................................................... II F 3-43.4 Speed control ................................................................ II F 3-43.5 Torque control ............................................................... II F 3-43.6 HMI (Human Machine Interface) ................................... II F 3-43.7 Torque generation ......................................................... II F 3-53.7 Software diagrams ........................................................ II F 3-6
4 Connection examples ................................. II F 4-1
How the DCS 600 MultiDrive Documentation Sys-tem works
This is to give you an overview how the system ofinformation for DCS 600 MultiDrive converters isbuilt up. The shaded part indicates the volume withinthe total system you are just now working with. Inaddition you see all other available documents for thesame system.
System Description DCA 600 Enclosed
3ADW000121
Volume II F1
Oper. InstructionsDCS(F) 600 3ADW000080
Volume IV F
SW DescriptionDCS(F) 6003ADW000076
Volume V F
Technical Data3ADW000165
Volume III
System Description DCS(F) 6003ADW000072
Volume II F
Installation Man.DCA 600 ... 3ADW000091
Volume VI F1
Service ManualDCS 500/600
3ADW000093
Volume VI A
12-Pulse ManualDCS 600
3ADW000115
Volume II F2
II F 1-1
1 DCS 600 MultiDrive - the power converter
state-of-the-art technology flexible design user-friendly
Unit rangeThe range comprises of 4 sizes, C1, C2, A5 and C4.We can deliver both modules and standard cabinets.
Basic hardware components Thyristor bridge(s) (from size A5 with installed
branch fuses) Temperature monitor for the thyristor bridge(s) Fan Integrated power supply for the electronics Microprocessor board AMC (Application Motor Control) board with DSP
(Digital Signal Processor) for drive control andDDCS link
Additional components integrated in the module Field supply converter
– uncontrolled full wave diode bridge, 6A or– half-controlled diode/thyristor bridge, 16A
Control panel
Moreover, the accessories listed below can be usedto individually customize the drive package in ac-cordance with the application intended External field supply units 12-Pulse parallel configuration 12-Pulse serial/sequential configuration Additional I/O boards (isolated) Interface modules for various communication pro-
tocols EMC filter PC programs
C1 - Module Cabinet
ABB’s long years of experience with variable-speed DCdrives, plus use of the latest state-of-the-art technolo-gies, have been combined to create this product. TheDCS 600 MultiDrive contains a complete programwith ratings between 25 A and 5150 A as a powerconverter module (in 12-pulse parallel configurationappr. 10,000 A). It is suitable for all commonly usedthree-phase systems.
All our products are CE approved.
The DC drives factory of ABB Automation Products,Drives Division in Lampertheim has implemented andmaintains a quality management system according toDIN EN ISO 9001 and an environmental manage-ment system according to DIN EN ISO 14001.
DCS 600 MultiDrives are approved according to UL(Underwriters Laboratory).
They also comply with the relevant EMC standards forAustralia and New Zealand and are C-Tick marked.
DCS 600 MultiDrive converter units are suitable forstandard and system drive applications.
Appropriate PC programs ensure that the drives areengineered for user-friendly operator control.
II F 1-2
Design and commissioning toolsDriveWindowPC program for commissioning and maintenance un-der Windows® for:
Parameter settingFault detectionTrendingData loggerFault loggerLocal operation (Drives Panel)
CDP 312 removable control and display panel withplain text display for:
Parameter settingFault detectionParameter uploading and downloadingLocal operation
Monitoring functionsSelf-testNon-volatile fault memoryMotor protectionIn the event of:• Speed feedback error• Overtemperature• Overload• Overspeed• Zero speed• Armature overcurrent• Armature ripple• Armature overvoltage• Minimum field current• Field overcurrentPower converter protection• Overtemperature• Software errors (watchdog function)Incorrect supply protection• Mains overvoltage and undervoltage• Auxiliary undervoltage• Incorrect mains phase sequence (only inform.)
Basic functionsAll units are provided with the same digital controlboards and software. The DCS 600 MultiDrive flexi-bility allows the user to configure functions of the driveeasily, suitable for different applications. Functions ofthe DCS 600 MultiDrive are normally activated byparameters.
The basic software includes the following options:• Processing the speed reference with a speed ramp
generator (S-ramp capability, accel/decel ramp)• Processing the speed feedback• Speed controller• Torque reference processing• Current controller• Field weakening• Automatic/manual field reversal• Autotuning of current controller• Speed monitor• Drive control logic• Remote/local operation• Emergency stop• Electronic circuits are not sensitive to line phase
sequence• Electrical and mechanical brake control• Motor overload supervision• Dual field• Programmable analogue outputs• Field supply• Master follower via fibre optics
Controlling and operatingvia I/O's
analogue and digital inputs and outputs
via bus systemse.g.: Profibus, Modbus Plus, AF100 etc.
via HMI (Human Machine Interface)Outputs:
AlarmsFaultsStatus informationParameter settingLocal control of the drive
II F 2-1
2 DCS 600 MultiDrive Components Overview
The DCS 600 MultiDrive power converter range is asystem of components and complete standard cabinets tocontrol DC motors. It consists of individual components,based on the DCS 600 power converter modules. This
chapter provides a brief description of the DCS 600MultiDrive components available for matching the drivewith the conditions on site.
This overview has been designed to help you to familiarize yourselfwith the system; its main components are shown in the diagram above.The system’s heart is the DCS 600 converter module.
Fig. 2/1: DCS 600 MultiDrive Components overview for armature converters
DCS 600 Armature converter
DCF 601 / 602
X1
X2
X17
AM
C-D
C
X11
X33
DS
P
V260
CH
3
CH
0
CH
2
CO
N 2
P X16
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
Win
do
w+
FC
B
DCF 503A / 504A
PO
W 1
PIN
1x
PIN
51
IOB
2x
IOB
3
PS
5311P
IN 2
0xB
T3
F1
K5
K3
6
90V
1
000V
-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
X13X37
Mul
tiD
rive
sock
etN
DP
I
A92
T90
DC
S 6.
.-....
-.1-1
5....
. (..
.. -.1
-18.
....)
X10 X
16(2
4V)
X37
X12
X13
X12
X13
X12
X13
X2
X3
X4,
5X
6X
4X
3X
3X
5X
2X
1
X2
X17
X1
U1
V1
W1
C1
D1
X1
X1
X1
X1
X14
X14
U1
V1
U1
V1
W1
C1
D1
C1
D1
X16
X2
X99
X1
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
- d
etai
led
desc
riptio
n se
e ch
apte
r 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
Nxx
x
to other drives
Rev
D o
r la
ter
12-P
uls
e lin
k
Pow
ersu
pply Three-phase field supply
* co
nnec
tion
see
Tech
nica
l dat
a c
hapt
er 5
*
II F 2-2
The DCF 600 field supply converter range is a system ofcomponents and complete standard cabinets to controlthe field supply of DC motors. It consists of individualcomponents, based on the DCS 600 power convertermodules. The difference to the armature converter is only
the modified power interface board SDCS-PIN-1x (ifused) and the reduced range of current and voltage types(see table 2.2/2). The function for field supply will beselected by software parameters.Note: Armature and field converters use the same firmware.
This overview has been designed to help you to familiarize yourselfwith the system; its main components are shown in the diagram above.The system’s heart is the DCF 600 field supply converter module.
Fig. 2/2: DCS 600 MultiDrive Components overview for field supply converters
DCF 600 Field supply converter
AM
C-D
C
DS
P
CH
3
CH
0
CH
2
CO
N 2
PM
on
ito
rin
gL
ED
ba
rN
LM
D
Pan
elC
DP
312
Mul
tiD
rive
sock
etN
DP
I
L1K3
T2
Q1
F2
M
83
85
PC
+D
rive
Win
do
w+
FC
B
DCS 600
PO
W 1
PIN
1x
DCF 506
IOB
2x
IOB
3
F1
K5
6
90V
6
00V
M
DC
F 6.
.-....
-.1-1
5....
.
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
PIN
20x
B
V260
X10 X
16(2
4V)
X37
X12
X13
X12
X13
X1 X3
X4,
5X
6X
4X
3X
2X
1
X2
X17
X1
U1
V1
W1
C1
D1
C1
D1
X11
X12
X16
X1
X2
X17
X11
X33
X16
X14
X12
X13X
37
X4
X99
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
optic
al fi
bre
dig
ital
inp
ut /
out
pu
t
Leg
end
7.1
-
deta
iled
desc
riptio
n se
e ch
apte
r 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
Nxx
x
to other drives
mod
ified
Rev
D o
r la
ter
to a
dig
ital i
nput
of D
CF
600
II F 2-3
2.1 Environmental Conditions
System connectionVoltage, 3-phase: 230 to 1000 V according to IEC 38Voltage deviation: ±10% continuous; ±15% short-time *Rated frequency: 50 Hz or 60 HzStatic frequency deviation: 50 Hz ±2 %; 60 Hz ±2 %Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz
df/dt: 17 % / s
* = 0.5 to 30 cycles.Please note: Special consideration must be taken for voltage deviationin regenerative mode.
Degree of protectionConverter Module and accessories(line chokes, fuse holder,field supply unit, etc.): IP 00Enclosed converters: IP 20/21/31/41
Paint finishConverter module: NCS 170 4 Y015REnclosed converter: light grey RAL 7035
Fig. 2.1/1: Effect of the site elevation above sea levelon the converter’s load capacity.
Current reduction to (%)
Fig. 2.1/2: Effect of the ambient temperature on theconverter module load capacity.
Current reduction to (%)
Environmental limit valuesPermissible ambient temp. withrated I DC: 0 to +40°CRelative humidity (at 5...+40°C): 5 to 95%, no condensationRelative humidity (at 0...+5°C): 5 to 50%, no condensationAmbient temp. converter module: +40°C to 55°C; s. Fig. 2.1/2Change of the ambient temp.: < 0.5°C / minuteStorage temperature: -40 to +55°CTransport temperature: -40 to +70°CPollution degree: Grade 2
Site elevation:<1000 m above M.S.L.: 100%, without current reduction>1000 m above M.S.L.: with current reduct., see Fig. 2.1/1
Vibration converter module: 0.5 g, 5 Hz to 55 Hz
Sound pressure as module in the ABB standardlevel (1 m distance): cabinet
Size LP LP
C1 59 dBA 57 dBAC2 71 dBA 64 dBAA5 75 dBA 73 dBAC4 83 dBA 76 dBA
Regulatory ComplianceThe converter module and enclosed converter components are designed for use inindustrial environments. In EEA countries, the components fulfil the requirements of theEU directives, see table below.
North American StandardsIn North America the system componentsfulfil the requirements of the table below.
70
80
90
100
110
30 35 40 45 50 55°C
Note:Only for Converter Modules
50
60
70
80
90
100
1000 2000 3000 4000 5000 m
European Union Directive Manufacturer's AssuranceHarmonized Standards
Converter module Enclosed converter
Machinery Directive89/392/EEC93/68/EEC
Declaration ofIncorporation
EN 60204-1[IEC 204-1]
EN 60204-1[IEC 204-1]
Low Voltage Directive73/23/EEC93/68/EEC
Declaration of Conformity
EN 60146-1-1[IEC 146-1-1]EN 50178 [IEC --]see additionalIEC 664
EN 60204-1[IEC 204-1] EN 60439-1 [IEC 439-1]
EMC Directive89/336/EEC93/68/EEC
Declaration of ConformityProvided that all installationinstructions concerningcable selection, cabling andEMC filters or dedicatedtransformer are followed.
EN 61800-3 ➀[IEC 1800-3]
EN 61800-3 ➀[IEC 1800-3]
were limits are under considerationEN 50081-2 / EN 50082-2 has been supplied
➀ in accordance with3ADW 000 032
➀ in accordance with3ADW 000 032/3ADW 000 091
The Technical Construction File to which thisdeclaration relates has been assessed byReport and Certificate from ABB EMCCertification AB being the competent Bodyaccording to EMC Directive.
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II F 2-4
2.2 DCS 600 Power Converter Modules
The power converter modules are modular in construc-tion. They are based on the housing, which contains thepower section with the RC snubber circuit. There are 4different sizes, depending on current and voltage. Allunits are forced cooled.
The power section is controlled by the unit’s electronicsystem, which is identical for the entire product range.Parts of the unit’s electronic system can be installed inthe unit, depending on the particular application in-
volved, e.g. a field supply for the motor, or an interfaceboard to connect the converter to an overriding controlsystem. A control/display panel is available for theoperator. It can be mounted to the power convertermodule or installed in the cabinet's door by means of amounting kit.
Accessories such as external fuses, line reactors and thelike are available, for putting together a complete drivesystem.
Reference variablesThe voltage characteristics are shownin Table 2.2/1. The DC voltage char-acteristics have been calculated usingthe following assumptions:
• UVN
= rated mains voltage, 3-phase• Voltage tolerance ±10 %• Internal voltage drop approx. 1%• If a deviation or a voltage drop has
to be taken into consideration incompliance with IEC and VDEstandards, the output voltage orthe output current must be re-duced by the actual factor accord-ing to table 2.2/1.
➀ in case of a 2-Q converter, which is used in regenerative mode, 4-Q voltagevalues have to be used.
Table 2.2/1: DCS 600 max. DC voltages achievable with a given mains voltage.
