Hardware Manual DCS800 Drives (20 To 5200 A)

DCS800
Hardware Manual
DCS800 Drives (20 to 5200 A)
DCS800 Single Drive Manuals
Language
Public. number E D I ES F CN RES
DCS 800 Quick Guide (191 + CD) 3 ADT 645 0 ?? NN
DCS 800 converter module
Flyer DCS800 3 ADW 000 190 x x p p p p JF
Flyer DCS800 E Panel solution 3 ADW 000 0?? JF
Catalogue DCS800 3 ADW 000 192 x p p p p p JF
Hardware Manual DCS800 00S 3 ADW 000 194 x p p p p p TW
Firmware Manual 3 ADW 000 193 x p p p p p TV
Installation according to EMC 3 ADW 000 032 x TW
Technical Guide 3 ADW 000 163 x TW
Service Manual DCS800 3 ADW 000 195 p p NN
Planning and Start-up for12-Pulse converters 3 ADW 000 196 p NN
CMA-2 Board 3 ADW 000 136 p TW
Flyer Hard - Parallel 3 ADW 000 153 p UW
Tools + optical link

DriveWindow 2.x 3 BFE 645 60981 x UW
DriveOPC 3 BFE 000 73846 x UW
Optical DDCS Communication Link 3 AFE 639 88235 x UW
DDCS Branching unit User´s manual 3 BFE 642 85513 x UW
NETA Remote diagnostic interface 3 AFE 546 05062 x UW
vdB
DCS800 Application
1131Programming Tool +Libary CoDeSys2.3 x x vdB
1131 DCS800 target +tool description 3ADW000199 x vdB
Winding with the DCS 800XXXXX 3 ADW 000 058 vdB
Winder application description vdB
Flyer magnetic application vdB
Magnetic application description vdB
DCS800 00A Enclosed

Flyer DCA 800 UW
System description DCS800 00A 3 ADW 000 198 p p UW
Installation of DCS800 00A 3 ADW 000 091 p p UW
DCR 500 rebuild system

Flyer DCR 3 ADW 000 007 p p TW
DCR Manual 3 ADW 000 197 p TW
DCS500/DCS600 upgrade manual TW
Hardware Extension
RAIO-01 Analogue IO Extension 3AFE 644 84567 x TV
RDIO-01 Digital IO Extension 3AFE 644 85733 x TV
AIMA R-slot extension 3AFE64661442 x TV
Serial interfaces vdB

Drive specific serial communication vdB
Installation and Start-up GuideRPBA-12 (PROFIBUS) x vdB
Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) 3 AFE 645 04215 x vdB
Fieldbus Adapter with DC Drives RCAN-02 (CANopen) vdB
Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3 AFE 645 06005 x vdB
Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3 AFE 645 504223 x vdB
Fieldbus Adapter with DC Drives RMBA (MODBUS) 3 AFE 644 98851 x vdB
Fieldbus Adapter with DC Drives RETA (Ethernet) vdB

x -> existing p -> planned
DCS800 Drives
20 to 5200 Amps
Hardware Manual
3ADW000194R0201 Rev B
EFFECTIVE: 05.10.2005
¤ 2005 ABB Automation Products GmbH. All rights reserved.served.
3ADW000194R0201 DCS800 Hardware Manual e b

5
Safety instructions
What this chapter contains

This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
To which products this chapter applies

This chapter applies to the DCS800... Size D1 to D7and field exciter units DCF800...
Use of warnings and notes

There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment. They also tell you how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause

physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by

electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Safety instructions
6
Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death.
Only qualified electricians are allowed to install and maintain the drive.
• Never work on the drive, motor cable or motor when main power is applied.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. Voltage between drive input phases U1, V1 and W1 and the frame is close to
0 V.
2. Voltage between terminals C1 and D1 and the frame is close to 0 V.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages inside the drive even when the main power on the drive is
switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the C1 and D1 terminal
is correct.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)

may be present on the terminals of relay outputs SDCS-IOB-2, RDIO.
• DCS800 with enclosure extension: Before working on the drive, isolate the
whole drive from the supply.
Safety instructions
7
WARNING! The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
• Ground the drive, motor and adjoining equipment to ensure personnel safety in
all circumstances, and to reduce electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized as required by

safety regulations.
• In a multiple-drive installation, connect each drive separately to protective

earth (PE).
• Minimize EMC emission and make a 360° high frequency grounding of

screened cable entries at the cabinet lead-through.
• Do not install a drive with EMC filter on an ungrounded power system or a high
resistance-grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Safety instructions
8
Fibre optic cables
WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4 in.).
Mechanical installation
These notes are intended for all who install the drive. Handle the unit carefully to
avoid damage and injury.
• DCS800 Size D4...D7: The drive is heavy. Do not lift it alone. Do not lift the unit
by the front cover. Place the unit only on its back.
DCS800 Size D6/D7: The drive is heavy. Lift the drive by the lifting lugs only.
Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.
• Make sure that dust from drilling does not enter the drive when installing.
Electrically conductive dust inside the unit may cause damage or lead to
malfunction.
• Ensure sufficient cooling.
• Do not fasten the drive by riveting or welding.
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the base speed.
• Do not activate automatic fault reset functions of the Standard Application

Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (disconnecting switch);
instead, use the control panel keys and , or commands via the I/O
board of the drive.
• Mains connection
You can use a switch disconnector (with fuses) in the power supply of the
thyristor power converter to disconnect the electrical components of the unit
from the power supply for installation and maintenance work. The type of
disconnector used must be a switch disconnector as per EN 60947-3, Class B,
so as to comply with EU regulations, or a circuit-breaker type which switches
off the load circuit by means of an auxiliary contact causing the breaker's main
contacts to open. The mains disconnector must be locked in its "OPEN"
position during any installation and maintenance work.
• EMERGENCY STOP buttons must be installed at each control desk and at all
other control panels requiring an emergency stop function. Pressing the STOP
button on the control panel of the thyristor power converter will neither cause
an emergency motor stop, nor will the drive be disconnected from any
dangerous potential.
To avoid unintentional operating states, or to shut the unit down in case of any
imminent danger according to the standards in the safety instructions it is not
sufficient to merely shut down the drive via signals "RUN", "drive OFF" or
"Emergency Stop" respectively "control panel" or "PC tool".
• Intended use the operating instructions cannot take into consideration every
possible system configuration, operation or maintenance. Thus, they mainly
give such advice only, which is required by qualified personnel for normal
operation of the machines and devices in industrial installations.
If in special cases the electrical machines and devices are intended for use in
non-industrial installations - which may require stricter safety regulations (e.g.
protection against contact by children or similar). These additional safety
measures for the installation must be provided by the customer during
assembly.
Safety instructions
10
Note:
• When the control location is not set to Local (L not shown in the PC tool status
row), the stop key on the control panel will not stop the drive.
Safety instructions
11
Table of contents
DCS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table of contents
The DCS800
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The DCS800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Armature circuit converter DCS800 D1...D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Armature circuit converter DCS800 D5...D7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rebuild system DCR800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mounting the converter module D6 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting the converter module D7 inside an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Planning the electrical installation

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Options for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Line reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Aspects of fusing for the armature-circuit and field supplies of DC drives . . . . . . . . . . . . . . . 28
Table of contents
3ADW000194R0201_DCS800 Hardware Manual_e_b
12
Semiconductor type F1 fuses and fuse holders for AC and DC power lines . . . . . . . . . . . . . 30
Fuses F3.x and fuse holders for field supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single-phase Transformer T3 for field supply to match voltage levels . . . . . . . . . . . . . . . . . 31
Single-phase Commutating reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Auxiliary transformer T2 for electronic system / fan supply . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Residual current detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Three-phase filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Converters D1...D4 drive configuration using ’on board’ field exciter . . . . . . . . . . . . . . . . . . . . . . . 38
Converters D5 drive configuration using ’FEX-425-Int’ field exciter . . . . . . . . . . . . . . . . . . . . . . . . 39
Converters D5...D7 drive configuration using ’external’ field exciter DCF803, DCF804 . . . . . . . . . 40
START, STOP and E-STOP control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Drive configuration with reduced components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power section cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mains cable (AC line cable) short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cross-sectional areas - Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DCS800 panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical installation
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Location R-Extension and Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
I/O Board Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pulse encoder connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pulse encoder receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connecting the signal and control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DSL Link Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fan replacement (D6, D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table of contents
13
Technical data
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Current ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Control Board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Layout of the control board SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Memory circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Watchdog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Seven segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Terminal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Digital and analogue I/O connection of the SDCS-CON-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Interface Board SDCS-COM-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
DDCS Branching unit NDBU-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DSL Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Digital I/O board SDCS-IOB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Analogue and encoder I/O board SDCS-IOB-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Power Supply Board SDCS-POW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Interface Board SDCS-PIN-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Armature circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Field circuit interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Galvanic isolation - T90, A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
DC-DC transducer A92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Transformer T90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Dimensional drawings
Module D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Module D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Module D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Module D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Module D5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Module D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Module D7 left-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Module D7 right-hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuses installed inside the converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Accessories
DCF803-0035 and FEX 425 internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DCS LINK communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table of contents
14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
RS232-Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Fuses and fuse holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Line chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Line chokes type ND 01...ND 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Line chokes type ND 07...ND 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Line chokes type ND 401...ND 413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Autotransformer T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Line choke L3 for SDCS-FEX-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Supply transformer T2 for electronics and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Optical cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Table of contents
15
The DCS800

This chapter describes briefly the operating principle and construction of the drive in
short.
The DCS800
The DCS800 size D1...D7 are intended for controlling DC motors.
Size D1...D4 Size D5

20...1000 A 900...2000 A
Size D6 Size D7
1900...3000 A 2050...5200
The DCS800
16
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. DCS800-S01-
2005). The optional selections are given thereafter, on the name plate by plus code.
The main selections are described below. Not all selections are available for all
types.
Type code D C S 8 0 0 - A A X - Y Y Y Y - Z Z - plus code
Position A X Y Z B
Position Plus code

Product series DCS800
A Type S0 = Converter module IP00
R0 = Rebuild system
E0 = Panel solution
A0 = Enclosed converter
X Bridge type 1= Single bridge 2-Q
2= Double bridge 4-Q
Y Rated current YYYY = Rated current (e.g. 0025 = 25 amps)
ZZ Rated voltage 04 = 400 V
(nominal rating in bold) 05 = 500 V
06 = 600 V
07 = 690 V
08 = 790 V
10 = 990 V
12 = 1200 V
B Power connection - = Standard D1...D6
L= Left side D7
R= Right side D7
Internal field exciter +S163 0= with internal field exciter (only D5)
configuration +0S163 A= without internal field exciter (only D1...D4)
Fan voltage Standard
230 V / 1-ph
400 V / 500 V / 790 V at D6 = 400-500 V / 3-ph
600 V / 690 V at D6 = 600-690 V / 3-ph
+S171 115 V (only D4)
+S172 400-500 V; D6 converter
+S173 600-690 V; D6 converter
SDCS-DSL board +S199 SDCS-DSL board
+0S199 no SDCS-DSL board
+ plug-in options
Control panel 0J400 no control panel
Fieldbus K...
I/O and DDCS L...
The DCS800
1000V
EMC filter
Earth-fault monitor
500V
500V
PC + Door PLC F2 Q1 F3
DriveWindow mounting F1
kit T2 T3
-NDPA-02 Panel
(PCMCIA)
-NDPC-12 K3
-NISA-03 (ISA)
CDP 312 K1 Power
230 V (115V) supply
L1 K5
RJ45
DCS800 D1...D4
NDBU95
Main circuit and control
X33
Panel
optical fibre
PIN-4
X9
Fieldbus
CON-4
Slot 1
interface R...
X19
Ch3
Master/
Ch2
Follower
M
X10
X11
Slot 3
COM-8
Slot 2
RAIO
RDIO
Ch1
Slot1
Ch0
Slot 4
DCF 803 / 804
Memory Card
Slot2
X2
X20
NAMIA
Slot3
On Board FEX PIN 4
X1 24V-

Armature circuit converter DCS800 D1...D4
X51X52 DSL X53

Three-phase field supply
X34 DSL
optical fibre
X3 X4 X5 X6 X7
DCS link twisted pair
NDBU95
4 3 8 7
Advant
control
M
to field
IOB-2x IOB-3
Legend
PC + 3 5
CON x - short designation of components
8 8
CoDeSys RS232 T digital input / output analogue input / output
DWL alternative * see Technical Data
T 7.1 - detailed description see chapter 7.1
DCS8_sys_ovw_a.dsf
The DCS800
17
18
1000V
EMC filter
Earth-fault monitor
500V
The DCS800
PC + Door PLC F2 Q1 F3
kit T2 T3
-NDPA-02 Panel
(PCMCIA)
-NDPC-12 K3
-NISA-03 (ISA)
CDP 312 K1 Power
supply
L1 K5 *
RJ45
L3
DCS800 D5...D7
NDBU95
X33
Panel
optical fibre
POW-1
X9
Fieldbus
CON-4
Slot 1
interface R...
PIN-41
PIN-51
X19 PIN-41
Ch3
Master/
Ch2 M
Follower
X10
X11
Slot 3
COM-8
Slot 2
RAIO
RDIO
Ch1
Slot1
Ch0
Slot 4
DCF 803 / 804
Memory Card
Slot2
FEX 425 internal **
X2
X20
NAMIA
Slot3 X1 24V-
Armature circuit converter DCS800 D5...D7
X51X52 DSL X53

X34 DSL
optical fibre
X3 X4 X5 X6 X7

NDBU95
4 3 8 7
Advant
control
M
to field
IOB-2x IOB-3 * three-phase D6 and D7
** only D5 types
Legend
PC + 3 5
8 8
DCS8_sys_ovw_a.dsf
1000V
EMC filter
Earth-fault monitor
500V
Existing part
Q1 Q1
PC + Door PLC F2 F3
kit T2 T3
-NDPA-02 Panel
(PCMCIA)
-NDPC-12 K3
-NISA-03 (ISA)
CDP 312 K1 K1 Power
supply
L1 L1 K5
RJ45 L3
~ ~ NPSM-01
DCR800 - -
NDBU95
X33
Panel
optical fibre
Rebuild system DCR800
POW 1
POW-1 PIN-41
X9
Fieldbus
CON-4
Slot 1
interface R...
PIN 1x
PIN-51
X19
Ch3 REB-1
Master/
Ch2 M
M
Follower
X10
X11
Slot 3
COM-8
Slot 2
RAIO
RDIO
Ch1 REB-2 REB-3
Slot1
Ch0
Slot 4
FEX 425 internal
DCF 803 / 804
Memory Card
Slot2
X2
X20
NAMIA

Slot3 X1 24V-
X51X52 DSL X53 PIN-41
X34 DSL
optical fibre
X3 X4 X5 X6 X7
NDBU95
4 3 8 7
Advant
control
M
to field
IOB-2x IOB-3
Legend
PC + 3 5
8 8
DCS8_sys_ovw_a.dsf
The DCS800
19
20
The DCS800
21
Unpacking the unit

• open box
• take out shock dampers
• separate manual and accessories
• do not lift the drive by cover.
2
1
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC rating, UL, C-UL, CSA
and CE markings, a type code and a serial number, which allow individual
identification of each unit. The remaining digits complete the serial number so that
there are no two units with the same serial number.
Example labels are shown below.
Type designation label
22
Before installation
The drive must be installed in an upright position with the cooling section facing a
wall. Check the installation site according to the requirements below. Refer to
Dimensional drawings for frame details.
Requirements for the installation site

See Technical data for the allowed operation conditions of the drive.
Wall
The wall should be as close to vertical as possible, of non-flammable material and
strong enough to carry the weight of the unit. Check that there is nothing on the wall
to inhibit the installation.
Floor
The floor/material below the installation should be non-flammable.
Free space around the unit
Required free space around the drive to enable cooling air flow, service and
maintenance see chapter Dimensional drawings.
Cabinet installation
The required distance between parallel units is five millimetres (0.2 in.) in
installations without the front cover. The cooling air entering the unit must not exceed
+40 °C (+104 °F).
Preventing cooling air recirculation Unit above another
Prevent air recirculation inside and outside the cabinet.
Main air flow out

HOT
Air baffle plates
COOL AREA
max.+40 °C (+104 °F)
Air baffle plate
Main air flow in
Cooling w baffle.dsf
Airflow
Lead the exhaust cooling air away from the unit above.
Distances see chapter Dimensional drawings
23
Mounting the converter module D6 inside an enclosure

Cooling air entry Free space around the conerter module
The cooling fan takes the air from the backside, both sides and from the area under- optimum compromise
neath the converter module.
50 ~ 100
View from: the right side the back the left side
~ 100
50 50
Top view Top view

air flow air flow air flow air flow
Cooling air outlet

To avoid circulating air inside the enclosore it is recom-
air flow air flow mended to make sure the exhaust air leaves the enclo-
A6_li_air_inlet.dsf sure.
Cable entries Power cable connection The figure below gives an example, how the right angle
The power cable connection is performed via Terminal busbars can be mounted in case all cable connections
option 01 for A6. This option consists of one right are still made at the left side of the converter module.
electronics power supply
angle copper busbar. The mechanical details are This results in four layers for the power cables.
shown by the figure below.
C 100 In case the AC or DC connection or perhaps both of
72.2 Ø14 75
them have to be made at the right side of the converter
21.8 25 module use the space behind the converter and move
D
0 the power terminals via a right angle busbar up to that
point where the final connection is most suitable. In this
125
175
272
312
352
372
25
75
0
do not unscrew these bolts !
250
case the busbars need to be fixed at the cubicle /
enclosure, not at the converter module! The figures
U below give a rough example, how a right side connec-
control cables
tion can be made.

140
V A6_cable_term_busb.dsf
When mounting the right angle busbars or connecting

cables directly please make sure the correct bolts are
W
used. The converter module is equipped with a thread
hole at its end. Because of that the length of the
remaining threads is limited to 35 mm (see drawing
pressure
below).
(left and right side) switch
converter fan
max.
A6_li_air_inlet_a.dsf
35mm
468.2
136
Example right side connection
24
Mounting the converter module D7 inside an enclosure

Cooling air entry Cable entries
The cooling fan takes the air from the backside, both The cable entries are existing symmetrically on both
sides and from the area underneath the converter sides. Nevertheless only the entries on the left side
module. should be used for cables going to the electronics
View from front left side / (right side) power supply (SDCS-POW-1) or the controller board
(SDCS-CON-x).
electronics power supply

air flow
air flow
converter fan control cables

w
flo
air
View from bottom

pressure
switch
Free space around the conerter module

Do not place the converter module in a corner. In case
the fan cannot take the air through the bottom plate of
the enclosure non of the remaining entires has to be
blocked.
A7_re_air_inlet.dsf
>20
50
Air entry through bottom plate

Make sure the converter module gets clean air,
because there is no air filter in front of the fan at the
converter.
Cooling air outlet
To avoid circulating air inside the enclosore it is rec-
ommended to make sure the exhaust air leaves the
enclosure.
25

This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive system. Always
follow local regulations.
Note: If the recommendations given by ABB are not followed, the drive may
experience problems that the warranty does not cover.
Reference: Technical Guide - publ. no.: 3ADW000163
To which products this chapter applies

This chapter applies to the DCS800 Size D1...D7.
Options for the drive
Line reactors
for armature (DCS800) and field (DCF800) supply.
When thyristor power converters operate, the line voltage is short-circuited during
commutation from one thyristor to the next. This operation causes voltage dips in the
mains PCC (point of common coupling). For the connection of a power converter
system to the mains, one of the following configurations can be applied:
Configuration A
Line
When using the power converter, a minimum of impedance is
PCC required to ensure proper performance of the snubber circuit. A line
(Pcc) reactor can be used to meet this minimum impedance requirement.
The value must therefore not drop below 1% uk (relative impedance
uk LR > 1% voltage). It should not exceed 10% uk, due to considerable voltage
drops at converter output.

26
Configuration B
Line
LLine
If special requirements have to be met at the PCC (standards like EN
61 800-3, DC and AC drives at the same line, etc), different criteria
must be applied for selecting a line reactor. These requirements are
PCC often defined as a voltage dip in percent of the nominal supply
(P ) voltage.
LLRcc
The combined impedance of ZLine and ZLR constitute the total series
impedance of the installation. The ratio between the line impedance
and the line reactor impedance determines the voltage dip at the
connecting point. In such cases line chokes with an impedance
around 4% are often used.
Example calculation with Uk Line=1%;
Uk LR=4%; Voltage Dip = ZLine/(ZLine+ZR)=20%. Detailed calculation
see Technical Guide.
Configuration C
Line
If an isolation transformer is used, it is possible to comply with certain
PCC connecting conditions per Configuration B without using an additional
line reactor. The condition described in Configuration A will then
(Pcc)
likewise be satisfied, since the uk is >1 %.
Configuration C1
If 2 or more converters should be supplied by one
Line transformer the final configuration depends on the
number of drives in use and their power capability.
PCC
Configuration A or B has to be used which are based on
(Pcc)
commutation chokes, if the drive system consists of any
of the converters (D1, D2, D5, D6, D7). In case only two
LLR LLR LLR .... converters type D7 are involved no commutation chokes
are necessary because the design of these converters is
adapted to that wiring.
Netzdr_f.dsf
With reference to the power converter:

The line reactors listed in table below
• have been sized to the units nominal current
• are independent of converter's voltage classification; at some converter types the
same line choke is used up to 690 V line voltage
• are based on a duty cycle
• can be used for DCS800 as armature converter as well as field converter but
rated line choke current must be considered.
You will find further information in publication:
Technical Guide chapter: Line reactors

27
Line reactors L1
DCS Type Line choke Design Line choke Design
400V-690V type for Fig. type for Fig.
50/60 Hz
configur. A configur. B
2-Q Converter 4-Q Converter
DCS800-S01-0020-04/05 DCS800-S02-0025-04/05 ND01 1 ND401 4
DCS800-S01-0045-04/05 DCS800-S02-0050-04/05 ND02 1 ND402 4
DCS800-S01-0065-04/05 DCS800-S02-0075-04/05 ND04 1 ND403 5
DCS800-S01-0090-04/05 DCS800-S02-0100-04/05 ND06 1 ND404 5
DCS800-S01-0125-04/05 DCS800-S02-0140-04/05 ND06 1 ND405 5
DCS800-S01-0180-04/05 DCS800-S02-0200-04/05 ND07 2 ND406 5
DCS800-S01-0230-04/05 DCS800-S02-0260-04/05 ND07 2 ND407 5
DCS800-S01-0290-06 DCS800-S02-0320-06 ND08 2 on request -
DCS800-S01-0315-04/05 DCS800-S02-0350-04/05 ND09 2 ND408 5
DCS800-S01-0405-04/05 DCS800-S02-0450-04/05 ND10 2 ND409 5
DCS800-S01-0590-06 DCS800-S02-0650-06 ND13 3 on request -
DCS800-S01-0500-04/05 DCS800-S02-0550-04/05 ND10 2 ND410 5
DCS800-S01-0610-04/05 DCS800-S02-0680-04/05 ND12 2 ND411 5
DCS800-S01-0740-04/05 DCS800-S02-0820-04/05 ND13 3 ND412 5
DCS800-S01-0900-04/05 DCS800-S02-1000-04/05 ND13 3 ND413 5
DCS800-S01-0900-06/07 DCS800-S02-0900-06/07 ND13 3 on request -
DCS800-S01-1500-04/05/06/07 DCS800-S02-1500-04/05/06/07 ND15 3 on request -
DCS800-S01-2000-06/07 ND16 * 3 on request -
* with forced cooling (1m/s)
Fig. 1 Fig. 2
Fig. 3
Fig. 4 Fig. 5

28
Aspects of fusing for the armature-circuit and field supplies of DC drives

General
Unit configuration
Protection elements such as fuses or overcurrent trips are used whenever
overcurrents cannot entirely be ruled out. In some configurations, this will entail the
following questions: firstly, at what point should which protective element be
incorporated? And secondly, in the event of what faults will the element in question
provide protection against damage?
AC supply: public mains / plant's mains

Cabinet
The figure shows the arrangement of the
switch-off elements in the armature-circuit
3 2
M converter
.
. .
. .
You will find further information in

For field supply 2 publication:
see Fig. 2.6/2
Technical Guide chapter: Aspects
for fusing
Conclusion for the armature supply