Mains DC voltage Ideal DC Recommended voltage (max. Motor voltage) voltage DCS 600
Uv Ud without load Voltage class2-Q ➀ 4-Q Udi0 y=
230 265 240 310 4380 440 395 510 4400 465 415 540 4415 480 430 560 4440 510 455 590 5460 530 480 620 5480 555 500 640 5500 580 520 670 5525 610 545 700 6575 670 600 770 6600 700 625 810 6660 765 685 890 7690 800 720 930 7790 915 820 1060 81000 1160 1040 1350 91190 1380 1235 1590 1
II F 2-5
Converter type y → y=4 (400 V) y=5 (500 V) y=6 (600 V) y=7 (690 V)
x=1 → 2-Q IDC [A] IAC [A] P [kW] P [kW] P [kW] P [kW]
x=2 → 4-Q 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q
DCS60x-0025-y1 25 25 20 20 10 12 13 15DCS60x-0050-y1 50 50 41 41 21 23 26 29DCS60x-0050-61 50 50 41 41 31 35DCS60x-0075-y1 75 75 61 61 31 35 39 44DCS60x-0100-y1 100 100 82 82 42 47 52 58DCS60x-0110-61 110 100 90 82 69 70DCS60x-0140-y1 140 125 114 102 58 58 73 73
DCS60x-0200-y1 200 180 163 147 83 84 104 104DCS60x-0250-y1 250 225 204 184 104 105 130 131DCS60x-0270-61 270 245 220 200 169 172DCS60x-0350-y1 350 315 286 257 145 146 182 183DCS60x-0450-y1 450 405 367 330 187 188 234 235 281 284DCS60x-0520-y1 520 470 424 384 216 219 270 273DCS60x-0680-y1 680 610 555 500 282 284 354 354DCS60x-0820-y1 820 740 670 605 340 344 426 429DCS60x-1000-y1 1000 900 820 738 415 418 520 522
DCS60x-0903-y1 900 900 734 734 563 630 648 720DCS60x-1203-y1 1200 1200 979 979 498 558 624 696DCS60x-1503-y1 1500 1500 1224 1224 623 698 780 870 938 1050 1080 1200DCS60x-2003-y1 2000 2000 1632 1632 830 930 1040 1160 1400 1600
DCF60x-0025-y1 25 25 20 20 10 12 13 15DCF60x-0050-y1 50 50 41 41 21 23 26 29DCF60x-0075-y1 75 75 61 61 31 35 39 44DCF60x-0100-y1 100 100 82 82 42 47 52 58DCF60x-0200-y1 200 180 163 147 83 84 104 104DCF60x-0350-y1 350 315 286 257 145 146 182 183DCF60x-0450-y1 450 405 367 330 187 188 234 235DCF60x-0520-y1 520 470 424 384 216 219 270 273
Table 2.2/2: Table of DCS 600 / DCF 600 units - construction types C1, C2, A5
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) y=1 (1190V)
➀IDC [A] IAC [A] P [kW] P [kW] P [kW] P [kW] P [kW] P [kW] P [kW]
2-Q convertersDCS601-2050-y1 2050 1673 1435 1640 1876 2378DCS601-2500-y1 2500 2040 1163 1450 1750 2000DCS601-2650-y1 2650 2162 3074 3658DCS601-3200-y1 3200 2611 2928 3712 4417DCS601-3300-y1 3300 2693 1535 1914 2310 2640DCS601-4000-y1 4000 3264 1860 2320 2800 3200 3660 4640 5520DCS601-4750-y1 4750 3876 3325 3800 4346DCS601-5150-y1 5150 4202 2395 2987
4-Q convertersDCS602-2050-y1 2050 1673 1281 1476 1681 2132DCS602-2500-y1 2500 2040 1038 1300 1563 1800DCS602-2650-y1 2650 2162 2756 3280DCS602-3200-y1 3200 2611 2624 3328 3960DCS602-3300-y1 3300 2693 1370 1716 2063 2376DCS602-4000-y1 4000 3264 1660 2080 2500 2880 3280 4160 4950DCS602-4750-y1 4750 3876 2969 3420 3895DCS602-5150-y1 5150 4202 2137 2678
➀ These converters are equipped with additional components. More information on request
Table 2.2/3: Table of DCS 600 units - construction type C4
Higher currents up to 15,000 A are achieved by paralleling converters. More information on request.
II F 2-6
Construction type C2
Construction type C1
Converter type ➂ Dimensions Weight Clearances Construct. Power loss Fan Semiconductor H x W x D top/bottom/side type at 500V connection Fuses
[mm] [kg] [mm] PV [kW]
DCS60x-0025-y1 420x273x195 7.1 150x100x5 C1 < 0.2 230 V/1 ph externalDCS60x-0050-y1 420x273x195 7.2 150x100x5 C1 < 0.2 230 V/1 ph externalDCS60x-0050-61 420x273x195 7.6 150x100x5 C1 - 230 V/1 ph externalDCS60x-0075-y1 420x273x195 7.6 150x100x5 C1 < 0.3 230 V/1 ph externalDCS60x-0100-y1 469x273x228 11.5 250x150x5 C1 < 0.5 230 V/1 ph externalDCS60x-0110-61 469x273x228 11.5 250x150x5 C1 - 230 V/1 ph externalDCS60x-0140-y1 469x273x228 11.5 250x150x5 C1 < 0.6 230 V/1 ph external
DCS60x-0200-y1 505x273x361 22.3 250x150x5 C2 < 0.8 230 V/1 ph externalDCS60x-0250-y1 505x273x361 22.3 250x150x5 C2 < 1.0 230 V/1 ph externalDCS60x-0270-61 505x273x361 22.8 250x150x5 C2 - 230 V/1 ph externalDCS60x-0350-y1 505x273x361 22.8 250x150x5 C2 < 1.3 230 V/1 ph externalDCS60x-0450-y1 505x273x361 28.9 250x150x10 C2 < 1.5 230 V/1 ph externalDCS60x-0520-y1 505x273x361 28.9 250x150x10 C2 < 1.8 230 V/1 ph externalDCS60x-0680-y1 652x273x384 42 250x150x10 C2b < 1.6 230 V/1 ph externalDCS60x-0820-y1 652x273x384 42 250x150x10 C2b < 2.0 230 V/1 ph externalDCS60x-1000-y1 652x273x384 42 250x150x10 C2b < 2.5 230 V/1 ph external
DCS60x-0903-y1 1050x510x410 110 300x100x20 A5 - 230 V/1-ph internalDCS60x-1203-y1 1050x510x410 110 300x100x20 A5 < 5.2 230 V/1-ph internalDCS60x-1503-y1 1050x510x410 110 300x100x20 A5 < 5.5 230 V/1-ph internalDCS60x-2003-y1 1050x510x410 110 300x100x20 A5 < 6.6 230 V/1-ph internal
DCS60x-2050-y1 2330x820x624 ➀ ➁ 350 C4 - 400/690 V/3-ph➃ internalDCS60x-2500-y1 2330x820x624 ➀ 350 C4 < 12 400/690 V/3-ph➃ internalDCS60x-2650-y1 2330x820x624 ➀ ➁ 350 C4 - 400/690 V/3-ph➃ internalDCS60x-3200-y1 2330x820x624 ➀ ➁ 350 C4 - 400/690 V/3-ph➃ internalDCS60x-3300-y1 2330x820x624 ➀ 350 C4 < 15 400/690 V/3-ph➃ internalDCS60x-4000-y1 2330x820x624 ➀ ➁ 350 C4 < 16 400/690 V/3-ph➃ internalDCS60x-4750-y1 2330x820x624 ➀ 350 C4 - 400/690 V/3-ph➃ internalDCS60x-5150-y1 2330x820x624 ➀ 350 C4 < 20 400/690 V/3-ph➃ internal
➀ The dimensions for modules with busbar connection on the right side are 2330x800x624 mm (Busbar connection on the right side is optional)Example for the type designation: connection left DCS60x-2050-y1L; connection right DCS60x-2050-y1R
➁ The depth of 1000 V / 1190 V units is 654 mm➂ x=1 → 2-Q; x=2 → 4-Q; y=4...9/1 → 400...1000 V/1190 V supply voltage➃ Supply voltages up to 400 V in delta connection; 415 V or higher in star connection
Also available as field supply converter DCF60x- (for 500 V units see table 2.2/2). Data are the same as the armature current converter DCS60x
Table 2.2/4: Table of DCS 600 units
Construction type A5
to be installedin cabinet
Construction type C4Left busbar connection ➀
II F 2-7
2.3 DCS 600 Overload Capability
To match a drive system as efficiently as possible with the driven machine’sload profile, the armature power converters DCS 600 can be dimensioned by me-ans of the load cycle. Load cycles for driven machines have been defined in theIEC 146 or IEEE specifications.
Unit type IDC I
IDC II
IDC III
IDC IV
contin- 100 % 150 % 100 % 150 % 100 % 200 %uous 15 min 60 s 15 min 120 s 15 min 10 s
400 V / 500 V [A] [A] [A] [A]DCS60x-0025-41/51 25 24 36 23 35 24 48DCS60x-0050-41/51 50 44 66 42 63 40 80DCS60x-0075-41/51 75 60 90 56 84 56 112DCS60x-0100-41/51 100 71 107 69 104 68 136DCS601-0140-41/51 125 94 141 91 137 90 180DCS602-0140-41/51 140 106 159 101 152 101 202DCS601-0200-41/51 180 133 200 111 198 110 220DCS602-0200-41/51 200 149 224 124 219 124 248DCS601-0250-41/51 225 158 237 132 233 130 260DCS602-0250-41/51 250 177 266 147 260 147 294DCS601-0350-41/51 315 240 360 233 350 210 420DCS602-0350-41/51 350 267 401 258 387 233 466DCS601-0450-41/51 405 317 476 306 459 283 566DCS602-0450-41/51 450 352 528 340 510 315 630DCS601-0520-41/51 470 359 539 347 521 321 642DCS602-0520-41/51 520 398 597 385 578 356 712DCS601-0680-41/51 610 490 735 482 732 454 908DCS602-0680-41/51 680 544 816 538 807 492 984DCS601-0820-41/51 740 596 894 578 867 538 1076DCS602-0820-41/51 820 664 996 648 972 598 1196DCS601-1000-41/51 900 700 1050 670 1005 620 1240DCS602-1000-41/51 1000 766 1149 736 1104 675 1350DCS60x-1203-41/51 1200 888 1332 872 1308 764 1528DCS60x-1503-41/51 1500 1200 1800 1156 1734 1104 2208DCS60x-2003-41/51 2000 1479 2219 1421 2132 1361 2722DCS60x-2500-41/51 2500 1830 2745 1740 2610 1725 3450DCS60x-3300-41/51 3300 2416 3624 2300 3450 2277 4554DCS60x-4000-41/51 4000 2977 4466 2855 4283 2795 5590DCS60x-5150-41/51 5150 3800 5700 3669 5504 3733 7466600 V / 690 VDCS60x-0050-61 50 44 66 43 65 40 80DCS601-0110-61 100 79 119 76 114 75 150DCS602-0110-61 110 87 130 83 125 82 165DCS601-0270-61 245 193 290 187 281 169 338DCS602-0270-61 270 213 320 207 311 187 374DCS601-0450-61 405 316 474 306 459 282 564DCS602-0450-61 450 352 528 340 510 313 626DCS60x-0903-61/71 900 684 1026 670 1005 594 1188DCS60x-1503-61/71 1500 1200 1800 1104 1656 1104 2208DCS601-2003-61/71 2000 1479 2219 1421 2132 1361 2722DCS60x-2050-61/71 2050 1502 2253 1426 2139 1484 2968DCS60x-2500-61/71 2500 1830 2745 1740 2610 1725 3450DCS60x-3300-61/71 3300 2416 3624 2300 3450 2277 4554DCS60x-4000-61/71 4000 3036 4554 2900 4350 2950 5900DCV60x-4750-61/71 4750 3734 5601 3608 5412 3700 7400790 VDCS60x-2050-81 2050 1502 2253 1426 2139 1484 2968DCS60x-3200-81 3200 2655 3983 2540 3810 2485 4970DCS60x-4000-81 4000 3036 4554 2889 4334 2933 5866DCS60x-4750-81 4750 3734 5601 3608 5412 3673 73461000 VDCS60x-2050-91 2050 1577 2366 1500 2250 1471 2942DCS60x-2650-91 2650 2000 3000 1900 2850 1922 3844DCS60x-3200-91 3200 2551 3827 2428 3642 2458 4916DCS60x-4000-91 4000 2975 4463 2878 4317 2918 58361190 V
Data on request
x=1 → 2-Q; x=2 → 4-Q
The currents for the DC I to DC IV types of load (see table 2.3/2) for the power converter modulesare listed in the table below.
Table 2.3/1: Power converter module currents during corresponding load cycles.The characteristics are based on an ambient temperature of max. 40°C and an elevation of max. 1000 m.
II F 2-8
Load Load for Typical applications Load cycle cycle converter
DC I IDC I continuous (IdN) pumps, fans
DC II IDC II for 15 min and extruders, conveyor belts1,5 * IDC II for 60 s
DC III * IDC III for 15 min and extruders, conveyor belts1,5 * IDC III for 120 s
DC IV * IDC IV for 15 min and2 * IDC IV for 10 s
100%
150% 100%
150% 100%
200% 100%
15 min
15 min
15 min
If the driven machine’s load cycle doesnot correspond to one of the exampleslisted, you can determine the necessarypower converter using the DCSize soft-ware program.
This program can be run under Microsoft ® Windows,and enables you to dimension the motor and the powerconverter, taking types of load (load cycle), ambienttemperature, site elevation, etc. into account. Thedesign result will be presented in tables, charts, and canbe printed out as well.
To simplify the start-up as much as possible, everypower converter can be adjusted to the current requiredby means of parameters.
Fig. 2.3/1: Entry screen of DCSize.
Microsoft is a registered trademark. Windows is a designation of the Microsoft Corporation.
Types of load
* Load cycle is not identical with menu item Duty cycle in DCSize !Table 2.3/2: Definition of the load cycles
II F 2-9
2.4 Field Supply
General data
SDCS-FEX-1• Diode bridge.• 6 A rated current.• Internal non adjustable minimum field current
monitor.• Construction and components have been designed
for an insulation voltage of 600 V AC.• Output voltage U
A:
9.0*%100
%100*
TOLUU VA
TOL = tolerance of line voltage in %U
V = Line voltage
• Recommendation:Field voltage ~ 0.9 * U
V
SDCS-FEX-2• Half controlled thyristor/diode bridge (1-Q)• Microprocessor control, with the electronic system
being supplied by the armature converter.• Construction and components have been designed
for an insulation voltage of 600 V AC.• Fast-response excitation is possible with an appro-
priate voltage reserve; de-excitation takes place byfield time constant.
• Output voltage UA:
9.0*%100
%100*
TOLUU VA
TOL = tolerance of line voltage in %U
V = Line voltage
• Recommendation:Field voltage 0.6 to 0.8 * U
V
All field power converters (except for the SDCS-FEX-1) are controlled by the armature converter via a seriallink with a speed of 62.5 kBaud. The link serves toparameterize, control and diagnose the field powerconverter and thus provides an exact control. Moreo-ver, it enables you to control one internal (SDCS-FEX-2) and one external (DCF 503A/4A, DCF 601/2) ortwo external field supply units (2 x DCF 503A/4A,DCF 601/2). The respective software function re-quired is available in every DC power converter.
Field converter types
• Currents from 6 to 520 A.• Minimum field current monitor.• Integrated or external field power converter or in a
completely separate cabinet.• 2-phase or 3-phase model.• Fully digital control (except SDCS-FEX-1).