In some cases standard fusing is used instead of semi-conductor fusing in order to
save money on installation. If every possible fault scenario could be ruled out, this
would be acceptable. However this is seldom the case.
In the event of a fault condition, the small amount of money saved can cause
exploding power semi-conductor or other devices and could also cause fires.
Adequate protection against short-circuit and earth fault, as depicted in the
EN50178 standard, is possible only with appropriate semiconductor fuses.
Semiconductor Semiconductor
fuses fuses
DCS converter DCS converter
4-Q resp.
2-Q non-regen. 2-Q regenerative
Semiconductor
fuses
M M

29
Conclusion for the field supply

Basically, similar conditions apply for both field supply and armature-circuit supply.
Depending on the power converter used (diode bridge, half-controlled bridge, fully
controlled 4-quadrant bridge), some of the fault sources may not always be
applicable. Due to special system conditions, such as supply via an autotransformer
or an isolating transformer, new protection conditions may additionally apply.
The following configurations are very often used:
In contrast to the armature-circuit supply, fuses are never used on the DC side for
the field supply, since a fuse trip might under certain circumstances lead to greater
damage e.g. (small, but long-lasting overcurrent; fuse ageing; contact problems;
etc.).
Semiconductor fuse F3.1 (super-fast acting) should be used, if conditions similar to
those for armature-circuit supply are to apply, like for example protection of the field
supply unit and the field winding.
ND30 /
F3.1 built-in 2
Configuration for field supplies
The F3.2 and F3.3 fuse types serve as line protectors and cannot protect the field
supply unit. Only pure HRC fuses or miniature circuit-breakers may be used.
Semiconductor fuses would be destroyed, for example, by the transformer’s starting
current inrush.
F3.2
F3.1
2 Configurations for field supplies
ND30 /
F3.3 built-in
F3.1
2
FF_ASP_b.dsf

30
Semiconductor type F1 fuses and fuse holders for AC and DC power lines
(DCS800-S01 / DCS800-S02)
The converter units are subdivided into two groups:
• Unit sizes D1, D2, D3 and D4 with rated currents up to 1000 A require external
fuses.
• In unit sizes D5, D6 and D7 with rated currents of 900 A to 5200 A, the branch
semiconductor fuses are installed internally (no additional external semiconductor
fuses are needed).
The third column of the table below assigns the AC fuse type to the converter type.
In case the converter should be equipped with DC fuses according to the hints, use
the same type of fuse as on AC side at DC side (C1, D1). Blade type fuses are used
for all the converters construction type D1...D4 except the converters
(610 A, 680 A, 740 A, 820 A, 900 A, 1000 A).
Type of converter Type Fuse holder
2-Q Converter 4-Q Converter
DCS800-S01-0020-04/05 DCS800-S02-0025-04/05 170M 1564 OFAX 00 S3L
DCS800-S01-0125-04/05 DCS800-S02-0140-04/05 170M 3815 OFAX 1 S3
DCS800-S01-0180-04/05 DCS800-S02-0200-04/05 170M 3816 OFAX 1 S3
DCS800-S01-0230-04/05 DCS800-S02-0260-04/05 170M 3817 OFAX 1 S3
DCS800-S01-0315-04/05 DCS800-S02-0350-04/05 170M 5810 OFAX 2 S3
DCS800-S01-0405-04/05 DCS800-S02-0450-04/05 170M 6811 OFAX 3 S3
DCS800-S01-0500-04/05 DCS800-S02-0550-04/05 170M 6811 OFAX 3 S3
DCS800-S01-0610-04/05 DCS800-S02-0680-04/05 170M 6163 3x 170H 3006
DCS800-S01-0740-04/05 DCS800-S02-0820-04/05 170M 6163 3x 170H 3006
DCS800-S01-0900-04/05 DCS800-S02-1000-04/05 170M 6166 3x 170H 3006
DCS800-S01-0290-06 DCS800-S02-0320-06 170M 5810 OFAX 2 S3

DCS800-S01-0590-06 DCS800-S02-0650-06 170M 6813 OFAX 3 S3
Fuses and fuse holders (details see chapter Technical Data)
Fuses F3.x and fuse holders for field supply

Depending on the protection strategy different types of fuses are to be used. The
fuses are sized according to the nominal current of the field supply device. If the field
supply unit is connected to two phases of the network, two fuses should be used; in
case the unit is connected to one phase and neutral only one fuse at the phase can
be used. Table below lists the fuse currents with respect to the table above.
The fuses can be sized according to the maximum field current. In this case take the
fuse, which fits to the rated field current levels.

31
Field conv. Field F3.1 F3.2 F 3.3

current
DCF803-0035 IF ≤ 6 A 170M 1558 * OFAA 00 H10 10 A
FEX-425-Int IF ≤ 12 A 170M 1559 * OFAA 00 H16 16 A
DCF803 IF ≤ 16 A 170M 1561 * OFAA 00 H25 25 A
DCF804
DCF803 IF ≤ 30 A 170M 1564 OFAA 00 H50 50 A
DCF804
DCF803 IF ≤ 50 A 170M 1565 OFAA 00 H63 63 A
DCF804
Type of protection Semiconduct. LV HRC type circuit breaker
elements type fuse for for 690 V; fuse for 500 V or
fuse holder hold. OFAX 00 690 V
type OFAX 00
* F3.1 Fuse KTK25 included in FEX-425-Int

Fuses and fuse holders for 2-phase field supply
Single-phase Transformer T3 for field supply to match voltage levels

The field supply units’ insulation voltage is higher than the rated operating voltage
(see Chapter Field supplies), thus providing an option in systems of more than 500 V
for supplying the power section of the converter directly from the mains for purposes
of armature supply, and using an autotransformer to match the field supply to its
rated voltage. Moreover, you can use the autotransformer to reduce the voltage
ripple. Different types (primary voltages of 400...500 V and of 525...690 V) with
different rated currents each are available.
Field converter type for field current Transformer
≤500 V; 50/60 Hz IF type 50/60 Hz
external supply
Uprim = ≤500 V
≤6A T 3.01
DCF803-0035 Autotransformer.dsf
FEX-425-Int ≤12 A T 3.02
≤16 A T 3.03
DCF803/4-0050 ≤30 A T 3.04
DCF803/4-0050 ≤50 A T 3.05
Uprim = ≤600 V
≤6A T 3.11
DCF803-0035
FEX-425-Int ≤12 A T 3.12
≤16 A T 3.13
Uprim = ≤690 V
DCF803/4-0050 ≤30 A T 3.14
T3 autotransformer
DCF803/4-0050 ≤50 A T 3.15
Autotransformer data (details see chapter Technical Data)

32
Single-phase Commutating reactor

For DCF803-0035 and FEX-425-Int field power converter with external supply must
be connected via additionally commutating reactor because of EMC considerations if
the supply has a separate mains. With DCF803/804 field power converters, it is
already installed.
Converter for field Reactor
≤500 V; 50/60 Hz current
IF 1ph_reactor.dsf
DCF803-0035 (16 A) 16 A ND 30
FEX-425-Int >16A *
* 3-phase operation and 3-phase line choke recommended

Commutating reactor (for more information see chapter ??)
Auxiliary transformer T2 for 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/690 V/3-
ph, according to their size. The T2 auxiliary transformer is designed to supply the
unit’s electronic system and all the single-phase fans including the fan of the D5
converter
.
Input voltage: 380...690 V/1-ph; 50/60 Hz

Output voltage: 115/230 V/1-ph
Power:1400 VA
Residual current detection

This function detects current to ground. If needed, the analogue input AI4 of the
SDCS-IOB-3 board has to be activated, a current signal of the three phase currents
should be supplied to AI4 by a current transformer.
EMC filters
Filter in a grounded line (earthed TN or TT network)
The filters are suitable for grounded lines only, for example in public European 400 V
lines.
According to EN 61800-3 filters are not needed in insulated industrial networks with
own supply transformers. Furthermore they could cause safety risks in such floating
lines (IT networks).

33
According to EN 61800-3 filters are not needed in industrial zone (Second

Environment) for DCS800 drives above 100 A rated current. For rated currents
below 100 A the filter requirement is identical to Light Industry (First Environment).
Three-phase filters
EMC filters are necessary to fulfil the standard for emitted interference if a converter
shall be run at a public low voltage line, in Europe for example with 400 V between
the phases. Such lines have a grounded neutral conductor. ABB offers suitable
three-phase filters for 400 V and 25 A...600 A and 500 V filters for 440 V lines
outside Europe. The filters can be optimized for the real motor currents:
IFilter = 0.8 • IMOT max ; the factor 0.8 respects the current ripple.
Lines with 500 V to 1000 V are not public. They are local networks inside factories,
and they do not supply sensitive electronics. Therefore converters do not need EMC
filters if they shall run with 500 V and more.
Type of converter Constr. Filter type f. y=4 Filter type f. y= 5
type
2-Q Converter IDC [A] 4-Q Converter IDC [A]
DCS800-S01-0020-0y 20A DCS800-S02-0025-0y 25A D1 NF3-440-25 NF3-500-25
DCS800-S01-0740-0y 740A D4 NF3-500-600 NF3-500-600
DCS800-S02-0820-0y 820A D4 NF3-690-1000 ➀ NF3-690-1000 ➀
DCS800-S01-0900-0y 900A DCS800-S02-1000-0y 1000A D4 NF3-690-1000 ➀ NF3-690-1000 ➀
≤ 3000A ≤ 3000A D6 NF3-690-2500 ➀ NF3-690-2500 ➀
➀ Filter only available on request

34
Single-phase filters for field supply

Many field supply units are single-phase converters for up to 50 A excitation current.
They can be supplied by two of the three input phases of the armature supply
converter. Then a field supply unit does not need its own filter.
If the phase to neutral voltage shall be taken (230 V in a 400 V line) then a separate
filter is necessary. ABB offers such filters for 250 V and 6...30 A.
Converter type of dc current Filter type ➀
field supply unit [A] Umax = 250 V
DCF803-0035 * 8 NF1-250-8
FEX-425-Int * 16 NF1-250-20
DCF803-0050 50 NF1-250-55
DCF804-0050 50 NF1-250-55 ➀ The filters can be optimized for the real field cur-
further filters for 12 NF1-250-12 rents: IFilter = IField
30 NF1-250-30
* single-phase operation

35

36
EMC filters
You will find further infor- The paragraphs below describe selection of the electri- •the product's actual emissions
mation in publication: cal components in conformity with the EMC Guideline. The EMC Guideline expects EMC to be taken into
Technical Guide chapter: The aim of the EMC Guideline is, as the name implies, account when a product is being developed; however,
EMC Compliant Installa- to achieve electromagnetic compatibility with other EMC cannot be designed in, it can only be quantita-
tion and Configuration for a products and systems. The guideline ensures that the tively measured.
Power Drive System emissions from the product concerned are so low that
they do not impair another product's interference immu- Note on EMC conformity
nity. The conformity procedure is the responsibility of both
In the context of the EMC Guideline, two aspects must the power converter's supplier and the manufacturer of
be borne in mind: the machine or system concerned, in proportion to their
•the product's interference immunity share in expanding the electrical equipment involved.
First environment (residential area with light industry) with restricted distribution
Not applied, since general distribution sales channel excluded
Not applicable satisfied
satisfied
Medium-voltage network Medium-voltage network
Residential area Supply transformer for a residential Light industry Supply transformer for a residential
area (rating normally 1,2 MVA) area (rating normally 1.2 MVA)
Residential area
Earthed
neutral
Earthed
neutral Earthed public 400-V Earthed public 400-V Earthed public 400-V
network with neutral network with neutral network with neutral
conductor conductor conductor
To other loads which have to be protected from the system disturbances caused by
To other loads, e.g. drive systems
power converters (HF interference and commutation notches)
To other loads which have to be protected from the system disturbances caused by
power converters (HF interference and commutation notches)

Mains filter Mains filter Mains filter
Line reactor +
Line reactor Y-capacitor Line reactor Line reactor
Converter Converter Converter Converter Converter Converter

alternative
alternative
M M M M M M M M
Operation at public An isolating transformer Operation at public Operation at public An isolating transformer
low-voltage network with an earthed screen low-voltage network low-voltage network with an earthed screen
together with other and earthed iron core together with other together with other and earthed iron core
loads of all kinds. renders mains filter and loads of all kinds. loads of all kinds. renders mains filter and
line reactor superfluous. line reactor superfluous.

37
For compliance with the protection objectives of the For emitted interference, the following apply:
German EMC Act (EMVG) in systems and EN 61000-6-3 Specialised basic standard for emissions in light industry can
machines, the following EMC standards must be sat- be satisfied with special features (mains filters, screened power
isfied: cables) in the lower rating range *(EN 50081-1).
Product Standard EN 61800-3 EN 61000-6-4 Specialised basic standard for emissions in industry *(EN
EMC standard for drive systems (PowerDriveSys- 50081-2)
tem), interference immunity and emissions in resi- For interference immunity, the following apply:
dential areas, enterprise zones with light industry EN 61000-6-1 Specialised basic standard for interference immunity in residen-
and in industrial facilities. tial areas *(EN 50082-1)
This standard must be complied with in the EU for EN 61000-6-2 Specialised basic standard for interference immunity in industry.
satisfying the EMC requirements for systems and If this standard is satisfied, then the EN 61000-6-1 standard is
machines! automatically satisfied as well *(EN 50082-2).
* The generic standards are given in brackets
Standards
Second environment (industry) with restricted distribution EN 61800-3
Not applicable EN 61000-6-3
satisfied on customer's request satisfied EN 61000-6-4
satisfied EN 61000-6-2
EN 61000-6-1
Classification
The following overview uti-
Medium-voltage network Medium-voltage network lises the terminology and
Supply transformer for a Converter indicates the action
Industrial zone residential area (rating Industrial zone required in accordance with
transformer
normally 1.2 MVA) with earthed Product Standard
Converter EN 61800-3
transformer For the DCS 500B series,
Earthed iron core the limit values for emitted
neutral (and earthed I > 400 A
Earthed 400-V network
screen where
interference are complied
with neutral conductor; and/or with, provided the action
appropriate) U > 500 V
3~ 400 A indicated is carried out. This
action is based on the term
Restricted Distribution used
in the standard (meaning a
sales channel in which the
products concerned can be
placed in the stream of
commerce only by suppli-

ers, customers or users
Case-referenced EMC analysis
which individually or jointly

possess technical EMC
Mains filter expertise).
For power converters with-

out additional components,
the following warning
applies:
This is a product with
restricted distribution
under IEC 61800-3. This
Line reactor + product may cause radio
Y-capacitor Line reactor Line reactor
interference in residen-
tial areas; in this case, it
may be necessary for the
operator to take appropri-
ate action (see adjacent
diagrams).
Converter Converter Converter Converter
The field supply is not

alternative
alternative
alternative
alternative
depicted in this overview

diagram. For the field cur-
rent cables, the same rules
apply as for the armature-
circuit cables.
M M M M M M M M
Operation at low-voltage network together with Operation with separate power converter transformer. If there Legend
other loads of all kinds, apart from some kinds are other loads at the same secondary winding, these must be Screened cable
of sensitive communication equipment. able to cope with the commutation gaps caused by the power Unscreened cable with restriction
converter. In some cases, commutating reactors will be
required.

38
A C Voltage levels E
L1 N L1 L2 L3 see description L1 L2 L3
T2
230V F1
690V
660V
600V
1 1 1 575V 1 3
F2
F7 F5 F8 525V
115V
2 2 2 500V 2 4
450V F6 1 3 5 13
415V
K15 400V
380V

14
X96:1 I> I> I>

OFF STOP
K10 K11 2 4 6
X96:2
ON START 13 X2:4
K1 K21 F6
14
X2:5
1 1 3 1 3 5 1 3 5
EMER. K1 K6
K8
STOP S1 2 4 2 4 6
K20 2 4 6
2
K20 K21 K6 K8 K3 K1 K15 L1
X96: 1 2 X99: 1 2 X2: 4 5 X2: 1 2 3 U1 V1 W1 PE

Communication
monitoring functions done by the drive.
IN3 V5 board (COM-8x) Control board (CON-4)

OUT3 V6 M
DO8 ~
IN1 V1
Power supply depending on the unit type
OUT1 V2 (POW-1) an other configuration is possible
S1 DCS800
5 6 Converter 'on board' field exciter
X33 AI4

AITAC AI1 AI2 AI3
_ + _ + _ + _ + _ + +10V -10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 module
0V 0V 0V 0V 0V
X3: 1 2 3 4 5 6 7 8 9 10 X4: 1 2 3 4 5 6 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 10 X7: 1 2 3 4 5 6 7 8 X5: 1...10 C1 D1 X1: 5 3

_ _
+ +
e.g. Pressure K6 1 K20

switch at D7
module S1
K10
2
K1 K11
K8 K21
if there are intermediate terminals the polarities are shown for motoring V
U W
T M M
3~
+
T
_ DCS8_ans_1_1.dsf
Converters D1...D4 drive configuration using ’on board’ field exciter
Wiring the drive according to this diagram offers the highest degree of standard
A C Voltage levels D E
L1 N L1 L2 L3 see description L1 N L1 L2 L3
T2
230V F1
690V
660V
600V
1 1 1 575V 1 3
F2 T3
F7 F5 F8 525V
115V
2 2 2 500V 2 4 500V
450V 460V
F6 1 3 5 13
415V F3 415V
K15 400V 400V
380V 14
365V
350V
X96:1 265V I> I> I>
OFF STOP
K10 K11 250V 2 4 6
90V
X96:2 60V
START
30V
ON 13 X2:4
K1 K21 F6
14
X2:5
1 1 3 1 3 5 1 3 1 3 5
EMER. K1 K3 K6
K8
STOP S1 2 4 2 4 6 2 4 2
supplied internally (3-phase).
K20 4 6
2
K20 K21 K6 K8 K3 K1 K15 L1 L3
X96: 1 2 X99: 1 2 X2: 4 5 X2: 1 2 3 U1 V1 W1 PE X1: 1 7

Communication

OUT3 V6 M
DO8 ~
IN1 V1
OUT1 V2 (POW-1) an other configuration is possible
S1 DCS800 Field exciter unit
5 6 Converter FEX-425-Int
X33 AITAC AI1 AI2 AI3 AI4
_ + _ + _ + _ + _ + +10V -10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 module
0V 0V 0V 0V 0V
X3: 1 2 3 4 5 6 7 8 9 10 X4: 1 2 3 4 5 6 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 10 X7: 1 2 3 4 5 6 7 8 X5: 1...10 C1 D1 X1: 5 3

_ _
+ +

switch at D7
module S1
K10
2
K1 K11
K8 K21
U W
T M M
3~
+
T
Converters D5 drive configuration using ’FEX-425-Int’ field exciter
_ DCS8_ans_1_2.dsf
an independent net. For drives up to 500 V mains voltage FEX-425-Int can be
Wiring the drive according to this diagram gives the most flexibility and offers the
FEX-425-Int are equipped with their own synchronization and can be supplied from
highest degree of standard monitoring functions done by the drive. Field converters

39
40
A C Voltage levels D E
L1 N L1 L2 L3 see description L1 N L1 L2 L3
T2
230V F1
690V
DCF803, DCF804
660V
600V
1 1 1 575V 1 3
F2 T3
F7 F5 F8 525V
115V
2 2 2 500V 2 4 500V
450V 460V
F6 1 3 5 13
415V F3 415V
K15 400V 400V

380V 14
365V
350V
X96:1 265V I> I> I>
OFF STOP
K10 K11 250V 2 4 6
90V
X96:2 60V
START
30V
ON 13 X2:4
K1 K21 F6
14
X2:5
1 1 3 1 3 5 1 3 1 3 5
EMER. K1 K3 K6
K8
STOP S1 2 4 2 4 6 2 4
K20 2 4 6
2
K20 K21 K6 K8 K3 K1 K15 L1 L3
X96: 1 2 X99: 1 2 X2: 4 5 X2: 1 2 3 U1 V1 W1 PE X1: 1 7

Communication
OUT3 V6 M
DO8 ~
IN1 V1
OUT1 V2 (POW-1) an other configuration is possible DCS800
S1 Converter Field exciter unit
5 6 module DCS803

X33 AITAC AI1 AI2 AI3 AI4
_ + _ + _ + _ + _ + +10V -10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V DO1 DO2 DO3 DO4 DO5 DO6 DO7 DCS804
0V 0V 0V 0V 0V
X3: 1 2 3 4 5 6 7 8 9 10 X4: 1 2 3 4 5 6 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 10 X7: 1 2 3 4 5 6 7 8 X5: 1...10 C1 D1 X1: 5 3

_ _
+ +

switch at D7
module S1
K10
2
K1 K11
K8 K21
U W
T M M
3~
+
T
_ DCS8_ans_1_3.dsf
Converters D5...D7 drive configuration using ’external’ field exciter
Wiring the drive according to this diagram gives the most flexibility and offers the
from an independent net. DCF803-0035 can be supplied wit 3-phase aux. supply.
highest degree of standard monitoring functions done by the drive. Field converters
DCF803 / DCF804 are equipped with their own synchronization and can be supplied
41
START, STOP and E-STOP control

The relay logic can be split into three parts:
a: Generation of the ON/OFF and START/STOP command:
The commands represented by K20 and K21 (latching interface relay) can be e.g. generated by a
PLC and transferred to the terminals of the converter either by relays, using galvanic isolation or
directly via 24V signals. There is no need to use hardwired signals. These commands can be as well
transferred via serial communucation. Even a mixed solution can be realized by selecting different
possibilities for the one or the other signal (see parameter group 11).
PC tool or panel
ON
MCW (7.01) RUN
ON RESET
USED MCW
RUN
RESET 7.04
HW I/O used
Main Control Word
ON
RUN
RESET local /
remote
command
location (10.01) gen_ctrl_cmd.dsf
b: Generation of control and monitoring signals:

The main contactor K1 for the armature circuit is controlled by a dry contact (DO 8) located on the
SDCS-PIN-4, Status of fans and fans klixon can be monitored by means of fans ack signals:
MotFanAck (10.06) and ConvFanAck (10.20).
c: OFF2, OFF3 Stop function:
Beside ON/OFF and START/STOP the drive is equipped with two additional stop functions OFF2 and
OFF3 according Profibus standard. OFF3 is a scalable stop function (rampstop, max torque stop,
dynamic braking …) to perform stop category 1. This function should be connected to the E-STOP
button without any time delay. In case of ramp stop selection the K 15 timer relay must be set longer
than EStopRamp (22.04). For COAST selection the drive opens the main contactor immediately.
OFF2 switches off DC current as fast as possible and prepares the drive for losing main contactor or
mains supply. For a normal DC motor load the time to switch OFF the DC current is below 20 ms. This
function should be connected to all signals and safety functions opening the main contactor. This
function is important for 4-quadrant drives. Do not open main contactor during regenerative current.
The correct sequence is
1. switch off regenerative current
2. then open the main contactor
In case of E-STOP is hit, the information is transferred to the converter via digital input 5. In case of
(rampstop, or max torque selection) the converter will decelerate the motor and then open main
contactor.
If the drive has not finished the function within the K15 timer setting, the drive must get the command
to switch OFF the current via K16. After K16 timer set has elapsed the main contactor is opened
independent of the drives status.