We recommend integrating an autotransformer in thefield power converter's supply to adjust the AC inputvoltage to the field voltage, to reduce the voltage andcurrent ripple of the field.
II F 2-10
DCF 503A• Half controlled thyristor/diode bridge (1-Q).• Microprocessor control with the control electronics
being supplied separately (115...230 V/1-ph).• Construction and components have been designed
for an insulation voltage of 690 V AC.• Output voltage U
A:
9.0*%100
%100*
TOLUU VA
TOL = tolerance of line voltage in %U
V = Line voltage
• Recommendation:Field voltage 0.6 to 0.8 * U
V
DCF 504A• like DCF 503A, but• fully controlled antiparallel thyristor bridges (4-Q).• With this unit fast response excitation / de-excita-
tion and field reversal is possible. For fast responseexcitation an appropriate voltage reserve is neces-sary.In steady-state condition, the fully controlled bridgeruns in half controlled mode to keep the voltageripple as low as possible. With a fast changing fieldcurrent, the bridge runs in fully controlled mode.
DCF 600This field power converter is used mainly for armatureconverters with rated currents of 2050 to 5150 A. It isa modified armature circuit converter.• Output voltage U
A respectively U
dmax 2-Q :
see table 2.2/1.• Recommendation:
Field voltage 0.5 to 1.1 * UV
• The three-phase field supply converters DCF 600needs a separate active overvoltage protection unitDCF 506 for protecting the power part against toohigh voltages.The overvoltage protection unit DCF 506 is suitablefor 2-Q converters DCF 601 and for 4-Q convertersDCF 602.
auxiliary supply (115...230V) if necessary via matching trans-former; external fuse; Dimensions HxWxD: 370x125x342 [mm]
DCF506-140-51,shown without cover
DCF601/602
Assignment Field supply converter to Overvol-tage protection unit
Field supply converter Overvoltage Protectionfor motor fields
DCF60x-0025-y1 ➀ ... DCF506-0140-51DCF60x-0100-y1 ➀
DCF60x-0200-y1 ➀DCF60x-0350-y1 ➀ ... DCF506-0520-51DCF60x-0520-y1 ➀
➀y = 400...500 V
DCF503A/4A
Unit type Output Supply Installation Remarkscurrent IDC ➀ voltage site
[A] [V]
SDCS-FEX-1-0006 0.02...6 110V -15%...500V/1-ph +10% internal external fuse, 6 A ⇒ IFrated
SDCS-FEX-2-0016 0.3...16 110V -15%...500V/1-ph +10% internal ext. fuse, reactor; for C1: 0.3 ... 8 A ➀, not to be used for C4 modules!
DCF 503A-0050 0.3...50 110V -15%...500V/1-ph +10% externalDCF 504A-0050 0.3...50 110V -15%...500V/1-ph +10% external
DCF 60x-xxxx-41/51 see table 200V...500V/3-ph external2.2/2
➀Current reduction see also 2.1 Environmental conditions Fig.: 2.1/1 and 2.1/2Table 2.4/1: Data field converter units
are based on the hardware of the DCS 600 and additionalhardware components (DCF 506); auxiliary supply (115/230 V)
II F 2-11
In-/output signalsaddition to this an extension of I/O´s by SDCS-IOE 1is possible.
Fig. 2.5/1: I/O´s via SDCS-CON-2Analogue I/O´s: standardDigital I/O´s: not isolatedEncoder input: not isolated
Fig. 2.5/2: I/O´s via SDCS-CON-2 and SDCS-IOB-2Analogue I/O´s: standarddigital I/O´s: all isolated by means of
optocoupler/relay; the signalstatus is indicated by LED
Fig. 2.5/3: I/O´s via SDCS-CON-2 and SDCS-IOB-3Analogue I/O´s: more input capacitydigital I/O´s: not isolatedencoder input: isolatedcurrent source for: PT100/PTC element
Fig. 2.5/4: I/O´s via SDCS-IOB-2 and SDCS-IOB-3Analogue I/O´s: more input capacitydigital I/O´s: all isolated by means of
optocoupler/relay; the signalstatus is indicated by LED
current source for: PT100/PTC element
The converter can be connected in 4 different ways toa control unit via analogue/digital links. Only one ofthe four choices can be used at the same time. In
X3: X4: X5: X6: X7:
X2: X1:
X17:
SDCS-CON-2
1 2
X3: X4: X5:
X2: X1:
X17:
SDCS-CON-2
X3: X1:
SDCS-IOB-2
1
4
X1: X2:
SDCS-IOB-3
X6: X7:
X2:
X17:
X1:
3
2
SDCS-CON-2
X2:
SDCS-IOB-3
X2:
X17:
SDCS-CON-2
X1:
SDCS-IOB-2
X1:
X1: X3:
3 4
2.5 Options for DCS 600 MultiDrive converter modules
II F 2-12
Description of I/O signals SDCS-CON-2
Mechanical system integrated in control board
TerminalsScrew type terminals for finely stranded wires up to 2.5 mm2
Functionality 1 tacho input
Resolution: 12 bit + sign; differential input; common mode range ±20 V3 ranges from 8...30...90...270 VDC with nmax
4 analogue inputsRange -10...0...+10 V, 4...20 mA, 0...20 mAAll as differential inputs; RE = 200 kΩ; time constant of smoothingcapacitor ≤2 msInput 1: Resolution: 12 bit + sign; common mode range ±20 VInputs 2, 3, 4: Resolution: 11 bit + sign; common mode range ±40 V
2 outputs+10 V, -10 V, IA ≤ 5 mA; sustained short-circuit-proofvoltage supply for reference potentiometer
1 analogue outputbipolar current actual - from power section; decoupledIdN = ±3 V; IA≤ 5 mA, short-circuit-proof
2 analogue outputsRange -10...0...+10 V; IA ≤ 5 mAOutput signal and scaling can be selected by means of softwareResolution: 11 bit + sign
1 pulse generator inputVoltage supply for 5 V/12 V/24 V pulse generators (sustained short-circuit-proof)Output current with 5 V: IA ≤ 0.25 A
12 V: IA ≤ 0.2 A24 V: IA ≤ 0.2 A
Input range: 12 V/24 V: asymmetrical and differential5 V: differential
Pulse generator as 13 mA current source: differentialLine termination (impedance 120Ω), if selectedmax. input frequency ≤300 kHz
Description of I/O signals SDCS-IOB-2x & SDCS-IOB-3
Mechanical system always external, outside the module
TerminalsScrew type terminals for finely stranded wires up to 2.5 mm2
Functionality of SDCS-IOB-3 1 tacho input
Resolution: 12 bit + sign; differential input; common mode range ±20 VRange 8 V- with nmax; if higher tacho voltages are in use tacho adaptationboard PS 5311 is needed.
4 analogue inputsAll as differential inputs; time constant of smoothing capacitor ≤2 msInput 1: Range -10 V...0...+10 V; -20 mA...0...+20 mA; 4... 20 mAunipolar; RE = 200 kΩ/ 500Ω/ 500Ω; Resolution: 12 bit + sign; commonmode range ±20 VInputs 2+3: Range see input 1, in addition -1 V...0...+1 VRE = 200 kΩ/ 500Ω/ 500Ω/ 20kΩ; Resolution: 11 bit + sign; commonmode range with -1 V...0...+1 V range ±10 V, otherwise ±40 VInput 4: Range see input 1RE = 200 kΩ/ 500Ω/ 500Ω; Resolution: 11 bit + sign; common moderange ±40 V
Fault current detection (Earth fault) in combination with analogueinput 4 (sum of phase currents ≠ 0)
2 outputs+10 V, -10 V; IA ≤ 5 mA; sustained short-circuit-proofvoltage supply for reference potentiometer
1 analogue outputBipolar current actual - from power section; decoupledIdN = ±3 V (at gain = 1); IA≤ 5 mA; UAmax = 10 V; gain can be adjusted bymeans of a potentiometer between 0.5 and 5; short-circuit-proof
2 analogue outputsRange -10...0...+10 V; IA ≤ 5 mA; short-circuit-proofOutput signal and scaling can be selected by means of softwareResolution: 11 bit + sign
Current source for PT 100 or PTC elementIA = 5 mA / 1.5 mA
1 pulse generator inputVoltage supply, output current, input range: see SDCS-CON-2Inputs electrically isolated from 0 V (housing) by means of optocouplerand voltage source.
Functionality of SDCS-IOB-2x3 different designs available: SDCS-IOB-21 inputs for 24...48 V DC; RE = 4.7 kΩ SDCS-IOB-22 inputs for 115 V AC; RE = 22 kΩ SDCS-IOB-23 inputs for 230 V AC; RE = 47 kΩ
TerminalsScrew type terminals up to 4 mm2
8 digital inputsThe functions can be selected by means of software.The signal status is indicated by LED.All isolated by means of optocouplers.Input voltage: IOB-21:0...8 V ⇒ "0 signal", 18...60 V ⇒ "1 sig."
IOB-22:0...20 V ⇒ "0 signal", 60...130 V ⇒ "1 sig."IOB-23:0...40 V ⇒ "0 signal", 90...250 V ⇒ "1 sig."
Filter time constant: 10 ms (channels 1...6); 2 ms (channels 7+8)Auxiliary voltage for digital inputs: +48 V DC; ≤ 50 mA; sustained short-circuit-proof; referenced to the unit housing potential.
8 digital outputsThe functions can be selected by means of software.The signal status is indicated by LED.6 of them potential isolated by relay (N.O. contact: AC: ≤250 V/ ≤3 A /DC: ≤24 V/ ≤3 A or ≤115/230 V/ ≤0.3 A), protected by VDR component.2 of them potential isolated by optocoupler, protected by zener diode(open collector) 24 V DC external, IA ≤ 50 mA.
8 digital inputsThe functions can be selected by means of software.Input voltage: 0...8 V ⇒ "0 signal", 16...60 V ⇒ "1 signal"Time constant of smoothing capacitor: 10 msRE = 15 kΩThe signal refers to the unit housing potential.Auxiliary voltage for digital inputs: +48 V DC, ≤ 50 mA, sustained short-circuit-proof
7+1 digital outputsThe function can be selected by means of software.7 outputs: relay driver with free-wheeling diode, total current limitation≤ 160 mA; short-circuit-proof.1 relay output - on power board SDCS-POW-1 (N.O. contact:AC: ≤250 V/ ≤3 A / DC: ≤24 V/ ≤3 A or ≤115/230 V/ ≤0.3 A) protectedby VDR component.
II F 2-13
There are various serial interface options available foroperation, commissioning, diagnosis and controlling.For the control and display panel CDP 312 are serialconnections X33:/X34: on the SDCS-CON-2 availa-ble. Three additional serial interfaces are available onthe SDCS-AMC-DC 2 board.These interfaces use plastic or HCS optical fibres.Channel 3 is used for drive/PC interfacing. Channel 0for fieldbus module interfacing or communication tothe overriding control system. Channel 2 is used forMaster-Follower link or for I/O extension. All threeserial interfaces are independent from each other.
Fig. 2.5/5: Options for serial communication
Different SDCS-AMC 2 boards are available to adaptoptical cables, cable length and serial interfaces. Thedifferent SDCS-AMC 2 boards are equipped with 10or 5 Mbaud optical transmitter and receiver devices.A few basic rules must be considered:• Never connect 5 Mbaud and 10 Mbaud devices.• 5 Mbaud can handle only plastic fibre optic.• 10 Mbaud can handle plastic or HCS cable.• The branching unit NDBU 95 extends the maxi-
mum distance.• The maximum distance and suitable configuration
can be found in the manual Configuration Instruc-tions NDBU 85/95; Doc no.: 3ADW000100.
Fig. 2.5/6: LED Monitoring Display
LED Monitoring DisplayIf the MultiDrive door Mounting kit is used it ispossible to insert up to three LED monitoring displaysfor indicating status as run, ready and fault and aselectable parameter indicator (0...150%) per drive.The display is connected to the SDCS-CON-2 board(X33:/X34:) or to the panel socket NDPI through auniversal Modbus link.
RDY
RUN
FLT 0 50 100 1501
Remark:Fieldbus modules Nxxx(CH0) require theSDCS-AMC-DC Classic 2board - all others (FCI,AC80...) require theSDCS-AMC-DC 2 board.
Fig. 2.5/7: Connection of the LED Monitoring Display
Serial interfaces
Operation by panel
Panel locationThere are different possibilities for mounting the panel:• On the converter module.• With MultiDrive door mounting kit.
X16:
PC
3 m
CDP 312
D20
0C
H 3
TxD
RxD
CH
2Tx
D
RxD
CH
0Tx
D
RxD
D40
0
SDC
S-A
MC
-DC
2SD
CS-
AM
C-D
C C
lass
ic 2
AC800M
FCIAC80
Nxxx Nxxx-01xxxxxxxxADAPTER
BUST ERM INAT ION
ON
OFF
RXD
T XD
PE SHF DG D(N) D(P)X1
X2PE SHF DG D(N) D(P)SH
XM IT
REC
ERRO R
+24V 0V SH
X33:X34:
SDCS-CON-2
electricalconnection
optic
al fi
bre
Power supply
Control Operation
- Master-Follower link- I/O Extension
to the PLC
Interface
X33:/X34:
SDCS-CON-2
RDY
RUN
FLT 0 50 100 1501
NLMD
SDCS-CON-2 NDPI
NLMDRDY
RUN
FLT 0 50 100 1501
CDP 312
X33:/X34:
II F 2-14
Panel (control and display panel)The CDP 312 control and display panel communicateswith the power converter via a serial connection inaccordance with the RS 485 standard at a transmissionrate of 9.6 kBaud. It is an option for the converter unit.After completion of commissioning, the panel is notnecessarily required for diagnostic. The basic unit has a7-segment display indicating errors.
Fig. 2.5/8: Function keys and various displays on the removablecontrol and display panel.
ActualSelects the display of feedback values plus the
signal group and the error memory group.
ParametersFor selecting and adjustingall parameters and signals.
FunctionSelects the “functions” operating mode; can be usedto perform special functions such as uploading anddownloading of parameter sets.
Drivefor extensions
Twin arrow keysare used to change the group. In the parameter and
reference presetting modes, you can alter the param-eter value or the reference setting ten times faster by
means of the twin arrow keys than by means of thesingle arrow key.
Arrow keysare used to select parameters within a group. You al-ter the parameter value or the reference setting inthe parameter and reference presetting modes. Inthe feedback signal display mode, you select the lineyou want.