42
E-STOP
K16
ELEC.
DISCONN.
speed
1
EMER. Timer K15
STOP S1 K15
2
Timer K16
K15 K16
Block current control
CON-2 K1 main contactor

DIx X6:9
K15
E-Stop ramp Coast
Stop-Mode.dsf
E-Stop reaction

Aux. supply 400V 50Hz
L1 MP L1 L2 L3
F1
1 1 1
F7 F5 F8
2 2 2
X96:1
OFF STOP
X96:2
ON START
K1 K21
1 3 5
K1
K20 2 4 6
F6 1 3 5 13
K20 K21 K1
L1
14
I> I> I>

X96: 1 2 X99: 1 2 X2: 4 5 X2: 1 2 3 U1 V1 W1 PE 2 4 6
Control board (CON-4)

M
DO8 ~
(PIN-4) another configuration is possible
S1
4 5 DCS800 * Field exciter unit

AITAC AI1 AI2 AI3 AI4 Converter (PIN-4) On board
_ + _ + _ + _ + _ + +10V -10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +24V DO1 DO2 DO3 DO4 DO5 DO6 DO7
module or
0V 0V 0V 0V 0V FEX-425-Int (D5)
X3: 1 2 3 4 5 6 7 8 9 10 X4: 1 2 3 4 5 6 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 10 X7: 1 2 3 4 5 6 7 8 X5: 1...10 C1 D1 X1: 5 3

_ _
+ +
K20
Drive configuration with reduced components
K1 K21
if there are intermediate terminals the polarities are shown for motor operation
V
U W
T M M
+
3~
Converters D5 (400...500V) using FEX-425-Int field exciter
T DCS8_ans_2.dsf
_
Converters D1...D4 (400...500V) using ’on board’ field exciters
flexibility. Dynamic Braking keeps the main contactor K1 in state ON during braking.
Selection of components: The wiring diagram is valid for a DCS800 converter construction type D1...D4 ≤ 525 V and D5
≤ 500 V. The ’on board’ field exciter (D1...D4) can be used at line voltages up to 525 V and will give field currents up to 6 /
15 / 20 / 25 A. For higher field currents, use the next larger field supply units DCF803/804 or a 3-phase field supply DCS800.
* D1-D4: On board field exciter (PIN-4)

D5: FEX-425-Int field exciter, supplied internal
Wiring the drive according to this diagram gives the same control performance, but a lower degree of

43
44
Power section cooling

Fan assignment for DCS800
Converter type Model Configuration Fan type
DCS800-S0x-0045-y1 ... D1 1 2x CN2B2
DCS800-S0x-00140-y1
DCS800-S0x-0180-y1 ... D2 1 2x CN2B2
DCS800-S0x-0260-y1
DCS800-S0x-0315-y1 ... D3 1 2x CN2B2
DCS800-S0x-0350-y1
DCS800-S0x-0405-y1 ... D3 2 4x CN2B2
DCS800-S0x-0550-y1
DCS800-S0x-0610-y1 ... D4 3 1x W2E200 (230 V)
DCS800-S0x-0820-y1
DCS800-S0x-0610-y1 ... D4 3 1x W2E200 (115 V)
DCS800-S0x-0820-y1 Pluscode E171
DCS800-S0x-0900-y1 ... D4 3 1x W2E250 (230 V)
DCS800-S0x-1000-y1
DCS800-S0x-0900-y1 ... D4 3 1x W2E250 (115 V)
DCS800-S0x-1000-y1 Pluscode E171
DCS800-S0x-0900-y1 ... D5 4 D2E 160
DCS800-S0x-2000-y1
DCS800-S0x-1900-y4/5/8 ... D6 5 GR31M
DCS800-S0x-3000-y4/5/8 400...500 V
DCS800-S0x-1900-y6/7 ... D6 5 GR31M
DCS800-S0x-3000-y6/7 500...690 V
DCS800-S0x-3300-y1... D7 5 GR35C
DCS800-S0x-5200-y1 400 V / 690 V
Fan Data for DCS800

Fan CN2B2 W2E200 W2E 200 W2E 250 W2E 250
Rated voltage [V] 115; 1~ 230; 1~ 115; 1~ 115; 1~ 230; 1~
Tolerance [%] ±10 +6/-10 +6/-10 ±10 +6/-10
Frequency [Hz] 50 60 50 60 50 60 50 60 50 60
Power consumption [W] 16 13 64 80 64 80 120 165 135 185
Current consumpt. [A] 0.2 0.17 0.29 0.35 0.6 0.7 1.06 1.44 0.59 0.82
Blocking current [A] < 0.3 < 0.26 < 0.7 < 0,8 < 1.5 < 1.8 < 1.8 < 1.8 < 0.9 < 0.9
Air flow [m3/h] freely blowing 156 180 925 1030 925 1030 1835 1940 1860 1975
Air flow [m3/h] - - - - -
at working point
Max. ambient temperature [° C] < 60 < 75 < 75 60 60
Useful lifetime of grease appr. appr. appr. 45000h/60° appr. appr.
40000 h/60° 45000 h/60° 40000 h 40000 h
Protection Impedance Temperatur detector: internal connected
➀
➀ Increased losses due to increased current with a blocked rotor will not result in a winding temper-
ature, higher than permissible for the insulation class being involved.

45
Fan D2E 160 GR31M GR31M GR35C

380... 500 V 525... 690 V 400 / 690 V
Rated voltage [V] 230; 1~ 400...450 ∆ 400...500 ∆ 500...690 500...690 400...500 ∆
450...500 500 ∆ 600...690
Tolerance [%] ±10 ±10 ±10 +5/-10 ±10
Frequency [Hz] 50 60 50 60 50 60 50 60
Power consumption [W] 653 860 800 ∆ 1340 ∆ 800 1200 2900 ∆ 3600 ∆
700 2200 3300
Current consumpt. [A] 2.50 3.4 1.45 ∆ 2.0 ∆ 0.9 1.2 6.5 ∆ 4.9 ∆
0.91 2.3 3.0
Blocking current [A] 3.75 4.5 at 450 V ∆ at 500 V ∆ at 690 V at 500 V ∆ at 400 V ∆ at 400 V ∆
8.5 8.5 4.4 8.5 >25 >30
Air flow [m3/h] freely blowing - - -
Air flow [m3/h] 800 750 1500 1600 1500 1600 4200 4250
at working point 2.5 A 3.2 A 1.26 A 1.6 A 0.7 A 1.65 A 3.6 A 4.1 A
(450V ∆) (500V ∆) (690V ) (500V ∆) (400V ∆) (400V ∆)
Max. ambient temperature [° C] < 55
Useful lifetime of grease appr. 30000 h/40°
Protection Temperatur detector: UN ≤ 230 V~; IN ≤ 2.5 A~
Fan connection for DCS800

|-------------------------------------- Terminals on top of converter housing --------------------------------------|
Converter housing
N
N
L
230 Vac
L
230 Vac
X99: 1 2 3 4 5 X99: 1 2 3 4 5
115 Vac either 230 Vac

N
115 Vac
N
L
or 115 Vac
X99: 1 2 3 4 5 X99: 1 2 3 4 5 L N TW TW
N
L
X99: 1 2 3 4 5 X99: 1 2 3 4 5 X99: 1 2 3 4 5

X2: 1 2 3 4 5 6
U1 V1 W1 U2 V2 W2 PE TK TK
L N
black
white
white
green/yellow
brown
blue
M
gray
gray
~
M M M M M
~ ~ ~ ~ M
~ ~
M55
M55 M56 M55 M56
at Connection
U1-W2
V1-U2
Fan_con_c.dsf
W1-V2
U2-V2-W2
M M
~ ~
M57 M58
Configuration 1 Configuration 2 Configuration 3 Configuration 4 Configuration 5
Monitoring the DCS800 power section

a.The size D1...D5 power section is likewise monitored by an electrically isolated
PTC thermistor detector, which is installed on the heat sink in an isolated
configuration. Evaluation of the resistance and the protection effect correspond to
max. temperature of type code.
b.The size D6 and D7 power section isolated PTC thermistor is used for air entry
temperature. The detector thus measures the power section’s radiated heat and any
changes in the cooling air temperature and volume. Since the cooling air volume can

46
only be detected indirectly, a differential-pressure switch has been additionally

installed at the unit’s housing, always located close to the power terminals.
The resistance change proportional to the temperature is acquired and evaluated in
the unit’s software. If the temperature rises above the preset value, then first an
alarm will be signaled, and - if the temperature continues to rise - an error message.
The value to be set for this parameter must not be more than 5 degrees above the
permissible ambient temperature.
The differential-pressure switch compares the pressure inside the unit with the
normal atmospheric pressure. If the fan has been switched on and the unit door
closed (and no unit casings have been removed), the pressure switch will signal
“Cooling conditions ok”, which means the drive may be enabled. There is no need to
set any specific differential pressure (recommendation: center setting).
Thermal overload and short-circuit protection

The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive.
Mains cable (AC line cable) short-circuit protection

Always protect the input cable with fuses. Size the fuses according to local safety
regulations, appropriate input voltage and the rated current of the drive (see chapter
Technical Data).
High-speed semiconductor fuses provide short-circuit protection, but don’t provide
thermal overload protection.

47
Cross-sectional areas - Tightening torques

Recommended cross-sectional area to DINVDE 0276-1000 and DINVDE 0100-540
(PE) trefoil arrangement, up to 50°C ambient temperature.
Converter type C1, D1 (AM1, KM1) U1, V1, W1(AK1, AK3, AK5) PE
1 (2.) 1 (2.)
IDC Iv
[A-] [mm²] [mm²] [A~] [mm²] [mm²] [mm²] [Nm]
DCS800-S0x-0050-xx 50 1 x 10 - 41 1x 6 - 1x 6 1 x M6 6
DCS800-S0x-0075-xx 75 1 x 25 - 61 1 x 25 - 1x 16 1 x M6 6
DCS800-S0x-0100-xx 100 1 x 25 - 82 1 x 25 - 1x 16 1 x M6 6
DCS800-S0x-0140-xx 140 1 x 35 - 114 1 x 35 - 1x 16 1 x M6 6
DCS800-S0x-0200-xx 200 2 x 35 1 x 95 163 2 x 25 1 x 95 1x 25 1 x M8 13
DCS800-S0x-0260-xx 260 2 x 35 1 x 95 204 2 x 25 1 x 95 1x 25 1 x M8 13
DCS800-S0x-0???-xx 270 2 x 35 1 x 95 220 2 x 25 1 x 95 1x 25 1 x M8 13
DCS800-S0x-0350-xx 350 2 x 70 - 286 2 x 50 1x 50 1 x M8 13
DCS800-S0x-0450-xx 450 2x 95 - 367 2 x 95 - 1x 50 1 x M10 25
DCS800-S0x-0550-xx 550 2x 95 - 424 2 x 95 - 1x 50 1 x M10 25
DCS800-S0x-0680-xx 680 2 x 120 - 555 2 x 120 - 1x120 1 x M12 50
DCS800-S0x-0820-xx 820 2 x 150 - 669 2 x 120 - 1x120 1 x M12 50
DCS800-S0x-0900-6/7 900 4x 95 3 x 150 734 4 x 70 3 x 95 1x150 2 x M12 50
DCS800-S0x-1000-xx 1000 2 x 185 - 816 2 x 150 - 1x150 1 x M12 50
DCS800-S0x-1200-xx 1200 4 x 120 - 979 4 x 95 3 x 120 1x185 2 x M12 50
DCS800-S0x-1500-xx 1500 4 x 185 - 1224 4 x 150 - 2x150 2 x M12 50
DCS800-S0x-2000-xx 2000 8 x 120 6 x 185 1632 4 x 240 - 2x240 2 x M12 50
DCS800-S0x-1900-xx ➁ 1900 8 x 120 6 x 185 1550 4 x 240 3x120 4 x M12 50
DCS800-S0x-2050-xx ➁ 2050 8 x 120 6 x 185 1673 6 x 120 5 x 150 3x120 4 x M12 50
DCS800-S0x-2500-xx ➁ 2500 7 x 185 - 2040 8 x 120 6 x 185 4x120 4 x M12 50
DCS800-S0x-2600-xx 2600 7 x 185 - 2122 8 x 120 6 x 185 4x120 4 x M12 50
DCS800-S0x-3000-xx ➁ 3000 8 x 185 - 2448 7 x 185 - 4x150 4 x M12 50
DCS800-S0x-3300-xx 3300 8 x 185 - 2693 7 x 185 - 4x150 4 x M12 50
DCS800-S0x-4000-xx 4000 7 x 300 - 3264 8 x 240 - 4x240 4 x M12 50
DCS800-S0x-4800-xx ➀ 4800 8 x 300 - 3876 6 x 300 - 3x300 4 x M12 50
DCS800-S0x-5200-xx ➀ 5200 8 x 300 - 4202 6 x 300 - 3x300 4 x M12 50
➀Reduced ambient temperature 40°C

➁Option for more flexible cable connection available
You will find instructions on how to calculate the PE conductor’s cross-sectional area
in VDE 0100 or in equivalent national standards. We would remind you that power
converters may have a current-limiting effect.

48
Selecting the control cables

All control cables except 220 V or 115 V must be shielded.
Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables,
Finland or BELDEN type, USA) for analogue signals. This type of cable is
recommended for the pulse encoder signals also. Employ one individually shielded
pair for each signal. Do not use common return for different analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (Figure b) is also usable.
a b
A double-shielded twisted A single-shielded twisted
pair cable multipair cable
Run analogue and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals be run as twisted pairs.
! Never mix 24 VDC and 115/230 VAC signals in the same cable.
DCS800 panel cable

The cable connection of the DCS800 panel to the drive must not exceed 3 meters
(10 ft). The cable type tested and approved by ABB is used in control panel option
kits.

49
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfill this requirement, the connection of a thermistor (and other similar
components) to the inputs of the drive can be implemented by three alternate ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive.

50

51

This chapter describes the electrical installation procedure of the drive.
WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive was already connected to the mains, wait for 5 min.
after disconnecting mains power.
Reference: Technical Guide - publ. no.: 3ADW000163
Checking the insulation of the assembly

Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage
tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the
drive. Check the insulation of the assembly as follows.
WARNING! Check the insulation before connecting the drive to the mains. Make
sure that the drive is disconnected from the mains (input power).
1. Check that the motor cable is disconnected from the drive output terminals C1,
D1, F+ and F-.
2. Measure the insulation resistances of the motor cable and the motor between
each circuit (C1, D1) or (F+, F-) and the Protective Earth by using a measuring
voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm.
C1, D1
M
ohm
F+, F-
PE
ohm
52
IT (ungrounded) systems
Don’t use EMC filters.
The screen winding of dedicated transformers must be grounded.
For installation without low voltage switch (e.g. contacter, air-circuit-breaker) use
overvoltage protection.
The voltage shift of isolated supply must be limited of a range of an earth fault.
Supply voltage
Check supply voltages of:
Aux X99
Fan Terminals
AC voltage for field circuit U1, V1, W1 (if used)
AC voltage for armature circuit U1, V1, W1
Connecting the power cables

Grounding and sreening of power cables see manual Technical Guide, see
Reference
Cross sectional areas and tightening torques of power cable see chapter Planning
the electrical installation
Location R-Extension and Interface Modules
53
Connect the signal cables as described below. Tighten the screws to secure the
connection.
DCS800 SLOT 1
Panel connector R IO Extension module
X33: or
R-Fieldbus module
SLOT 2
R IO Extension module
Interface connector
SLOT 3
X2: SDCS-IOB-3
R IO Extension module
X1: SDCS-IOB-2
or
R DDCS interface
board
54
I/O Board Configuration

In-/output signals
The converter can be connected in four different ways to a control unit via analogue/
digital signals. Only one of the four choices can be used at the same time. .
SDCS-CON-4 SDCS-CON-4
X2: X2:
X1: X1:
X3: X4: X5: X6: X7: X3: X4: X5:
X3: X1:
SDCS-IOB-2
I/O´s via SDCS-CON-4 I/O´s via SDCS-CON-4 and SDCS-IOB-2

Analogue I/O´s: standard Analogue I/O´s: standard
Digital I/O´s: not isolated digital I/O´s: all isolated by means
Encoder input: not isolated of optocoupler/relay,
the signal status is
indicated by LED
IO_poss_b.dsf
X2: X2:
X1: X1:
X6: X7:
X1: X2: X1: X2: X3: X1:
SDCS-IOB-3 SDCS-IOB-3 SDCS-IOB-2
I/O´s via SDCS-CON-4 and SDCS-IOB-3 I/O´s via SDCS-IOB-2 and SDCS-IOB-3
Analogue I/O´s: Standard + one Analogue I/O´s: Standard + one
channel for residual channel for residual
current measurement current measurement
digital I/O´s: not isolated digital I/O´s: all isolated by means of
encoder input: isolated optocoupler/relay, the
current source for: PT100/PTC element signal status is
indicated by LED
current source for: PT100/PTC element
55
Pulse encoder connection

Connecting a pulse encoder to the DCS800 converter
The connection diagram for a pulse encoder to the electronics of a DCS converter is
quite similar, if the SDCS-CON-4 or the SDCS-IOB-3 is used. The basic difference
between these 2 boards is the galvanically isolated circuit and pulse receivers via
opto coupler on the SDCS-IOB-3 board.
Power supply for incremental encoder
SDCS-CON-4 and SDCS-IOB-3 board have jumpers to select a supply voltage. V17
LED on SDCS-IOB-3 indicates supply is OK.
Hardware configuration
Encoder supply SDCS-CON-4 SDCS-CON-4 SDCS-IOB-3

supplied by PIN-4 supplied by POW-1/POW-4
5V sense controlled sense controlled sense controlled
12 V - no sense sense controlled
24 V no sense no sense no sense
Sense feedback connection is recommended when power supply level for

differential pulse encoder is 5 V. The wiring is shown on figure below.
Commissioning hint
DIFFERENTIAL = twisted Note:

pair IOB-3 CON-4
A
X5:1 ChA+ X5:1 If the drive’s direction of rotation is
X5:2 ChA- X5:2
A
X5:3 ChB+ X5:3 correct (if necessary, correct by
B
B
X5:4 ChB- X5:4 exchanging the field connections), the
X5:5 ChZ+ X5:5
Z
X5:6 ChZ- X5:6
Tacho error message may appear
Z
+U
X5:7 Power source X5:10 during start-up.
X5:8 Sense power X5:9
0V
X5:9 Sense GND X5:8 If with a positive reference the
X5:10 GND X5:7
TACHO_PULSES signal does not
look like the illustration below, then
SINGLE-ENDED IOB-3 CON-4
tracks A & must be mutually
X5:1 ChA+ X5:1
A
X5:2 ChA- X5:2
exchanged with encoders with
A
B
X5:3 ChB+ X5:3 inverted signals, and tracks A and B
X5:4 ChB- X5:4
B
X5:5 ChZ+ X5:5
with encoders without inverted
Z
Z
X5:6 ChZ- X5:6 signals.
X5:7 Power source X5:10
+U
0V
X5:8 X5:9
If the TACHO_PULSES signal is
X5:9 X5:8
X5:10 GND X5:7 missing or non-linear, the encoder’s
pulses are not being read correctly.
IOB3x3_f.dsf
Possible reasons for this may be the
encoder supply, the encoder itself, or
the wiring.
65535
Forward
56
Pulse encoder receiver

Two different incremental encoder connections are available.
-differential connection; pulse encoders generating either voltage or current signals
can be used
-single-ended (push pull) connection; voltage signals
Restrictions using jumper S4 (CON-4): or S10 (IOB-3): depending on the board
Line termination via S4/S10 should not be used at 12 V or 24 V encoders, because
of the power consumption taken from the encoder. If a pulse encoder with a build in
current source is used a burden resistor of 120 Ω is activated via jumper S4/S10: 1-2
a.s.o.
Pulse encoder connection principles
single ended
open collector SDCS-IOB-3 + SDCS-CON-4 +
X5:1 e.g. CH A X5:1 e.g. CH A
n.c. n.c. 120
120 3 6 +24V 1 2 3
2 5 10k 10k
S10 + S4 +24 V +
1 4
X5:2 X5:2
single ended
push pull
+U SDCS-IOB-3 +U
+ SDCS-CON-4 +
e.g. CH A e.g. CH A
X5:1 X5:1
120 3 6 +24V 120 1 2 3
2 5 10k 10k
S10 1 4 + S4 +24 V +
-U -U
X5:2 X5:2
R R
GND GND
In case of a single ended 5 V encoder the jumpers S4 / S10 will be set to a neutral position. To get a threshold lower than 5 V each
terminal X5:2 / X5:4 / X5:6 must be connected via a resistor R to GND according to the table below.
R 1 kΩ 1.5 Ω 2.2 kΩ
U thresh 1.2 V 1.8 V 2.3 V
Make sure the threshold is half of the supply voltage and the minimum voltage of the encoder output (saturation voltage UCE of a
transistor).
differential
SDCS-IOB-3 + CON-4 IOB-3
CH+ X5:1 e.g. CH A
5V 12/24 V 5V 12/24 V
120 3 6 +24V
differential S4 S4 S10 S10
2 5 10k
S10 voltage source 1-2 3=park 2-3 4-5
1 4 +
X5:2 4-5 6=park 8-9 10-11
CH- 7-8 9=park 14-15 16-17
differential S10
iob14_e.dsf current source 1-2
- - 7-8 -
13-14
57
The distance between pulse encoder and interface board is dependent on the
voltage drop on the connecting lines and on the output and input configuration of the
used components. If cables are used according to the table below the voltage drop
caused by the cable can be compensated by the voltage regulator.
Cable length parallel wires for Cable used
power source & GND
0 ... 50 m 1x 0.25 mm² 12x 0.25 mm²
50 ... 100 m 2x 0.25 mm² 12x 0.25 mm²
100 ... 150 m 3x 0.25 mm² 14x 0.25 mm²
58
Connecting the signal and control cables

The cables for digital signals, which are longer than 3 m and all cables for analogue
signals, must be screened. Each screen must be connected at both ends by metal
clamps or comparable means directly on clean metal surfaces, if both earthing points
belong to the same earth line. Otherwise a capacitor must be connected to earth on
one end. In the converter cubicle this kind of connection must be made directly on
the sheet metal as close as possible to the terminals and if the cable comes from
outside also on the PE bar. At the other end of the cable the screen must be well
connected with the housing of the signal emitter or receiver.
Connection of a cable
screen with the aid of
metal clamp to the me-
tal surface of the PCB
carrier at a DCS con-
verter
Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the
grounding electrodes. Aluminium tray systems can be used to improve local
equalizing of potential.
A diagram of the cable routing is shown below.
Control cable duct
24 V 230 V 24 V 230 V
Motor cable
Drive min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90 °

min 500 mm (20 in.)
Control cables
Not allowed unless the 24 V Lead 24 V and 230 V

cable is insulated for 230 V or control cables in separate
insulated with an insulation ducts inside the cabinet.
sleeving for 230 V.
59
DSL Link Wiring

DSL Link is a 800 KBaud serial communcation between:
• Drive to drive or
• Drive to Field exciter
based on CAN hardware and twisted pair cabling.
The topology of the bus must be: Bus
Switched OFF nodes can remain in the bus and do not disturb the serial
communucation.
The bus is designed for cable length up to 50 meters. A repeater with additional
hardware based on POF cable is available on request.
The function of the interface is predefined:
1 Mailbox function for peer to peer communication
2 Communication to field exciter DCF 804, DCF803 and three-phase field
supply of DCS800
3 Communication for12-pulse operation, DCS800 to DCS800
Cabling
Every bus node requires the setting of Node number.
The bus termination of twisted pair cable is performed with a pre-designed
termination resistor 120 Ohm inside Drive / field exciter.
The termination resistance of 120 Ohm is selected for typical twisted pair cable and
must be located in both ends.
Preferred cable type:
DEVICENET PUR
Supplier: Helu Kabel, Germany type 81910
Node 1 ••• Node n
CAN_H
120 ohm 120 ohm

1%, 1/4 W 1%, 1/4 W
CAN_L
CAN_Bus_termination.dsf
The bus must be isolated but can be ground terminated at one end only.
Example of two DCS800 D5 converters with FEX-425-Int internal field supply.
DCS800 D5 Converter DCS800 D5 Converter
FEX-425-Int SDCS-DSL SDCS-DSL FEX-425-Int
X3 X51 X52 X51 X52 X3
Set bus Termination OFF Termination OFF Set bus

termination ON termination ON
60
61
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. (See Mechanical installation, current ratings
Ambient conditions.)
The unit is fixed properly on a vertical non-flammable wall. (See Mechanical installation.)
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the electrical
installation)
All screen terminals are checked for tightness.
All cable connections are seated properly.
ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)
The drive is grounded properly.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.
Appropriate mains (input power) fuses and disconnector are installed.
The motor connections at C1, D1 and F+, F- and their tightening torques are OK.
Proper function of E_Stop circuit and relay..
Fan power wiring connected.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Drive, motor connection box and other covers are in place.
62
63
Maintenance

This chapter contains preventive maintenance instructions.
Reference: Service manual - publ. no.: 3ADW000195
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance Interval Instruction
Heatsink temperature check Depends on the dustiness of See Heatsink.

and cleaning the environment (every 6 to 12
months)
Cooling fan change Every six years See Fan.
Maintenance
64
Heatsink
The heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. In a “normal”
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section Fan).
2. Blow clean compressed air (not humid, no oil) from bottom to top and
simultaneously use a vacuum cleaner at the air outlet to trap the dust. Note: If
there is a risk of the dust entering adjoining equipment, perform the cleaning in
another room.
3. Replace the cooling fan.
Fan
The cooling fan lifespan of the drive is about 50 000 operating hours. The actual
lifespan depends on the drive usage and ambient temperature.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB specified spare parts.
Fan replacement (D6, D7)
Maintenance
65
Technical data