Enteris used in the following modes:Parameter setting: enter new parameter valueActual valuesignal display: enter the current signal selec-
tion modeSignal selection: accept selection and return to
the feedback value signal dis-play mode
Local/Remoteis used to select local (control
panel) or remote control.
ResetFault acknowledge key.
Referenceis used to activate the reference presetting mode.
Startstarts the drive in local mode.
Stopshuts the drive down if you are in local mode.
Onin local mode switches the main contactor on.
Offin local mode switches the main contactor off.
Features• 16 membrane pushbuttons in three function groups• LCD display has four lines with 20 characters each• Language: English• Options for the CDP 312:
– Cable to separate the panel from the converter.– Kit for mounting the panel in the cabinet door.
Status row
Functions to be selected
Display contrastsetting
0 L 0,0 rpm 00UPLOAD <==DOWNLOAD ==>CONTRAST
Groupand name
Subgroupand name
0 L 0,0 rpm 0017 RAMP GENERATOR08 ACCEL 1 20.0 s
Value
0 L 0,0 rpm 00SPEEED ACT 0,0 rpmCONV CUR 0 AU ARM ACT 0 V
ID number of thedriveselected
ControllocationL = local
= remote
Main contactorstatus0 = open1 = closed
Speedreferencerpm
Run status1 = Run0 = Stop
Status row
Actual signalname and value
Cursor showsthe row selected
0 L 0,0 rpm 001 LAST FAULTEmergency stop3212:59:35:56
1 = last fault2 = last-but-one fault99 = last fault
Total time afterswitch-on
HHHH:MM:SS.ss
Name of Fault or alarm
II F 2-15
Drive controlComponents required:• Plastic optical fibre for distances up to 15 m.• Field bus module Nxxx-xx• FCI (CI810)• AC80 (PM825)• AC800 M
Functionality:Depends on the used module, interface e.g. to:• PROFIBUS with NPBA-12• MODBUS+ with NMBP-01• AF100 with FCI (CI810)• AC80 (PM825) or• AC800 M• further modules on requestYou will find more detailed information on data ex-change in the specific PLC or fieldbus module docu-mentation.
Operation by PCComponents required:• Plastic optical fibre for distances up to 20 m.• Network up to 200 drives (same as for ACS 600).• HCS optical fibre cable up to 200 m.
See separate manual Configuration InstructionsNDBU 85/95; Doc no.: 3ADW000100.
Functionality:• DriveWindow software package➀ for commission-
ing, diagnosis, maintenance and trouble shooting;structure of connections see Technical Data; Docno.: 3ADW000165.
System requirements/recommendation:• PC (IBM-compatible) with 486 processor or higher
(min. 50 MHz).• 8 MB RAM.• DOS version 5.0 or later.• Windows 3.1, 3.11, Windows95/98; Windows
NT4.0.• VGA monitor.• CD-ROM drive.• PCMCIA or ISA card slot.In addition to the options provided by the CDP 312control and display panel, there are further functionsavailable, and these are described on the following page.
➀ For further information see the specific publications
II F 2-16
Operation by PC (continued)
DriveWindowDriveWindow is the most comprehensive commis-sioning and maintenance tool available for ABB prod-ucts. DriveWindow is a PC tool designed for onlinecommissioning and maintenance of ABB products. Itprovides several different displays to effectively andeasily utilize the tool. DriveWindow is able to connectto various target devices through several different typesof communication links.
System Configuration Display
The System Configuration Display provides an over-view of the system as well as the type and status ofeach product connected to the communication link(s).Included in the System Configuration Display arepreviously saved files located on the hard drive of thecomputer. This display is built automatically by theDriveWindow by scanning the communication links tofind the configuration of the system.
Drives Panel Display
The Drives Panel Display is used for controlling theoperation of a selected drive within the system. Youcan control different drives by changing the targetdrive selection. The following commands are avail-able with the Drives Panel:- Start and Stop.- Set speed reference.- Change reference direction.- Reset active fault.- Change to Local/Remote control mode.
Signals and Parameters Display
The Signals and Parameters Display is used forhandling signals and parameters of the target drive.The signal and parameter list is uploaded from thedrive and can be viewed, saved to a file or comparedto another parameter set. Previously set values canbe downloaded to the active drive. You can also setthe parameter values in either offline or online mode.
Monitor Display
The Monitoring Display is used for monitoring graphi-cally the actual values of the target. The followingfunctions are also supported:- Zoom-in and Zoom-out- Scaling the graphs- Setting the sampling interval- Setting the time window- Triggering on specific conditions- Signals from multiple drives can be displayed in
the same view
Data Logger Display
The Data Logger Display provides facilities for view-ing the contents of the data loggers in the drive. Youcan display the data in either graphical or numericalform as well as setting up the data logger triggeringconditions.
Event Logger Display
The contents of the Event Logger can be viewed andcleared by using this display.
Fault Logger Display
The contents of the Fault Logger can be viewed andcleared by using this display.
Application Display
Application programs can be downloaded and de-bugged with this display.
Please note:For more information obout DriveWindow use thehelp function of the program.
Fig. 2.5/9: Display of DriveWindow
II F 2-17
2.6 Options
Line reactorsFor armature (DCS 600) and field (DCF600) supply
When power converters are operated with thyristors,the line voltage is short-circuited during commutationfrom one thyristor to the next. This operation causesvoltage dips in the mains. For the connection of a powerconverter system to the mains, following configura-tions can be made:
Configuration AWhen using the power converter, aminimum of 1% impedance is requiredto ensure proper performance of thesnubber circuit. A line reactor can beused to meet this minimum impedancerequirement. The value must thereforenot drop below 1% u
k (relative imped-
ance voltage). It should not exceed 10%u
k, due to considerable voltage drops.
Configuration BIf special requirements have to be met atthe connecting point, different criteriamust be applied for selecting a linereactor. These requirements are mostoften defined as a voltage dip in percentof the nominal supply voltage.The combined impedance of Z
Line and
ZLR
consists of the total series imped-ance of the installation. The ratio be-tween the line impedance and the linereactor impedance determines the volt-
age dip at the connecting point. In such cases linereactors with an impedance of about 4% are used.
VoltagedipZ
Z ZLine
Line LR
*100%
Example:Maximum allowable voltage dip is 20% at the powerconverter's connecting point. Above equation used andchanged to:
Z ZLR Line 4 * (1)
Since the line impedance is seldom known (it can bedetermined by means of a measurement), and theshort-circuit power at the same point is more frequentlyavailable, the line reactor can be calculated by means ofthis value.
Connectingpoint
LineLLine
LLR
Connectingpoint
Line
uk LR ca. 1%
Assumption: The system's short-circuit power at thepower converter’s connecting point is 180 times thepower converter’s rated power.• The system’s relative impedance voltage u
k can be
determined:
uk Line
1180
100% 055%* .
• In accordance with equation (1), the followingapplies for the line reactor:
u Uk LR K Line 4 2 2%* .
• Since the line reactor has to be sized specific to thepower converter, the relative variable U
k must be
converted into an absolute value. For this purpose,use following equation:
uI f L
Uk
dN N LR
N
* * * * *23
3 2
IdN: rated direct current of the converterfN: rated frequency of the systemUN: rated line voltageLLR: line reactor inductance
Configuration CIn the case of high power converteroutputs or high currents, a power con-verter transformer must be used fre-quently to match the voltage. If anautotransformer is used for this pur-pose, a commutating reactor must addi-tionally be used if special conditionsmust be complied with as per configu-ration B. The reason for this is that theu
k of commonly used autotransformers
is generally too small. If you do not havespecial conditions of this kind, you must neverthelesscheck whether the u
k of the autotransformer concerned
is sufficient to satisfy configuration A.
Connectingpoint
Line
LLR
An examination of volume and costs results in thefollowing configuration:Configuration D
If an isolating transformer is used, it isoften possible to comply with certainconnecting conditions per configura-tion B without using an additional linereactor. The condition described in con-figuration A will then likewise be satis-fied, since the u
k is >1 %.
Connectingpoint
Line
II F 2-18
With reference to the power converter:
- The line reactors listed in the table (2.6/1)- have been allocated to the converter's nominal
current- are independent of converter's voltage classifica-
tion; at some converter types the same line chokeis used up to 690 V line voltage
- are based on a duty cycle- can be used for DCS 600 as well as for DCF 600
converters- The duty cycle taken into account varies from line
choke to line choke and is between 80% and 100%.If the converter is sized on a duty cycle or is used fora drive running with high load all time like extrudersdo next steps to check the overall selection:- Calculate the I
DCrms based on the duty cycle and the
motor current- Multiply the I
rms of the line choke by 1.2
- In case Irms
is higher than IDCrms
the combination isokay
- In case Irms
is lower than IDCrms
take the line chokeused for the next bigger converter with the samevoltage classification
- If the line choke should be used for a DCF 600converter make sure the nominal field current doesn'texceed the thermal current of the choke. In case thefield current is higher than I
rms of the line choke take
the one used for the next bigger converter with thesame voltage classification
- For units >2000 A or >690 V, we recommend usingone isolating transformer per power converter asseem in configuration D.
II F 2-19
Fig. 1 Fig. 2 Fig. 3
DCS Type Line choke Fig. Line choke Design400V-690V type for type for Fig.50/60 Hz configur. A configur. B
DCS60x-0025-41/51 ND01 1 ND401 4DCS60x-0050-41/51 ND02 1 ND402 4DCS60x-0050-61 ND03 1 on request -DCS60x-0075-41/51 ND04 1 ND403 5DCS60x-0100-41/51 ND06 1 ND404 5DCS60x-0110-61 ND05 1 on request -DCS60x-0140-41/51 ND06 1 ND405 5
DCS60x-0200-41/51 ND07 2 ND406 5DCS60x-0250-41/51 ND07 2 ND407 5DCS60x-0270-61 ND08 2 on request -DCS60x-0350-41/51 ND09 2 ND408 5DCS60x-0450-41/51 ND10 2 ND409 5DCS60x-0450-61 ND11 2 on request -DCS60x-0520-41/51 ND10 2 ND410 5DCS60x-0680-41/51 ND12 2 ND411 5DCS601-0820-41/51 ND12 2 ND412 5DCS602-0820-41/51 ND13 3 ND412 5DCS60x-1000-41/51 ND13 3 ND413 5
DCS60x-0903-61/71 ND13 3 ND413 5DCS60x-1203-41/51 ND14 3 on request -DCS60x-1503-41/51/61/71 ND15 3 on request -DCS60x-2003-41/51 ND16 3 on request -DCS601-2003-61/71 ND16 * 3 on request -
* with forced cooling
Line reactors L1
Table 2.6/1: Line reactors (for more information see publication Technical Data)
Fig. 5
II F 2-20
General
Unit configurationProtection elements such as fuses or overcurrent tripsare used whenever overcurrents cannot entirely be ruledout. In some configurations, this will entail the follow-ing questions: firstly, at what point should whichprotective element be incorporated? And secondly, inthe event of what faults will the element in questionprovide protection against damage?Possible sources of faults are:
Fig. 2.6/1 Arrangement of the switch off elements in thearmature circuit converter
Faults within the unit electronics• Usually the coverter will limit the current. The
maximum current corresponds to the set currentlimit. If this limitation or one of its componentsfails, then the current will often rise sharply.Output current I >> I
RATED ; Fault: 1
• If one or more false firing pulses are generated, e.g.due to component failures or other factors, then thecurrent will likewise rise sharply.Output current I >> I
RATED ; Fault: 2
• If in 4-Q units thyristors of both bridges becomeconductive, circulating current is the consequence.The cause may be component defects or otherfactors. The current on the three-phase side will risesharply.I
AC >> I
RATED ; Fault: 3
Defective system conditions leading to commutationfailure• In the case of regeneration, the ratio of motor voltage
to line voltage rises above 1.05, which is followed bya situation called “shoot-through”. The current risessubstantially.Output current I >> I
RATED ; Fault: 4
Possible causes:- Network problems (line undervoltage).- Overspeed (load accelerates motor) or control er-
ror.- Field supply generates a field current larger than
IFRATED
or control error in the field weakeningrange.
Faults caused by components• Semiconductor faults can be, that a thyristor no
longer fires (5a), or in that it is permanently conduc-tive (5b). Depending on the system condition (4-Qoperation, regeneration, etc.), these two cases willthen show similar symptoms like cases 3 and 4.Faults: 5a, 5b
• Insulation faults may occur within the cabling of themains supply, the power converter and the motor.These can be subdivided into faults finally resultingin a short-circuit and those leading to an earth fault.- In the event of a short-circuit, the following
generally applies: I >> IRATED
- In the event of an earth fault, depending on wherethe fault has occurred, the current may rangebetween I = I
RATED and I >> I
RATED.
Fault: 6
Fusing of the armature-circuit supplyThe table below shows the fault cases in which semicon-ductor fuses (super fast) can protect the drive systemconsisting of motor and converter. Those cases marked(X) would protect the motor only, and not the convert-er.
Semiconductor fusesFault on the AC side on the DC side
1 X (X)2 X (X)3 X4 X
5a ⇒ 3 X5b ⇒ 4 X
6 X X
Before deciding whether fuses are going to be used onthe DC side, you must first check in which workingpoints the drive is used and how often (proportion oftime compared to the overall duration of operation).
Following general rule applies:- Analogue systems are more sensitive and more vul-
nerable to malfunctions than digital systems.- Digital systems are able to detect critical situations
much easier and have features to prevent the equip-ment from being shut down.
Aspects of fusing for armature circuits and field supplies of DC drives
M..
.
.
.
3
2
2
For field supplysee Fig. 2.6/2
AC supply: public mains / plant's mains
Cabinet
II F 2-21
Conclusion for the armature supply
Due to cost saving standard fuses are used instead of themore expensive semiconductor fuses at some applica-tions. Under normal and stable operating conditions,this is understandable and comprehensible, as long ascartain fault scenarios can be ruled out.
In the event of a fault , however, the saving may causevery high consequential costs. Exploding power semi-conductors may not only destroy the power converter,but also cause fires.
Adequate protection against short-circuit and earthfault, as laid down in the EN50178 standard, is possi-ble only with appropriate semiconductor fuses.
Complies with Basic Principles on:1 – Explosion hazard yes2 – Earth fault yes3 – “Hard“ networks yes4 – Spark quenching gap yes5 – Short-circuit yes6 – 2-Q regenerative yes
M M
DCS converter
2-Q non-regen.