This chapter contains the technical specifications of the drive, e.g. the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and other
markings and warranty policy.
Reference: Hardware extension RAIO Analog I/O Extension publ.no.:3AFE64484567
Hardware extension RDIO Digital I/O Extension publ.no.:3AFE64485733
DCS800 1131 Programming target publ.no.:3ADW000199
Branching units NDBU-95 publ.no.:3ADW000100
Environmental Conditions
System connection Environmental limit values
Voltage, 3-phase: 230 to 1000 V acc. to IEC 60038 Permissible cooling air temperat.
Voltage deviation: ±10% continuous; ±15% short-time * - at converter module air inlet: 0 to +55°C
Rated frequency: 50 Hz or 60 Hz with rated DC current: 0 to +40°C
Static frequency deviation: 50 Hz ±2 %; 60 Hz ±2 % w. different DC curr. acc. Fig. +30 to +55°C
below:
Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz - Options: 0 to +40°C
df/dt: 17 % / s Relative humidity (at 5...+40°C): 5 to 95%, no condensation
* = 0.5 to 30 cycles. Relative humidity (at 0...+5°C): 5 to 50%, no condensation
Please note: Special consideration must be taken for voltage devi- Change of the ambient temp.: < 0.5°C / minute
ation in regenerative mode.
Degree of protection Storage temperature: -40 to +55°C
Converter Module and Transport temperature: -40 to +70°C
options (line chokes, fuse Pollution degree (IEC 60664-1,
holder, IEC 60439-1): 2
field supply unit, etc.): IP 00 Vibration class D1...D4 3M3
Enclosed converters: IP 20/21/31/41 D5...D7 3M1
Paint finish Site elevation
Converter module: NCS 170 4 Y015R <1000 m above M.S.L.: 100%, without current reduction
Enclosed converter: light grey RAL 7035 >1000 m above M.S.L.: with curr. reduct., see Fig. below
Size Sound pressure level LP (1 m distance) Vibration

as module enclosed conv. as module
D1 55 dBA ?? dBA
D2 55 dBA ?? dBA
D3 60 dBA ?? dBA 0.5 g, 5...55 Hz
D4 66...70 dBA, 77 dBA
depending on fan
D5 73 dBA 78 dBA
1 mm, 2...9 Hz
D6 75 dBA 73 dBA
0.3 g, 9...200 Hz
D7 82 dBA 80 dBA
Effect of the site elevation above sea level on the converter’s load capacity Effect of the ambient temperature on the converter module load capacity
100 110
90
100
80
90
70
60 80
50 70
1000 2000 3000 4000 5000 m 30 35 40 45 50 55°C
Current reduction to (%) Current reduction to (%) for converter modules
Technical data
66
Regulatory Compliance
The converter module and enclosed converter components are designed for use in industrial environments. In EEA countries,
the components fulfil the requirements of the EU directives, see table below.
European Union Directive Manufacturer's Assurance Harmonized Standards
Converter module Enclosed converter
Machinery Directive
98/37/EEC Declaration of Incorporation EN 60204-1 EN 60204-1
93/68/EEC [IEC 60204-1] [IEC 60204-1]
Low Voltage Directive
73/23/EEC Declaration of Conformity EN 60146-1-1 EN 60204-1
93/68/EEC [IEC 60146-1-1] [IEC 60204-1]
EN 50178 [IEC --] EN 60439-1
see additional [IEC 60439-1]
IEC 60664
EMC Directive
89/336/EEC Declaration of Conformity EN 61800-3 ➀ EN 61800-3 ➀
93/68/EEC [IEC 61800-3] [IEC 61800-3]
(Provided that all installation
instructions concerning cable ➀ in accordance with ➀ in accordance with
selection, cabling and EMC filters 3ADW 000 032 3ADW 000 032/3ADW 000
or dedicated transformer are fol- 091
lowed.)
North American Standards

In North America the system components fulfil the requirements of the table
below.
Rated supply voltage Standards
Converter module Enclosed converter
to 600 V UL 508 C UL/CSA types: on request
Power Conversion Equip-
ment
CSA C 22.2 No. 14-95
Industrial Control Equip-
ment,Industrial Products
Available for converter
modules including field
exciter units.Types with UL
mark:
• see UL Listing-
www.ul.com / certificate no.
E196914
• or on request
>600 V to 1000 V EN / IEC xxxxx see table EN / IEC types: on
above. request(for details see
Available for converter table above
modulesincluding field
exciter units.
Technical data
67
Current ratings
The current ratings for the DCS800 with 50 Hz and 60 Hz supplies are given below. The symbols are
described below the table.
Power converter module currents with corresponding load cycles.
The characteristics are based on an ambient temperature of max. 40°C and an elevation of max.
1000 m a.s.l.
internal
Unit type IDC I IDC II IDC III IDC IV Size
field curr.
continu- 100 % 150 % 100 % 150 % 100 % 200 %
2-Q converters ous 15 min 60 s 15 min 120 s 15 min 10 s
400 V / 500 V [A] [A] [A] [A]
DCS800-S01-0020-04/05 20 18 27 18 27 18 36
DCS800-S01-0045-04/05 45 40 60 37 56 38 76
DCS800-S01-0065-04/05 65 54 81 52 78 55 110 D1 6A
DCS800-S01-0090-04/05 90 78 117 72 108 66 132
DCS800-S01-0125-04/05 125 104 156 100 150 94 188
DCS800-S01-0180-04/05 180 148 222 144 216 124 248
D2 15 A
DCS800-S01-0230-04/05 230 200 300 188 282 178 356
DCS800-S01-0315-04/05 315 264 396 250 375 230 460
DCS800-S01-0405-04/05 405 320 480 310 465 308 616 D3 20 A
DCS800-S01-0500-04/05 500 436 654 418 627 380 760
DCS800-S01-0610-04/05 610 490 735 482 723 454 908
DCS800-S01-0740-04/05 740 596 894 578 867 538 1076 D4 25 A
DCS800-S01-0900-04/05 900 700 1050 670 1005 620 1240
DCS800-S01-1200-04/05 1200 888 1332 872 1308 764 1528
DCS800-S01-1500-04/05 1500 1200 1800 1156 1734 1104 2208 D5 25 A *
DCS800-S01-2000-04/05 2000 1479 2219 1421 2132 1361 2722
DCS800-S01-2050-05 2050 1550 2325 1480 2220 1450 2900
DCS800-S01-2500-04/05 2500 1980 2970 1880 2820 1920 3840 D6 -
DCS800-S01-3000-04/05 3000 2350 3525 2220 3330 2280 4560
DCS800-S01-3300-04/05 3300 2416 3624 2300 3450 2277 4554
DCS800-S01-4000-04/05 4000 2977 4466 2855 4283 2795 5590 D7 -
DCS800-S01-5200-04/05 5200 3800 5700 3669 5504 3733 7466
600 V / 690 V
DCS800-S01-0290-06 290 240 360 225 337 205 410 D3 -
DCS800-S01-0590-06 590 470 705 472 708 434 868 D4 -
DCS800-S01-0900-06/07 900 684 1026 670 1005 594 1188
DCS800-S01-1500-06/07 1500 1200 1800 1104 1656 1104 2208 D5 25 A *
DCS800-S01-2000-06/07 2000 1479 2219 1421 2132 1361 2722
DCS800-S01-2050-06/07 2050 1520 2280 1450 2175 1430 2860
DCS800-S01-2500-06/07 2500 1940 2910 1840 2760 1880 3760 D6 -
DCS800-S01-3000-06/07 3000 2530 3795 2410 3615 2430 4860
DCS800-S01-3300-06/07 3300 2416 3624 2300 3450 2277 4554
DCS800-S01-4000-06/07 4000 3036 4554 2900 4350 2950 5900 D7 -
DCS800-S01-4800-06/07 4800 3734 5601 3608 5412 3700 7400
790 V
DCS800-S01-1900-08 1900 1500 2250 1430 2145 1400 2800
DCS800-S01-2500-08 2500 1920 2880 1820 2730 1860 3720 D6 -
DCS800-S01-3000-08 3000 2500 3750 2400 3600 2400 4800
DCS800-S01-3300-08 3300 2655 3983 2540 3810 2485 4970
DCS800-S01-4000-08 4000 3036 4554 2889 4334 2933 5866 D7 -
DCS800-S01-4800-08 4800 3734 5601 3608 5412 3673 7346
990 V
DCS800-S01-2050-10 2050 1577 2366 1500 2250 1471 2942
DCS800-S01-2600-10 2600 2000 3000 1900 2850 1922 3844
D7 -
DCS800-S01-3300-10 3300 2551 3827 2428 3642 2458 4916
DCS800-S01-4000-10 4000 2975 4463 2878 4317 2918 5836
1190 V Data on request
* as option
Technical data
68
internal
Unit type IDC I IDC II IDC III IDC IV Size
field curr.
continu- 100 % 150 % 100 % 150 % 100 % 200 %
4-Q converters ous 15 min 60 s 15 min 120 s 15 min 10 s
400 V / 500 V [A] [A] [A] [A]
DCS800-S02-0025-04/05 25 23 35 22 33 21 42
DCS800-S02-0050-04/05 50 45 68 43 65 38 76
DCS800-S02-0075-04/05 75 66 99 64 96 57 114 D1 6A
DCS800-S02-0100-04/05 100 78 117 75 113 67 134
DCS800-S02-0140-04/05 140 110 165 105 158 99 198
DCS800-S02-0200-04/05 200 152 228 148 222 126 252
D2 15 A
DCS800-S02-0260-04/05 260 214 321 206 309 184 368
DCS800-S02-0350-04/05 350 286 429 276 414 265 530
DCS800-S02-0450-04/05 450 360 540 346 519 315 630 D3 20 A
DCS800-S02-0550-04/05 550 436 654 418 627 380 760
DCS800-S02-0680-04/05 680 544 816 538 807 492 984
DCS800-S02-0820-04/05 820 664 996 648 972 598 1196 D4 25 A
DCS800-S02-1000-04/05 1000 766 1149 736 1104 675 1350
DCS800-S02-1200-04/05 1200 888 1332 872 1308 764 1528
DCS800-S02-1500-04/05 1500 1200 1800 1156 1734 1104 2208 D5 25 A *
DCS800-S02-2000-04/05 2000 1479 2219 1421 2132 1361 2722
DCS800-S02-2050-05 2050 1550 2325 1480 2220 1450 2900
DCS800-S02-2500-04/05 2500 2000 3000 1930 2895 1790 3580 D6 -
DCS800-S02-3000-04/05 3000 2330 3495 2250 3375 2080 4160
DCS800-S02-3300-04/05 3300 2416 3624 2300 3450 2277 4554
DCS800-S02-4000-04/05 4000 2977 4466 2855 4283 2795 5590 D7 -
DCS800-S02-5200-04/05 5200 3800 5700 3669 5504 3733 7466
600 V / 690 V
DCS800-S02-0320-06 320 256 384 246 369 235 470 D3 -
DCS800-S02-0650-06 650 514 771 508 762 462 924 D4 -
DCS800-S02-0900-06/07 900 684 1026 670 1005 594 1188
DCS800-S02-1500-06/07 1500 1200 1800 1104 1656 1104 2208 D5 25 A *
DCS800-S02-2050-06/07 2050 1520 2280 1450 2175 1430 2860
DCS800-S02-2500-06/07 2500 1940 2910 1870 2805 1740 3480
DCS800-S02-3000-06/07 3000 2270 3405 2190 3285 2030 4060 D6 -
DCS800-S02-3300-06/07 3300 2416 3624 2300 3450 2277 4554
DCS800-S02-4000-06/07 4000 3036 4554 2900 4350 2950 5900
DCS800-S02-4800-06/07 4800 3734 5601 3608 5412 3700 7400 D7 -
790 V
DCS800-S02-1900-08 1900 1500 2250 1430 2145 1400 2800
DCS800-S02-2500-08 2500 1910 2865 1850 2775 1710 3420
DCS800-S02-3000-08 3000 2250 3375 2160 3240 2000 4000 D6 -
DCS800-S02-3300-08 3300 2655 3983 2540 3810 2485 4970
DCS800-S02-4000-08 4000 3036 4554 2889 4334 2933 5866
DCS800-S02-4800-08 4800 3734 5601 3608 5412 3673 7346 D7 -
990 V
DCS800-S02-2050-10 2050 1577 2366 1500 2250 1471 2942
DCS800-S02-2600-10 2600 2000 3000 1900 2850 1922 3844
DCS800-S02-3300-10 3300 2551 3827 2428 3642 2458 4916
D7 -
DCS800-S02-4000-10 4000 2975 4463 2878 4317 2918 5836
1190 V Data on request
* as option
Sizing
Note 1: The ratings apply at ambient temperature of 40 °C (104 °F). In lower temperatures the D5, D6,
D7 ratings are higher (except Imax).
Note 2: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is
below 40 °C (104 °F) or the drive is loaded cyclically.
Derating
Technical data
69
Control Board SDCS-CON-4