Semiconductorfuses
Semiconductorfuses
Semiconductorfuses
4-Q resp.2-Q regenerative
DCS converter
ABB's recommendations
Fusing of the field supply
Basically similar conditions apply to both field supplyand armature circuit supply. Depending on the powerconverter used (diode bridge, half-controlled bridge,fully controlled 4-Q bridge), some of the fault sourcesmay not always be applicable. Due to special systemconditions, such as supply via an autotransformer or anisolating transformer, new protection conditions haveto be added.
In opposite to the armature circuit supply, fuses arenever used on the DC side for the field supply, since afuse trip might under certain circumstances lead togreater damage than the cause tripping the fuse in thefirst place (small, but long lasting overcurrent; fuseageing; contact problems; etc.).
Fault 4 can also occur in the case of field supply units,but will not cause such a rapid and substantial currentrise as encountered with the armature circuit supply.This is due to the significantly higher inductance of thefield winding.
If conditions similar to those for armature circuitsupply are to apply, like for example protection of thefield supply unit and the field winding, then semicon-ductor fuses (super fast F3.1) must be used.
The following configurations are relatively frequentused:
Fig 2.6/2 Configurations for field supplies
F3.3
2
2
2
F3.2
F3.1
RK
F3.1
F3.1
F
R Possible field supply units:- SDCS-FEX-1: uncontrolled diode bridge; Fault: 5a, 6- SDCS-FEX-2: half-controlled bridge, 1-Q; Fault: 1, 5a, 6- DCF 503A: half-controlled bridge, 1-Q; Fault: 1, 5a, 6- DCF 504A: fully controlled bridge, 4-Q; Fault: 1, 3, 4, 6The faults listed here are described under “Aspects of fusing for armature circuitsand field supplies”.
Note: in the case of 1, 4, and 6, the current is limited to relatively small overcurrentsdue to the ohmic content of the field winding, so that the fuses may not trip.
K See section Line reactors
F The F3.2 and F3.3 fuse types serve as line protectors and cannot protect the fieldsupply unit. Only pure HRC fuses or miniature circuit breakers may be used.Semiconductor fuses would be destroyed by the inrush current.
II F 2-22
Field converter type for field current Transformer≤≤≤≤≤500 V; 50/60 Hz IF type 50/60 Hz
Uprim ≤≤≤≤≤500 VSDCS-FEX-1 ≤6 A T 3.01SDCS-FEX-2 ≤12 A T 3.02SDCS-FEX-2 ≤16 A T 3.03DCF503A/4A-0050 ≤30 A T 3.04DCF503A/4A-0050 ≤50 A T 3.05
Uprim ≤≤≤≤≤600 VSDCS-FEX-1 ≤6 A T 3.11SDCS-FEX-2 ≤12 A T 3.12SDCS-FEX-2 ≤16 A T 3.13
Uprim ≤≤≤≤≤690 VDCF503A/4A-0050 ≤30 A T 3.14DCF503A/4A-0050 ≤50 A T 3.15
Table 2.6/4: Autotransformer data (details see Technical Data)
Transformer T3 for field supply to match voltage levels
Fig. 2.6/3: T3 autotransfor-mer
Type of converter Manufacturer / Type Fuse holder
DCS60x-0025-41/51 Bussman 170M 1564 OFAX 00 S3LDCS60x-0050-41/51 Bussman 170M 1566 OFAX 00 S3LDCS60x-0050-61 Bussman 170M 1566 OFAX 00 S3LDCS60x-0075-41/51 Bussman 170M 1568 OFAX 00 S3LDCS60x-0100-51 Bussman 170M 3815 OFAX 1 S3DCS60x-0110-61 Bussman 170M 3815 OFAX 1 S3DCS60x-0140-41/51 Bussman 170M 3815 OFAX 1 S3DCS60x-0200-41/51 Bussman 170M 3816 OFAX 1 S3DCS60x-0250-41/51 Bussman 170M 3817 OFAX 1 S3DCS60x-0270-61 Bussman 170M 3819 OFAX 1 S3DCS60x-0350-41/51 Bussman 170M 5810 OFAX 2 S3DCS60x-0450-41/51/61 Bussman 170M 6811 OFAS B 3DCS60x-0520-41/51 Bussman 170M 6811 OFAS B 3DCS60x-0680-41/51 Bussman 170M 6813 OFAS B 3DCS60x-0820-41/51 Bussman 170M 6813 OFAS B 3DCS60x-1000-41/51 Bussman 170M 6166 3x 170H 3006
Table 2.6/2: Fuses and fuse holders (details see Technical Data)
Fuses F1 and fuse holders for armature and 3-phase field supply(DCS 600 - DCF 600)The converter units are subdivided into twogroups:– Unit sizes C1 and C2/C2b with rated
currents up to 1000 A require externalfuses.
– In unit sizes A5 and C4 with rated cur-rents up to 5150 A, the semiconductorfuses are installed internally (no addition-al external semiconductor fuses are need-ed).
The semiconductor fuses for C1 and C2/C2b unit sizes are blade fuses except170M6166. The relevant data is listed intable 2.6/2.The fuses’ type of construction requires spe-cial fuse holders.
The field supply units’ insulation voltage ishigher than the rated operating voltage (seechapter Field supply). This provides the op-tion in systems with more than 500 V tosupply the armature of the converter directlyfrom the mains. An autotransformer is usedto match the field supply to its rated voltage.Moreover, you can use the autotransformerto adjust the field voltage (SDCS-FEX-1diode bridge) or to reduce the voltage ripple.Different types (primary voltages of 400...500V and of 525...690 V) with different ratedcurrents are available.
Depending on the protection strategy dif-ferent types of fuses are to be used. The fusesare sized according to the nominal current ofthe field supply. If the field supply is con-nected to two phases of the network, twofuses should be used. In case the unit isconnected to one phase and neutral only thefuse in the phase can be used. Table 2.6/3lists the fuses currents with respect to Fig.2.6/2.The fuses can be sized according to themaximum field current of the motor. In thiscase take the fuse, which fits to the fieldcurrent levels of the motor.
Fuses F3.x and fuse holders for 2-phase field supply
Field conv. Field current F3.2 F 3.3
SDCS-FEX-1 IF ≤ 6 A OFAA 00 H10 10 ASDCS-FEX-2
SDCS-FEX-2 IF ≤ 12 A OFAA 00 H16 16 A
SDCS-FEX-2 IF ≤ 16 A OFAA 00 H25 25 ADCF 503ADCF 504A
DCF 503A IF ≤ 30 A OFAA 00 H50 50 ADCF 504A
DCF 503A IF ≤ 50 A OFAA 00 H63 63 ADCF 504A
Type of protection elements LV HRC type circuit breakerfor 690 V; fuse for 500 V orhold. OFAX 00 690 V
Table 2.6/3: Fuses and fuse holders for 2-phase field supply
II F 2-23
Electronic system / fan supply
The converter unit requires various auxiliary voltages.E.g. the unit’s electronics require 115 V/1-ph or 230 V/1-ph. The unit fans require 230 V/1-ph or 400 V/690V/3-ph, according to their size. The T2 auxiliary trans-former is available to supply the unit’s electronic systemand the single-phase fans.
Earth fault monitor
An earth fault monitor is provided by the standardsoftware. If needed, the analogue input AI4 has to beactivated. A current signal of the three phase currentsshould be supplied to AI4 by a current transformer. Ifthe addition of the three current signal is different fromzero, a fault is generated (details see Technical Data).
Line reactor
When using the SDCS-FEX-2 field power converter,you should additionally use a line reactor because ofEMC considerations. A line reactor is not necessary forthe SDCS-FEX-1 (diode bridge). In DCF 503A/504Afield power converters a line reactor is already installed.
Converter Reactor≤≤≤≤≤500 V; 50/60 Hz
SDCS-FEX-2 ND 30
Table 2.6/5: Line reactor (details see Technical Data)
Auxiliary transformer T2
Input voltage: 380...690 V/1-ph; 50/60 HzOutput voltage: 115/230 V/1-ph
Fig. 2.6/4: T2 auxiliary transformer
II F 2-24
Fig. 2.6/5: Classification
Not applicable
First environment (residential area with light industry) with restricted obtainability
Not applied, since general obtainability sales channel excluded
satisfied
satisfied
The paragraphs below describe selection of the electri-cal components in conformity with the EMC Guide-line.
The aim of the EMC Guideline is, as the name implies,to achieve electromagnetic compatibility with otherproducts and systems. The guideline ensures that theemissions from the product concerned are so low thatthey do not impair another product's interferenceimmunity.
In the context of the EMC Guideline, two aspects haveto be considered:• the product's interference immunity
• the product's actual emissionsThe EMC Guideline expects EMC to be taken intoaccount when a product is being developed. However,EMC cannot be designed in, it can only be quantita-tively measured.
Note on EMC conformityThe conformity procedure is the responsibility of boththe power converter's supplier and the manufacturer ofthe machine or system concerned, in proportion totheir share in expanding the electrical equipment in-volved.
EMC filters
MM
Mains filter
Converter
Line reactor
Mountingplate
Supply transformer for a residential area (rating normally 1,2 MVA)
Earthed public 400-V network with neutral conductor
Medium-voltage network
Earthed neutral
To
othe
r lo
ads,
e.g
. driv
e sy
stem
s
An isolating transformer with an earthed screen and earthed iron core renders mains filter and line reactor superfluous.
Operation at public low-voltage network
together with other loads of all kinds.
Residential area
To
othe
r lo
ads
whi
ch h
ave
to b
e pr
otec
ted
from
the
syst
em d
istu
rban
ces
caus
ed b
y po
wer
con
vert
ers
(HF
inte
rfer
ence
and
com
mut
atio
n no
tche
s)
Converter
MMMM MM
alte
rnat
ive
alte
rnat
ive
Line reactor + Y-capacitor
Mountingplate
Medium-voltage network
Supply transformer for a residential area (rating normally 1.2 MVA)
Earthed neutral Earthed public 400-V
network with neutral conductor
To
othe
r lo
ads,
e.g
. driv
e sy
stem
s
Mains filter
Line reactor
Converter Converter
Mains filter
Line reactor
Converter Converter
An isolating transformer with an earthed screen and earthed iron core renders mains filter and line reactor superfluous.
Operation at public low-voltage network
together with other loads of all kinds.
To
othe
r lo
ads,
e.g
. driv
e sy
stem
s
To
othe
r lo
ads
whi
ch h
ave
to b
e pr
otec
ted
from
the
syst
em d
istu
rban
ces
caus
ed b
y po
wer
con
vert
ers
(HF
inte
rfer
ence
and
com
mut
atio
n no
tche
s)
Earthed public 400-V network with neutral conductor
Operation at public low-voltage network together with other loads of all kinds.
Light industry Residential area
II F 2-25
EN 61800-3
EN 50081-1
EN 50081-2
EN 50082-2 EN 61000-6-2
EN 50082-1
satisfied
satisfied
Second environment (industry) with restricted obtainability
on customer's request satisfied
Not applicable
Standards Classification
The following overviewutilises the terminologyand indicates the actionrequired in accordancewith Product Standard
EN 61800-3For the DCS 600 series,the limit values for emit-
For compliance with the protection objectives of theGerman EMC Act (EMVG) in systems and machines,the following EMC standards must be satisfied:
Product Standard EN 61800-3EMC standard for drive systems (PowerDriveSys-tem), interference immunity and emissions in resi-dential areas, enterprise zones with light industryand in industrial facilities.
This standard must be complied with in the EU forsatisfying the EMC requirements for systems and
machines!
In cases where the product standard is not applied, the generic standards EN50081 and EN 50082 are sometimes adduced.For emitted interference, the following apply:EN 50081-1 Specialised basic standard for emissions in light industry can be
satisfied with special features (mains filters, screened powercables) in the lower rating range.
EN 50081-2 Specialised basic standard for emissions in industry
For emitted interference, the following apply:EN 50082-1 Specialised basic standard for interference immunity in residen-
tial areasEN 50082-2 Specialised basic standard for interference immunity in industry.
The EN 61000-6-2 standard replaces EN 50082-2. If this standardis satisfied, then the EN 50082-1 standard is automatically satis-fied as well.
The field supply is not depicted inthis overview diagram. For thefield current cables, the samerules apply as for the armature-circuit cables.
ted interference are complied with,provided the action indicated is car-ried out. This action is based on theterm Restricted Obtainability usedin the standard (meaning a sales chan-nel in which the products concernedcan be placed in the stream of com-merce only by suppliers, customersor users which individually or jointlypossess technical EMC expertise).
For power converters without addi-tional components, the followingwarning applies:This is a product with restrictedobtainability under IEC 61800-3.This product may cause radio inter-ference in residential areas; in thiscase, it may be necessary for theoperator to take appropriate action(see adjacent diagrams).
MMMM
Supply transformer for a residential area (rating normally 1.2 MVA)
Earthed 400-V network with neutral conductor; 3~ 400 A
Operation at low-voltage network together with other loads of all kinds, apart from some kinds of sensitive communication equipment.
To
othe
r lo
ads,
e.g
. driv
e sy
stem
s
Line reactor + Y-capacitor Line reactor
Converter Converter
Mains filter
Earthed neutral
Medium-voltage network
Industrial zone
alte
rnat
ive
alte
rnat
ive
MMMM
Convertertransformer
Cas
e-re
fere
nced
EM
C a
naly
sis
alte
rnat
ive
Converter transformer with earthed
iron core (and earthed screen where appropriate)
alte
rnat
ive
I > 400 A and/or U > 500 V
Operation with separate power converter transformer. If there are other loads at the same secondary winding, these must be able to cope with the commutation gaps caused by the power converter. In some cases, commutating reactors will be required.
To
othe
r lo
ads,
e.g
. driv
e sy
stem
s
Converter Converter
Line reactor
Medium-voltage network
Industrial zone
PE + PE- + PE- + PE- + PE-
Legend
Unscreened cable with restriction
Screened cable
Field-current conductor
Armature-circuit conductor
PE protective earth conductor
Cable rack acts as screening against
HF emissions
II F 2-26
Three - phase filtersEMC filters are necessary to fulfill EN 50081 if aconverter shall run at a public low voltage networks, inEurope for example with 400 V between the phases.Such networks have a directly earthed conductor. ABBoffers suitable three-phase filters for 400 V and25 A....600 A and 500 V filters for 440 V networksoutside Europe.
Networks with 500 V to 1000 V are not public. Theyare local networks inside factories, and they do notsupply sensitive electronics. Therefore converters donot need EMC filters if they run with 500 V and more.
Converter type Rated DC current Filter type
xxx = Voltage
[A]
DCS60x-0025-x1 25 NF3-xxx-25DCS60x-0050-x1 50 NF3-xxx-50DCS60x-0075-x1 75 NF3-xxx-64DCS60x-0100-x1 100 NF3-xxx-80DCS60x-0140-x1 140 NF3-xxx-110DCS60x-0200-x1 200 NF3-xxx-320DCS60x-0250-x1 250 NF3-xxx-320DCS60x-0350-x1 350 NF3-xxx-320DCS60x-0450-x1 450 NF3-xxx-600DCS60x-0520-x1 520 NF3-xxx-600DCS60x-0680-x1 610 NF3-500-600DCS601-0820-x1 740 NF3-500-600DCS602-0820-x1 820 NF3-690-1000DCS60x-1000-x1 900 NF3-690-1000DCS60x-0900-x1 900 NF3-xxx-1000DCS60x-1200-x1 1200 NF3-xxx-1000DCS60x-1500-x1 1500 NF3-xxx-1600DCS60x-2000-x1 2000 NF3-xxx-1600DCS60x-2500-x1 2500 NF3-xxx-2500
Filters 25... 2500 A are available for 440 V and 500 V.Filters 600...2500 A are available for 690 V as well.
➊ The filters can be optimized for the real motor currents:IFilter = 0.8 • IMOT max ; the factor 0.8 takes the current rippleinto account.
Table 2.6/6: Three-phase filters
➊
Converter type of DC current Filter typefield supply unit Umax = 250 V
[A]
SDCS-FEX-1 6 NF1-250-8SDCS-FEX-2 8 NF1-250-8SDCS-FEX-2 16 NF1-250-20DCF 503A-0050 50 NF1-250-55DCF 504A-0050 50 NF1-250-55further filters for 12 NF1-250-12
30 NF1-250-30
➊ The filters can be optimized for the real field currents:IFilter = IField
Table 2.6/7: Single-phase filters
➊
Filter in a grounded line (earthed TN or TTnetwork)The filters are suitable for grounded networks only, forexample in public European 400 V networks. Accord-ing to EN 61800-3 filters are not needed in insulatedindustrial networks with own supply transformers.Furthermore they could cause safety risks in floatingnetworks (IT networks).
Single-phase filters for field supplyMany field supply units are single-phase converters forup to 50 A excitation current. They can be supplied bytwo of the three input phases of the armature converter.In that case a field supply unit does not need its ownfilter.
If one phase voltage to neutral is taken (230 V in a400 V network) then a separate filter is necessary. ABBoffers such filters for 250 V and 6...30 A.
II F 2-27
Commutation and line reactors(see also Section Line reactors in this chapter)Due to the maximum power of public 400 V trans-formers (P
MAX = 1.2 MVA ⇒ I
MAX = 1732 A) and due
to their relative voltage drop of 6% or 4% the maxi-mum AC current which is available for a converter is346 A or 520 A (I
DC ≤ 422 A or 633 A).
Isolating transformersAn isolating transformer makes line chokes unneces-sary because of its leakage inductance, and a groundedscreen between its windings saves an EMC filter. Thescreen and the iron core must be well connected withthe mounting plate of the converter.
Converter transformersA converter transformer transfers a high power directlyfrom a medium voltage network to a single largeconverter or to a local low voltage network for severalconverters. Furthermore it acts as isolating transformer.
If such a converter transformer has no screen the EMCdemands are nevertheless fulfilled in most cases, be-cause the RF interference can hardly get via the medi-um-voltage network and the transformer of the publicnetwork to the loads which must be protected againstdisturbances.
PE
PE
Installation hints• All metal cabinets available on the market can be
used.• The mounting plate must be made from steel with
zinc coating and without any painting. It must beconnected with the PE busbar by several bolts/cables.
• The converter, the line reactors, fuses, contactorsand the EMC filter are to be placed on the mountingplate so that the connections are as short as possible,especially those from the converter via the line choketo the filter.
• The cables for digital signals which are longer than3m and all cables for analogue signals must bescreened. Each screen must be connected at bothends by metal clamps or comparable means directlyon clean metal surfaces. In the converter cubicle thiskind of connection must be made directly on thesheet metal close to the terminals.
• The necessity of a screen for power cables dependson the length of the cable and on the environmentaldemands. If a screen is necessary then it must bepressed by a well conducting metal clamp directlyagainst the mounting plate or the PE busbar of theconverter cabinet.
• Screened cables to the armature and to the excitationwinding cause the lowest noise level. The armaturecurrent cable must contain a wire for a PE connec-tion if the copper cross section of the screen cannotfulfil the safety demands.
• If a screen is not necessary the armaturecurrent cable must be a four-wire cable.Two wires are needed as PE to dischargethe parasitic RF currents from the motorto the EMC filter in the cabinet.
II F 2-28
Connection example in accordance with EMC
Fig. 2.6/6: Connection example in accordance with EMC
Important hint:The example shows the principle structure ofa DC drive and its connections. It is a notbinding recommendation, and it cannot takeall conditions of a plant into account.Therefore each drive must be consideredindividually and with respect due to its specialapplication. Additionally the general installa-tion and safety rules must be taken intoaccount.
M
A1 A2
F1
F2
A1 A2
F1
F2
L1
L2
L3
PE
U1
V1
W1C1
D1
U1
V1 F-F+
PE
PE
PE
PE
A
F
A FTacho
A FTacho
T
AF
AF
I/O
Mounting plate
DC motor
Tach
o
ScreensContact to the motorhousing at the whole
screen perimeter
Filter
Mounting plate with PE busbar and terminals
PE bar
DC motor
Tach
oSc
reen
Mounting plate with PEbusbar and terminals
PE bar
lower edgeof the PCB
carrier
Encoder inputs andanalogue I/O at the PCB
Fieldsupplyunit
Armature and field cables with screens for
"first environment"
Armature and field cables without
screens suitable for "second
environment"
Hint: The armature current cable must contain a third wire for a PE connection if the copper cross section of the screen cannot fulfil the PE safety demands.
II F 3-1
3 Overview of software (Version 15.xxx)
3.1 Basic structure ofDCS 600 MultiDrive
The control hardware of DCS 600 MultiDrive consistsof 2 parts:• converter control board SDCS-CON-2• drive control board SDCS-AMC-DC 2
(AMC = Application Motor Control)
Accordingly, the software is split into 2 parts:• All control functions superimposed to the torque
reference are done inside the AMC board. In addi-tion, all HMI (Human Machine Interface) andcommunication functions are part of the AMCboard's software. Also the Start/Stop functions('Drive Logic') are realized by the AMC board'ssoftware. All parameters and signals of the drive areaccessed via an on the AMC board residing datastructure called 'AMC-table'.
• All converter related functions and the handling ofstandard I/O are done by the SDCS-CON-2 soft-ware:• Armature current control• Field weakening• Motor protection• I/O handling
In general, the software functions are distributed be-tween the SDCS-CON-2 board and the SDCS-AMC-DC 2 board according to the following diagram:
3.2 Control Modes
The Control mode selects the source of control wordand references.
Local ModeCommissioning tool DriveWindow is connected toDDCS channel 3 of the AMC board and can use localmode. Local mode is also available on the panel CDP312.
Remote ModeReference and control word are supplied by an overrid-ing control system or a fieldbus adapter connected tothe DDCS channel 0.
Master/Follower ModeReference and control word are supplied to the followerdrive by the master drive via DDCS channel 2.
Fig. 3.1/1: Distribution of software functions
Human Machine Interface & Communication
SDCS-CON-2Software 15.2xx
Application ControlSDC
S-A
MC
-DC
2So
ftwar
e 15
.6xx
Drive Control
I/O handling
Torque Control
II F 3-2
3.3 Start, Stop and Fault Reactions
Power upWhen the electronics power supply is switched on thedrive stays in the ON_INHIBIT state until ON = 0 isdetected. In case of a fault the drive stays in the FAULTstate.
Normal startStatus bit RDY_ON = 1 signals that no faults arepending and that the device is ready to close the main,fan and field contactor.A rising edge of the ON command closes fan, field andmain contactor and activates the field control.Status bit RDY_RUN = 1 indicates that the fieldconverter is active and that the drive is ready to generatetorque.A rising edge of the RUN command activates speed andtorque control.Status bit RUNNING = 1 indicates that the drive is innormal operation.
Normal stopRUN = 0 sets the speed reference to zero and the drivedecelerates.After the actual speed has reached zero the status bitRUNNING is reset, the armature converter sets thefiring angle to maximum. The state RDY_RUN isentered, when the actual current has reached zero.ON = 0 sets RDY_RUN = 0 and the field currentreference to zero. The field converter sets the firingangle to maximum . The contactors are opened, whenthe actual current has reached zero.ON = 0 internally forces RUN = 0.
Emergency offField and armature current are removed as fast aspossible. After the current has reached I
DC = 0 the
contactors are opened. The normal start command isaccepted when OFF2_N = EME_OFF_N = 1.
Emergency stopCommand EME_STOP = 0 gives the same procedureas RUN = 0 (normal stop) except that the ramp isswitched from deceleration to emergency stop and thestate ON_INHIBIT is entered when the speed hasreached zero.The normal start command is accepted when OFF3_N= EME_STOP_N = 1.The reference handling and current limitation is con-trolled by EME_STOP_MODE.
Fault reactionDepending on the actual fault the armature currentand/or field current is reduced to zero as fast as possiblewith single pulses and maximum firing angle. Contac-tors are opened when the current has reached zero.Then the state TRIPPED is entered and after a success-ful reset the state ON_INHIBIT.
The following state diagram shows the transitionsbetween the different states.
Table 3.1/1: States of the drive
During operation, the drive is in one of the followingstates (ABB Drive profile):
TIBIHNI_NO
potsycnegremeretfAffoycnegremero)N_3FFO(
sietatssiht)N_2FFO(0=NOlitnuderetne
FFON_3FFO,ffosirotcatnocniaM
evitcaN_2FFOro
NO_YDR ffosirotcatnocniaM
NUR_YDR
rotcatnocnafdnadleif,niaMlortnocdleif,desolcera
nurrofydaer,detavitcadnammoc
FER_YDRlla,gninnursievirD
desaelererasrellortnoc
DEPPIRT detluafsievirD
N_ATS_2_FFO
oteudgnitsaocsievirDeht;dnammocffoycnegreme
F_DNA_A_OREZsetats →.deretneeraTIBIHNINO
N_ATS_3_FFO
ehtotgnidroccaspotsevirDpotsycnegremedemmargorp
demmargorpehtdnapmarta;edompotsycnegreme
etatseht,deepsorez.deretnesiTIBIHNI_NO
II F 3-3
Fig. 3.3/1: Control and status
Voltageswitched off
Switch oninhibit
not readyto swich on
Power ON OFF 1 (MCW Bit0=0)
Status Disable(MSW Bit6=1)
Status Not ready for startup(MSW Bit0=0)
ready to switch on Status Ready for startup
(MSW Bit0=1)
Main Control word basic condition(MCW=XXXX XXXX XXXX X110)
ON (MCW Bit0=1)
InhibitOperation active
operationdisabled
disable operation(MCW Bit3=0 RUN)
Ready Status Ready for operation
Releaseoperation
(MCW Bit3=1)
A B C D
OFF1
(n=0 / I=0) OR (MCW Bit3=0 (RUN))
OFF1 (MCW Bit0=0)
from every device status
OFF3active
Stop drive *)according toparameter 21.04eme stop mode
(MSW Bit5=0)n=0 / I=0
Emergency StopOFF3 (MCW Bit2=0)
from every device status
OFF2
(MSW Bit4=0)
Emergency OffOFF2 (MCW Bit1=0)
from every device status
Fault Stop drive
(MSW Bit3=1)
Fault
from every device status
EnableOperation
Release electronics and pulses (MSW Bit2=1)
RFG-output free
(MCW Bit4=1)RFG: Enable
output
RFG-output released
(MCW Bit5=1)
B
RFG: Acceleratorenable
Setpoint released
(MCW Bit6=1)
C
D
A
Operatingstate
D
n = n_set
(MSW Bit8=1)
MCW = Main Control WordMSW = Main Status Wordn = SpeedI = Power input currentRFG = Ramp Function Generator
Error correctedconfirm by RESET (MCW Bit7= 1)
B C D
C D
RFG-outputdisable(MCW Bit4=0RAMP_OUT_ZERO)
RFG stop(MCW Bit5=0RAMP_HOLD)
Setpointdisabled(MCW Bit6=0RAMP_IN_ZERO)
ABB Drive Profilefor DC-drives
Control andStatus
Inching 1 ActiveDrive Running Inching 1 setpoint
to speed control
MCW: Bit 4 = 0 and Bit 5 = 0 and Bit 6 = 0
INCHING 1 ON (MCW Bit 8 = 1)
Purpose: Main speed ref. is deactivated
Inching 2 setpointto speed control
INCHING 2 ON (MCW Bit 9 = 1)
Inching 2 ActiveDrive Running
INCHING 1 OFF (MCW Bit 8 = 0)
INCHING 2 OFF (MCW Bit 9 = 0)
ON INHIBIT
OFF
RDY_ON
RDY_RUN (MSW Bit1=1)
RDY_REF Status Operation released
OFF_3_STA
Coast Stop(no torque)
OFF_2_STA
TRIPPEDStatus:
Status:Status:
RUN
RAMP_OUT_ZERO
RAMP_HOLD
RAMP_IN_ZERO
AT_SETPOINT
activeactive
E F
E
F
dcs_600\docu\fig_4.dsf
Stop drive *) according to- DECELER TIME (22.02) at speed control- TORQ RAMP DOWN (25.06) / TORQ REF A FTC (25.02) at torque controlthen open Main ContactorStatus:OFF(not ready for startup,MSW Bit0=0)
*) while the drive is being stopped, status bit RDY_REF (MSW bit 2) remains at "1" as long as the drive generates torque.
Inhibitconverter pulsesStatus:Operation Disabled(MSW Bit2=0 RDY_REF)
II F 3-4
3.4 Speed Control
The speed controller is located in the AMC boardsoftware.
Speed referenceThe source of the reference is depending on the oper-ating mode.
Overriding controlsystem, fieldbus adapters remote mode, DDCS
via AMC boardDriveWindow local mode, DDCS via
AMC boardPanel CDP312 local mode, connector
on CON-2Analogue inputs local I/O
Speed reference features• Speed reference limiter• Additional speed ramp for emergency stop• Variable slope rate• Speed correction• Reference for inching before the ramp• 2 different references for inching behind the ramp
Speed measurementThe actual speed may be calculated from:• Armature voltage• Analogue tachometer• Pulse encoder
Controller features• PID controller• 2 first order low pass filters• Window control• Acceleration compensation• Speed and torque adaptation• Droop• Additional torque references• Torque limitation and gear backlash function (the
integral part of the controller is set to a suitable valueon limitation)
• Oscillation damping (band rejection filter for speederror)
The diagram Fig. 3.8/2 shows the functionality of thespeed reference chain as well as of the speed controller.
3.5 Torque Control
Flux and Torque CalculationThe torque control is in general an open loop control.The flux is adjusted by the field current. The referenceof the field current is generated by the superimposedarmature voltage control.The torque is adjusted by the armature current. Theconversion from torque to current reference is done bymeans of the calculated flux (based on the field currentand saturation characteristic).
Torque reference features• Torque reference A with 1st order filter and load
share• Torque reference B with torque ramp• Torque reference limiter• Torque correction and torque step• Torque correction by means of analogue input 1
A good behaviour in the field weakening requires speedmeasurement by tachometer or encoder.
A simplified scheme of the torque reference chain isgiven in diagram fig. 3.8/2.
3.6 HMI (Human Machine Interface)The HMI is performed by CDP 312 control panelor by DriveWindow.Both tools contain:• Display of drive signals• Setting of drive parameters• Display fault and alarm messages• Control the drive in local operation
II F 3-5
3.7 Torque Generation
Interface between SDCS-AMC-DC 2 board andDC control board SDCS-CON-2The major signals exchanged each 2 ms between CON-2 and AMC-DC 2 are:
SPEED_ACTUAL speed actual value fromCON-2
TORQ_USED_REF active torque reference toCON-2
In addition, the calculated torque limits are read fromthe CON-2 each 8 ms:
TC_TORQMAXTC_TORQMIN
The addition of the torque correction TQ_CORRfrom an analogue input of CON-2 is done by theCON-2 software.
Armature voltage ControlThis controller enables operation in the field weaken-ing range. It generates the field current reference. At lowspeeds the field current is constant and armature volt-age is roughly proportional to the speed. At higherspeeds (≥ base speed) the field current reference isreduced so that the armature voltage doesn’t exceed itsreference.
Field Current ControlTwo field exciters can be operated simultaneously fortwo different motors.The first field exciter can be operated with fixed currentreference, in field weakening or with a reduced refer-ence for field heating.The second field exciter has a fixed current reference(no field weakening possible). However, it may bereduced for field heating purposes.A field reversal control is available for the first fieldexciter.Optitorque is a special control method where the fluxis reduced at small torque reference. This is available fordrives with and without field reversal.
Armature Current ControlThe armature current reference is calculated from torquereference and flux. Then it is processed by a ramp,limitation and speed dependent limitation.The actual value of the armature current is the meas-ured mean value between two firing pulses.The armature voltage reference is generated by a PIcontroller.The firing angle is calculated from this voltage referencedepending on the actual line voltage and the conduc-tion time (adaptation between continuous and discon-tinuous state of the converter current).
A simplified scheme of the armature current control isgiven in diagram fig. 3.8/3.
II F 3-6
3.8 Software diagrams
IntroductionThe designation of parameters and signals consist of agroup and a index.
XParameter
01.02
23.05Signal
GroupIndex
The structure of the software is given. Changes of thefunctions or pointers are realized through setting pa-rameters.
This can be done via panel, DriveWindow (PC utility),fieldbus or overriding control system.
Changed parameters or pointers are stored immediate-ly in the non-volatile flash PROM.
All parameters can be transferred to the PC and bestored on a data medium by using DriveWindow.
Fig. 3.8/1: Parameter/signal designation
On the following pages the simplified software struc-ture is shown. Additionally there are specific tables for:
• Main Control Word (MCW)• Auxiliary Control Words (ACW)• Main Status Word (MSW)• Auxiliary Status Word (ASW)• Digital Inputs (Armature converter mode)• Digital Inputs (Field converter mode)• Digital Outputs (Armature converter mode)• Digital Outputs (Field converter mode)• Analogue Inputs (Armature converter mode)
II F 3-7
Fig. 3.8/2: Speed reference chain
50.0
6AC
W B
8
24.1
3
24.1
2
24.2
024
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24.1
8
24.1
7
24.1
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24.0
5
24.0
4
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s[7
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... [7
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E
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W B
x =
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x =
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(7.0
2)
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= bi
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IDTH
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7
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22.0
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22.0
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22.0
7
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22.0
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CW
B4
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20.0
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20.0
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50.0
4
50.0
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50.0
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50.0
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rese
rved
SPEE
D SC
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B11
B12
B13
B14
B15
TAC
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8.01
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0 =
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dcs_
600\
docu
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13.1
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B11
B12
B13
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B0 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
B11
B12
B13
B14
B15
DIG
_OU
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DIG
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8.01
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B11
B12
B13
B14
B15
RD
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8.02
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RDAS
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B0
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
LOG
G_D
ATA_
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OU
T_O
F_W
IND
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DI S
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S W
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B0 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
B11
B12
B13
B14
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DI1
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DI6
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LOC
AL
Dat
aset
s[7
0.20
]+1
... [7
0.20
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1
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Spee
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MO
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NO
M V
OLT
AGE
to TORQUE REF. SELECTOR
II F 3-8
Fig. 3.8/3: Torque control chain
TOR
QU
E C
ON
TRO
L C
HAI
N
LOC
AL
LOAD
SH
AR
E
FILT
ER
TOR
Q R
EF A
FTC
TOR
Q R
EF A
25.0
1
25.0
2
25.0
3
25.0
4
TOR
Q R
EF B
LOC
AL
TOR
QU
E R
EF(L
OC
AL R
EF 2
)TO
RQ
RA
MP
UP
TOR
Q R
AM
P D
OW
N
RAM
PIN
G
20.0
9
20.1
0
LIM
ITE
R
TREF
TO
RQ
MA
X
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F TO
RQ
MIN
TOR
Q R
EF 1
2.08
+ +
0 12
3 45
6
2.09
SPE
ED C
ON
TRO
LLE R
OU
TPU
T
TOR
Q R
EF 2
TOR
QU
E R
EFE
REN
CE
SELE
CTO
R (2
6.01
)
TOR
QU
E S
ELE
CTO
R
MIN
MA
X
TOR
Q R
EF 3
2.10
26.0
3
26.0
2
TOR
QU
E ST
EP
LOAD
CO
MPE
NS
ATIO
NTO
RQ
RE
F 4
2.11
TOR
Q R
EF 5
2.12
20.0
5
20.0
6
2.19
2.20
TOR
QU
E LI
MIT
ER
MAX
IMU
M T
OR
QU
E
MIN
IMU
M T
OR
QU
E
TC T
OR
QM
AX
TC T
OR
QM
IN
TOR
Q U
SED
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F
2.13
D
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AN
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T x
NO
M V
AL
AN
OU
T x
NO
M V
OLT
AN
OU
T x
OFF
S V
OLT
[AN
OU
T x
IND
EX]
AO
1(A
O2)
AN
OU
T 1
IND
EX
14.0
4A
N O
UT
1 N
OM
VAL
14
.03
AN
OU
T 1
OFF
S V
OLT
14
.02
AN
OU
T 1
NO
M V
OLT
14
.01
AN
OU
T 2
IND
EX
14.0
8A
N O
UT
2 N
OM
VAL
14
.07
AN
OU
T 2
OFF
S V
OLT
14
.06
AN
OU
T 2
NO
M V
OLT
14
.05
Anal
ogue
out
puts
+ +
A
D
AN
IN x
HI V
AL
AIx
AN
IN x
VA
LUE
Anal
ogue
inpu
ts
25.0
5
25.0
6
dcs_600\docu\fig_2a.dsf
AN
IN x
LO
VA
L
AN
IN T
AC
HO
VAL
UE
(sig
nal)
5.01
AN
IN T
AC
H H
I VA
L (a
t +10
V)
13.0
1A
N IN
TA
CH
LO
VAL
(at -
10V)
13
.02
AN
IN 1
VA
LUE
(sig
nal)
5.02
AN
IN 1
HI V
AL
(at +
10V
) 13
.03
AN
IN 1
LO
VAL
(at -
10V
) 13
.04
AN
IN 2
VA
LUE
(sig
nal)
5.03
AN
IN 2
HI V
AL
(at +
10V
) 13
.05
AN
IN 2
LO
VAL
(at -
10V
) 13
.06
AN
IN 3
VA
LUE
(sig
nal)
5.04
AN
IN 3
HI V
AL
(at +
10V
) 13
.07
AN
IN 3
LO
VAL
(at -
10V
) 13
.08
AN
IN 4
VA
LUE
(sig
nal)
5.05
AN
IN 4
HI V
AL
(at +
10V
) 13
.09
AN
IN 4
LO
VAL
(at -
10V
) 13
.10
AM
C
CO
N
AUX
CO
NTR
OL
WR
D 2
B 9
(SP
EED
_EXT
)
26.0
1TO
RQ
UE
SELE
CTO
R
Selector
26.0
4M
OD
E S
WIT
CH
SEL D
I1D
I2D
I3D
I4D
I5D
I6D
I7D
I8
1 2
0 1 8
2.19
+/- T
C T
OR
QM
AX
gear
back
lash
com
pen-
satio
n
from
PID
cont
rolle
r
to S
UM
II F 3-9
Fig. 3.8/4: Armature current control
TOR
QU
EC
OR
REC
TIO
N
TOR
Q U
SED
RE
F
2.13
2.14
FLU
X R
EF
FLD
WE
AK
3.14
CU
R R
EF S
LOP
E
di/d
t
41.1
0
SCAL
E
HL
LL20.1
2
CU
R L
IM M
OT
BRID
GE
20.1
3
CU
R L
IM G
EN B
RID
GE
CU
R R
EF
3
3.12
CU
RR
ENT
CO
NTR
OLL
ER
CO
NTR
OL
TYP
E SE
L
AR
M C
UR
PI P
-GA
IN
AR
M C
UR
PI I
-GA
IN
AR
M C
UR
IP P
-GA
IN
AR
M C
UR
IP I-
GA
IN
DIS
CO
NT
CU
R L
IMIT
43.0
1
43.0
2
43.0
3
43.0
4
43.0
5
43.0
6
PI-I
P
+ -
LOAD
CU
R A
CT
1.27
4096
==
Mot
or n
omin
al c
urre
ntLO
AD C
UR
AC
T FI
LT
1.28
Arm
atur
eC
urre
ntM
easu
rem
.
EMF
Cal
c.
HL
LL
20.1
4
MA
X FI
RIN
G A
NG
LE
20.1
5
MIN
FIR
ING
AN
GLE
ALPH
A_M
AXC
alc.
3.13
FIR
ING
AN
GLE
FIR
E U
NIT
1.19
SELE
CTE
D B
RID
GE
MO
TOR
NO
M V
OLT
AGE
MO
TOR
NO
MC
UR
REN
T
99.0
2
99.0
3
CO
NV
NO
M C
UR
R
4.13
Mai
nsVo
ltage
Mea
sure
m.
Con
verte
rC
urre
ntM
easu
rem
.
U_S
UPP
LY
42.0
6
RL
MAI
NS
VOLT
AC
T
MA
INS
VO
LT A
CT
RL
CO
NV
CU
R A
CT
CO
NV
CU
R A
CT
1.11
1.12
1.15
1.16
MM
MO
TOR
1M
OTO
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Fiel
dC
urre
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RE
L FI
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3.19
3.20
3.21
3.22
Fiel
dC
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rem
.
RE
L FI
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CU
R M
2
FIE
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MO
T 1
NO
M F
LD C
UR
41.0
3FI
ELD
CU
R R
EF
M1
3.17
US
ED F
EX
TYPE
15.0
51,
2,4,
5,6,
7,8,
9,10
,11,
12,1
3
FIE
LD C
UR
RE
F M
2
3.18
3,4
FLD
CU
R @
40%
FLU
X41
.14
41.1
5FL
D C
UR
@70
% F
LUX
41.1
6FL
D C
UR
@90
% F
LUX
FLU
X/FI
ELD
LIN
EAR
IZAT
ION
RL
EMF
VOLT
AC
T
1.17
EMF
CO
NTR
OLL
ER
46.0
3E
MF
CO
N K
P46
.04
EM
F C
ON
KI
FLU
XC
ON
TRO
L
MO
TOR
NO
MS
PEED
99.0
5
INT
EMF
REF
41.1
9
MO
TOR
SPE
ED
1.02
MN
= 1
0000
=M
max
= 3
.2 *
MN
4096
= 1
00%
of
I_M
OTx
_FIE
LD_A
ARM
ATU
RE
CU
RR
ENT
CO
NTR
OL
SEC
ON
DFI
ELD
EXC
ITER
MO
T 2
NO
M F
LD C
UR
41.1
7
dcs_
600\
docu
\fig_
3a_a
.dsf
FLU
X R
EF F
LD W
EAK
EMF
RE
F
45.0
3
45.0
2flu
x/em
f ref
sel
= EX
T R
EF
FLU
X R
EF
45.0
1
3.14
45.0
2 fl
ux/e
mf r
ef s
el =
EXT
REF
OR
46.0
7 fl
ux re
f sel
= E
XT R
EF
CU
R R
EF
2
3.28
FLU
X R
EF
SUM
3.15
AI V
REF
3.29
MU
X
EMF
RE
F SE
L
46.0
8
0 321
V R
EF 1
3.24
FLU
X R
EF
EMF
3.26
46.1
2V
REF
SLO
PE
46.0
5E
MF
CO
N B
LOC
KLE
V
46.1
0V
CO
R46
.11
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TEP
46.1
3V
LIM
P46
.14
V L
IM N
V re
f Mod
ifica
tion
V R
EF 2
3.25
VOLT
AC
TUA
L3.
23
EM
F A
CT
FILT
TC 46.0
6
Dia
gram
for
OP
ER M
OD
E S
ELEC
T (1
5.16
) < 5
FIE
LD 2
REF
44.2
3via
driv
e lo
gic
MA
XIM
UM
FLU
X45
.07
FLU
X C
OR
43.2
0
20.1
220
.13
2.19
2.20
torq
ue li
mit
clac
ulat
ion
set t
o 0,
if F
IX fi
eld
sele
cted
(15.
06)
set t
o M
AXIM
UM
FLU
X (4
5.07
), if
FIX
field
sel
ecte
d (1
5.06
)
OPT
ITO
RQ
UE
Fiel
d re
vers
al
+ +
scal
ed to
NO
M S
UPP
LY V
OLT
(42.
06)
from TORQUE Limiter
II F 3-10
Fig. 3.8/5: Inductive load current control
CUR
REF
SLO
PE
di/d
t
41.1
0
HL
LL
CUR
LIM
MO
TBR
IDG
E
CUR
LIM
GEN
BRI
DG
E
CUR
REN
T CO
NTR
OLL
ER
CO
NTR
OL
TYP
E S
EL
AR
M C
UR
PI P
-GA
IN
AR
M C
UR
PI I
-GA
IN
AR
M C
UR
IP P
-GA
IN
AR
M C
UR
IP I-
GA
IN
DIS
CO
NT
CU
R L
IMIT
43.0
1
43.0
2
43.0
3
43.0
4
43.0
5
43.0
6
PI-I
P+ -
LOAD
CU
R A
CT
4096
==
Load
nom
inal
cur
rent
LOAD
CU
R A
CT
FILT
Arm
atur
eC
urre
ntM
easu
rem
.
EM
FC
alc.
HL
LL
MAX
FIR
ING
AN
GLE
MIN
FIR
ING
AN
GLE
ALPH
A_M
AXC
alc.
FIR
ING
AN
GLE
FIRE
UN
IT
SELE
CTE
D B
RID
GE
MO
TO
R N
OM
VO
LTAG
E
MO
TO
R N
OM
CU
RR
ENT
99.0
2
99.0
3
CO
NV
NOM
CU
RR
Mai
nsV
olta
geM
easu
rem
.
Con
verte
rC
urre
ntM
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rem
.
U_S
UPP
LY
RL
MAI
NS
VOLT
AC
T
MAI
NS
VOLT
ACT
RL
CO
NV C
UR
AC
T
CO
NV
CUR
AC
T
RL
EMF
VOLT
ACT
EM
FC
ON
TRO
LLE
R 46.0
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MF
CO
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ON
KI
INT
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REF
IND
UC
TIVE
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AD C
UR
REN
T C
ON
TRO
L
dcs_
600\
docu
\fig_
3b_a
.dsf
EMF
REF
45.0
2flu
x/em
f ref
sel
= EX
T R
EF
AI V
REF
MUX
EMF
REF
SEL
0 321
V RE
F 1
FLU
X RE
F EM
F
46.1
2V
RE
F S
LOP
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ON
BLO
CK
LEV
46.1
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R46
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V L
IM N
V re
f Mod
ifica
tion
V RE
F 2
CUR
REN
T RE
F
AI C
UR
REF
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FLU
X RE
F SE
L
0 321
CUR
REF
1
0
INT
CUR
REF
4
FEX
LINK
REF
Ref
eren
ceSe
lect
ion
and
min
/max
-Lo
gic
FLU
X CO
R
FLU
X ST
EP
REF
SEL
43.1
5SE
L M
AX M
IN43
.16
43.1
5R
EF
SE
L
CUR
REF
1
V A
CT
SE
L
I AC
T S
EL
V I
SE
L 1
V I
SE
L 2
AR
M R
46.2
0
46.1
9
46.2
1
46.2
2
41.1
2
EM
F A
CT
FILT
TC
46.0
6V
AC
T C
AL
46.1
6
AR
M L
41.1
1
VOLT
AC
TUAL
3.23
actu
al v
olta
gese
lect
ion
Dia
gram
for
OPE
R M
OD
E SE
LEC
T (1
5.16
) = 5
TOR
QUE
USE
D R
EF
TOR
QUE
CO
RR
ECTI
ON
not u
sed
- CU
R R
EF 1
:= L
OC
AL R
EF 3
, i
f loc
al m
ode
and
REF
SEL
(43.
15) <
3- C
UR
REF
1 :=
LO
CAL
CUR
REF
(43.
19),
if l
ocal
mod
e an
d RE
F SE
L (4
3.15
) >=
3
3.25
3.27
45.0
3
3.29
41.1
9
46.0
8
3.24
3.26
43.2
1
3.11
43.2
0
3.30
43.1
7
46.0
7
2.14
2.13
3.27
20.1
2
20.1
3
1.27
20.1
5
3.13
1.19
20.1
4
42.0
6
1.11
1.12
1.15
4.13
1.16
1.28
1.17
FLD
CU
R @
40%
FLU
X41
.14
41.1
5FL
D C
UR
@70
% F
LUX
41.1
6FL
D C
UR
@90
% F
LUX
FLU
X/FI
ELD
LIN
EAR
IZA
TIO
N
CUR
REF
33.
12
FLU
X RE
F SU
M
3.15
CUR
REF
2
3.28
V RE
F 1
:= L
OCA
L R
EF 3
,if
loca
l mod
e;sc
aled
toN
OM
SUP
PLY
VOLT
(42.
06)
(EXC
ITAT
ION
: 15.
16 =
5)
II F 3-11
Control and Status WordsIn remote mode, the drive is controlled by the main control word and the auxiliary control words.The drive’s status is read from the main status word and the auxiliary status word.
Table 3.8/1: Main Control Word
Table 3.8/2: Auxiliary Control Word
Table 3.8/3: Auxiliary Control Word 2
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3 2_TUO_GID DMCNODLEIF
4 3_TUO_GID DMCNOTNOCNIAM
7..5 devreser )devreser(
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1etonees
9 TXE_DEEPS
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II F 3-12
Table 3.8/4: Main Status Word
Table 3.8/5: Auxiliary Status Word
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7 KCA_2XEF xeFdn2foegdelwonkca
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9 GNITIMILlangisees,gnitimilsievirD
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41 WSA_RID_EVIRDnoitceridevirdevitageN
evitca
51 GNISOLCER_OTUAcigolgnisolcerotua
detavitca
II F 3-13
Table 3.8/8: Digital outputs Armature converter mode (DCS600) Table 3.8/9: Digital outputs Field converter mode (DCF600)
Digital inputs/outputs
Depending on the drive modes there are differentpossibilities for digital inputs and outputs.
Table 3.8/6: Digital inputs Armature converter mode (DCS 600)
Table 3.8/7: Digital inputs Field converter mode (DCF 600)
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)pirt1rotom(noxilK81.82)pirt2rotom(noxilK52.82
:etoN rof2IDtcelestonoD!snoitcnufeseht
3ID 3ID
4ID 4ID
5ID 5ID
6ID 6ID
7ID 7ID
8ID 8ID
neht)O/Ilacol(1=22.51LESDNAMMOCfiNUR=8ID;NO=7ID;teseR=6ID
stuptuOlatigiD edomretrevnocerutamrA
tuptuO langiS esu noitpircseD
1OD 1TUO_GID
elbarugifnoc→
yb.margorp/eerf 20.21DMCNOSNAF:tluafed
2OD 2TUO_GIDyb.margorp/eerf 50.21
DMCNODLEIF:tluafed
3OD 3TUO_GIDyb.margorp/eerf 80.21
NOTNOCNIAM:tluafedDMC
4OD 4TUO_GID yb.margorp/eerf 01.41
5OD 5TUO_GID yb.margorp/eerf 31.41
6OD 6TUO_GID yb.margorp/eerf 61.41
7OD 7TUO_GID yb.margorp/eerf 91.41
8OD 8TUO_GID yb.margorp/eerf 22.41
stuptuOlatigiD edomretrevnocdleiF
tuptuO langiS esu noitpircseD
1OD 1TUO_GID
elbarugifnoc→
yb.margorp/eerf 20.21DMCNOSNAF:tluafed
2OD 2TUO_GIDyb.margorp/eerf 50.21
DMCNODLEIF:tluafed
3OD 3TUO_GIDyb.margorp/eerf 80.21
NOTNOCNIAM:tluafedDMC
4OD 4TUO_GID yb.margorp/eerf 01.41
5OD 5TUO_GID yb.margorp/eerf 31.41
6OD 6TUO_GID yb.margorp/eerf 61.41
7OD 7TUO_GID yb.margorp/eerf 91.41
8OD 8TUO_GID yb.margorp/eerf 22.41
II F 3-14
Table 3.8/10: Analogue inputs Armature converter mode (DCS600)
Analogue inputs
Depending on the drive modes there are differentpossibilities for analogue inputs.
stupnIeugolanA edomretrevnocerutamrA
:hguorhtlangisrofdesulennahC
lennahC CATIA 1IA 2IA 3IA 4IA
ycaruccA 6904± 6904± 8402± 8402± 8402±
langiS
EUQROTNOITCERROC
LES_LAV_1IA1=61.31
ECNEREFERDEEPSTCELESDEEPSIA
5=71.31TCELESDEEPSIA
1=71.31TCELESDEEPSIA
2=71.31TCELESDEEPSIA
3=71.31TCELESDEEPSIA
4=71.31
DLEIF.TXE.KCARETICXE
LES_CXEF9=50.51
LES_CXEF01=50.51
LES_CXEF11=50.51
LES_CXEF21=50.51
LES_CXEF31=50.51
.PMET1.TOMTNEMERUSAEM
LES_IA_PMET_1TOM5...1=90.82
.PMET2.TOMTNEMERUSAEM
LES_IA_PMET_2TOM5...1=21.82
TLUAFHTRAEGNIROTINOM
LES_TLF_RUC_HTRAE1=91.82
DEEPSTNEMERUSAEM
EDOM_SAEM_DEEPS4=30.05
II F 4-1
4 Connection examples
Fig. 4.1/1: DCS 600 Armature current converter wiring diagram
4.1 Armature current converter DCS 600
CH
0
X96:
DO
8
12
X99:
12
X2:
45
X2:1
23
U1W
1V1
PEX1
:1
7
K3K1
L1L2
L3
400V
50H
z
F1
F3
K11
35
24
6
K31
3
24
L1L3
M ~
T3
F21 2
3 4
F6
2 1
4 3
6 5
2 1
4 3
6 5
2 1
4 3
6 5
UV
W
M 3~
K6
F7
1 2
3 4K5
F4F5
1 2
1 2
T2
111 10 9 8 7 6 5 4 3 2
690V
660V
600V
575V
525V
500V
450V
415V
400V
380V
12 13 14
115V
230V
K16
K16
K11
F6
K6K5
X2:4
X2:
5
K10
500V
460V
415V
400V 36
5V35
0V26
5V25
0V 90V
60V
30V
8 7 6 5 4 3 2 1
12 11 10 9
X33
PAN
ELC
DP
312
C 1
D 1
X1:
53
AIT
ACA
I1A
I2A
I3AI
4+1
0V-1
0VAO
1AO
2IA
CT
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
+48V
DO
1D
O2
DO
3D
O4
DO
5D
O6
DO
7_
__
__
++
++
+
T
TM
0V0V
0V0V
0V
X3:
12
34
56
78
910
X4:
12
34
56
78
910
X6:
12
34
56
78
910
X7:
12
34
56
78
1...1
0X5
:+
_+
_
+ _
K1
K6
K5
K11
K10
S4 56
K15
K12
* [K13
]
K13K1
2
CH
2
CH
3
K12
K15
K16
K15
DC
S 60
0
AMC-DC 2
Con
trol b
oard
(CO
N-2
)
Pow
er s
uppl
y(P
OW
-1)
Con
verte
rm
odul
e
ELEC
TR.
DIS
CO
N-
NEC
T
EMER
.ST
OP
Fiel
d ex
cite
run
it (F
EX-1
/2)
depe
ndin
g on
the
unit
type
(C1,
C2,
A5,
C4)
the
pola
ritie
s ar
e sh
own
for m
otor
ing
if th
ere
are
inte
rmed
iate
term
inal
s
e.g.
Pre
ssur
e sw
itch
at C
4 m
odul
e
* if c
onta
ctor
rela
y K
13 is
use
d
If SD
CS-
IOB-
2 is
in u
se K
10,
K11
and
K12
are
not
nece
ssar
y
II F 4-2
Fig. 4.2/1: DCF 600 Field supply converter wiring diagram
4.2 Field supply converter DCF 600N
ote:
In c
ase
the
supp
ly v
olta
ge fo
r the
exc
itat
ion
is sw
itch
ed o
n th
e pr
imar
y si
de o
f its
supp
lytr
ansf
orm
er a
ddit
iona
l ove
rvol
tage
pro
tec-
tion
is r
equi
red.
Ple
ase
cont
act A
BB
!
CH
0
X96:
DO
8
12
X99:
12
X2:
45
X2:1
23
U1W
1V1
PEX4
:1
2
K1
L1L2
L3
400V
50H
z
F1 K11
35
24
6
L1
M ~F21 2
3 4
1 2
3 4K5
F4F5
1 2
1 2
T2
111 10 9 8 7 6 5 4 3 2
690V
660V
600V
575V
525V
500V
450V
415V
400V
380V
12 13 14
115V
230V
K16
K16
K5
X2:4
X2:
5
K10
X33
PAN
ELC
DP
312
C 1
D 1
X11
X12
AIT
ACA
I1A
I2A
I3AI
4+1
0V-1
0VAO
1AO
2IA
CT
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
+48V
DO
1D
O2
DO
3D
O4
DO
5D
O6
DO
7_
__
__
++
++
+
M
0V0V
0V0V
0V
X3:
12
34
56
78
910
X4:
12
34
56
78
910
X6:
12
34
56
78
910
X7:
12
34
56
78
1...1
0X5
:+
_+
_
K1
K5
K11
K10
S4 56
K12
* [K1
3]
K13K1
2
CH
2
CH
3
K12
K16
DC
F 50
6D
CF
600
AMC-DC 2
Con
trol b
oard
(CO
N-2
)
Pow
er s
uppl
y(P
OW
-1)
Fiel
d su
pply
conv
erte
rm
odul
e
ELEC
TR.
DIS
CO
N-
NEC
T
depe
ndin
g on
the
unit
type
(C1,
C2)
* if c
onta
ctor
rela
y K
13 is
use
d
If S
DC
S-I
OB
-2
is in
use
K10
, K
11 a
nd K
12
are
not
nece
ssar
y
Ove
rvol
tage
prot
ectio
n
K11
= A
larm
II F 4-3
Notes
II F 4-4
Since we aim to always meet the latest state-of-the-artstandards with our products, we are sure you willunderstand when we reserve the right to alter particularsof design, figures, sizes, weights, etc. for our equipmentas specified in this brochure.
3AD
W 0
00 0
72 R
0401
RE
V D
08_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
*072R0401A2340000**072R0401A2340000*