Layout of the control board SDCS-CON-4
247
Jumper coding
9
2 X300 1
S1 23 Jumper parking position 1 2

8
7
* No filter; Normal DC Tacho X33 X9
1
3 9 Filter for AC Tacho with rectifier
2 8
1 7
9 Tacho input X3:4 connected with 0 V / GND
X37
3
H2500
D2001
2 8
1 7
* D2001
3 9 Jumper parking position; D1000

2 8
no grounding of Tacho input
2
1
1 30
1 7
3 9 Tacho input 1 at X3:4 and X3:1/2/3 at
D2100
2 8
* SDCS-CON-4
X13
1 7
1
3 9 Tacho input 2 at X2:23 and X2:24 at
2 8
SDCS-IOB-3 / PS5311
1 7
2
1
1 1
S2 21 4 AI1 - X3:5-6: RIN = 200 kOhm 2 2

* X11 X10
X12
3 Range -10V...0V...+10V
230
2 4 AI1 - X3:5-6: RIN = 250 Ohm

1 3
2
1
Range IIN = -20mA...+20mA
S3 21 8 AI2 - X3:7-8: RIN = 200 kOhm

7 * Range -10V...0V...+10V
X20
2 8 AI2 - X3:7-8: RIN = 250 Ohm
1 7 Range I IN = -20mA...+20mA 1
X17 2
26
2 8 Jumper parking position 5-6 25
X2 1
Jumpers shown in default position
1
1 7 * 26 2
2 8 Pull-up resistor 4.74 kOhm activated at X3:7

1 7 for PTC temperature sensor
25
26 X1 1
2
X34 1
X8
S38 12 5 1
S5
3 9 S24 2
3
2 4
S121 8 2 2 11 S4 6 9 1 3
2
12 Encoder mode: differential; RC load with 7 1 3 1 7 1 10

S4 23 11 1 1 1 1 1
1
*
10 R = 121 Ohm and C = 100 nF activated X3 X4 X5 X6 X7
3 12 Encoder mode: single ended; Pull-up resistors
2 11
4.75 kOhm activated 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8
1 10
3 12 Encoder supply 5 V, sense X5:8-9 are active
2 11
1 10
*
3 12 Encoder supply 24 V, uncontrolled
2 11
1 10
S5 21 4 Step 1: Preparation for download operation

3
2 4 Step 2: download + normal program execution
1 3 *
* default value Con4_layout.dsf
Memory circuit
SDCS-CON-4 board is equipped with FlashPROM which contains the firmware plus the stored
parameters. Parameters handled by DCS800 panel or DWL, PCtool or by Serial communication
parameter service are stored immediately in the FlashPROM.
Parameters handled by cyclic serial communication (dataset table Group 90 - 92) are not stored in the
Flash PROM. They must be stored by means of ParApplSave (16.6) service.
The faultlogger entries are stored in the FlashPROM during power down (auxiliary power supply OFF).
Watchdog function
The control board has an internal watchdog. The watchdog controls the running of the control board
program. If the watchdog trips, it has the following effects:
• Writing to FPROM is disabled.
• Thyristor firing control is reset and disabled.
• Digital outputs are forced low.
• Programmable analogue outputs are reset to zero, 0V.
Technical data
70
Seven segment display

A seven segment display is located on the control board SDCS-CON-4 and it shows the state of drive.
0.7s 0.7s 0.7s
E01 internal FlashPROM error (check sum)
E02 external FlashPROM error (check sum)
E03 RAM error
E04 RAM error
E05 no Firmware
E06 watchdog error
Program is not running
Normal situation
Download firmware; S5=1-2
Request + download Firmware step 2; S5=3-4
Alarm
Fault
7seg_DCS8.dsf
Terminal description
X37: Connector is used for supply of SDCS-CON-4 from SDCS-POW-1, SDCS-POW-4, SDCS-PIN-4
supply voltage can be measured to ground.
X37:3= 48V
X37:5=24V
X37:7=15V
X37:11=-15V
X37:13=5V encoder
X37:23=5V CPU
Supply voltage monitoring
5V CPU is monitored by 4.75 V and forces CPU to reset. In parallel the CPU monitors Powerfail signal
from power supply (SDCS-PIN-4 or SDCS-POW-1).
X12: and X13: connector are used for measurement voltage, current and temperature and firing
thyristors of SDCS-PIN-51/PIN-41, SDCS-PIN-4.
see chapter Technical data
X17: and X300: are routine test connectors.
X1: and X2: are used to connect SDCS-IOB-2 and SDCS-IOB-3 board.
see chapter Technical data
X33: is used to connect DCS800 Panel. It can be connected direct via 40 mm jack or via CAT 1:1 cable
(RJ45).
X34: is used for download firmware and for DWL and IEC1131 programming connection.
Technical data
71
The RS232 interface is normally used for setting parameter in the drive via the PC Tool.
The default settings of this interface are as follows:
Signal level: RS232 (+12V / -12V)
Data format: UART
Message format: Modbus-Protocol
Transmission method: half-duplex
Baudrate: DriveWindow Light: variable

CodeSys download: 38.4 kBaud
FDT firmware download: self-adapting
Number of Data bits: 8
Number of Stop bits: 1
Parity-Bit: odd
X34: Description
1 not connected
2 TxD
3 RxD 5 1
X34:
4 not connected 9 6
5 SGND Signal ground
6...9 not connected
X8: is need for SDCS-DSL-4 board which provides the serial communication interface to field exciters,
12-pulse converters, master-follower and mailbox to other converters.
X9:, X10: and X11: are used for extension IO modules and serial communication interface adapter.
For detailed description see manual Hardware extension RAIO Analog I/O Extension
Hardware extension RDIO Digital I/O Extension
DCS800 1131 Programming target
see chapter SDCS-COM-8 board
X20 (Slot 4) is used for Memory Card, see description IEC1131 Programming.
Prepared function of:
Slot 1 Slot 2 Slot 3 Slot 4
X9: X10: X11: X20:
RDIO / RAIO x x x
R... Fieldbus adapter x
SDCS-COM-8 x
Second fieldbus RMBA x x
Memory Card x
Technical data
72
Digital and analogue I/O connection of the SDCS-CON-4
Resolution Input/output Scaling Com- Remarks

[bit] values by mon
SDCS-CON-4 Firmware Hardware mode
X2:
SDCS-IOB-3
±90...±270 V range
(PS5311)
X3:1 - ATACH2
39k2 9
2
±30...±90 V ±90...270 V ¿
12k8
+ 8 ATACH
3
±8...±30 V - 7 15 + sign ±30...90 V Firmware ±15 V
1 S1
S1 3 5k 1k66
+ ATACH1 ±8...30 V
4 S1 6 4
GND
5 S2
-
3 4 250 AI1 15 + sign -10...0...+10 V Firmware ±15 V
6 S3 6 5 4k75 +
(3.3 ms)
8 7 +10V
7 -
S3
3 4 250 AI2 15 + sign -10...0...+10 V Firmware ±15 V
8 +
(3.3 ms)
9 -
AI3 15 + sign -10...0...+10 V Firmware ±15 V
10 + (10 ms)
X4:1 -
AI4 15 + sign -10...0...+10 V Firmware ±15V
2 + (10 ms)
3 GND
Power
4 +10V
+10 V ≤ 5 mA for ext. use
5 -10V
-10 V ≤ 5 mA e.g. refer. pot.
6 GND (AOx)
100 47.5
7 AO1 11 + sign -10...0...+10 V Firmware ≤ 5 mA
100n
8 AO2 11 + sign -10...0...+10 V Firmware ≤ 5 mA
9 -10...0...+10 V Firmware ≤ 5 mA 3 V -> nom.??
10 GND X
+ Hardw. motor curr.
+/- I-act
ChA -
X5:1 S4
121 100nF 1 2 3 ChA Encoder supply Remarks
2 +
10k ChB Inputs not isolated
3 S4
-
4
121 100nF 4 5 6 ChB +
Impedance = 120 Ω, if selected
5
10k ChZ
-
max. frequence ≤300 kHz
S4
121 100nF 7 8 9 ChZ
6 +
10k GND 5V ≤ 250 mA Sense lines for GND and supply to
7
Sense 0 V 24 V ≤ 200 mA correct voltage drops on cable (only if
8
Sense 5 V S4
5 V encoder is in use).
9 10
Power 11 5V
10
2k21 221k 5V
12 24 V
-
X6:1 4k75 47nF Z15 + DI1
= 10 ms
Input value Signal defini- Remarks
2 DI2
tion by
3 = 10 ms DI3
Firmware
4 = 10 ms DI4
5 = 10 ms DI5
0...7.3 V -> “0“ status
6 = 10 ms DI6
7.5...50 V -> “1“ status
7 = 3.3 ms DI7
8 = 3.3 ms DI8
9 +24 V; 125 mA
10
X1:
Output Signal defini- Remarks

X7: 1 Relay driver DO1 value tion by
2 Relay driver DO2
3 Relay driver DO3
4 Relay driver DO4 50 * mA Firmware Current limit for all 7
5 Relay driver DO5 22 V at no outputs = 160 mA
6 Relay driver DO6 load Do not apply any reverse
7 Relay driver DO7 voltages!
8 GND
Con4_I_O.dsf * short circuit protected ➀ gain can be varied in 15 steps between 1
and 4 by software parameter
Technical data
73
Interface Board SDCS-COM-8

This board must be used together with a DCS800 to provide same serial communication DDCS options
as ACS800.
Furthermore the board is equipped with four optical channels (max. data transmission speed is 4 Mb for
each optical channel):
• Channel 0 is used to communicate data from the overriding control (FCI, APC2, AC80, Nxxx-xx
(adapter modules for fieldbus), AC800M) or via adapter modules from other controllers) to the
DCS600-drive.
• Channel 1 is used for DDCS I/O extension. AIMA-01 board see separate documentation.
• Channel 2 (Master-Follower) is used to operate two or more drives dependent on each other.
Channel 3 is prepared to connect the PC tool for commissioning and maintenance (DriveWindow).
• Connector X19 is used for CDP 312 panel as well as interface board NDPI.
148
SDCS-COM-8
D100
D200
V6
D400
86
CH 3
CH 2
CH 1
CH 0
V1
RxD
RxD
RxD
RxD
TxD
TxD
TxD
TxD
ey
e
grey
dark
grey
grey
dark
grey
grey
grey
blue
k gr
u
X19
b l
dar
COM_8_layout.dsf
Type optical components Channel 0 used for

Ch 0 Ch 1 Ch 2 Ch 3
SDCS-COM-81 10 Mb 5 Mb 10 Mb 10 Mb other interfaces
SDCS-COM-82 5 Mb 5 Mb 10 Mb 10 Mb Fieldbus adapter
modules Nxxx-xx
Color of optical components:

5 Mb -> blue driver current maximum 30 mA
10 Mb -> dark grey driver current maximum 50 mA
Remark: Only channels with the same components (e.g. 10 Mb component) may be connected to
each other.
Technical data
74
Technical data
75
Technical data
76
Technical data
77
DDCS Branching unit NDBU-95

DDCS Branching Unit (DBU) is used (for DCS 600/DCS800) to implement the star topology of DDCS
link. This allows a slave unit to fail or become unpowered without disabling the communication. The
NDBU receives messages from the master (PC) and sends them to all the slave units simultaneously.
Each slave unit has an individual address and only the addressed slave unit sends a reply message to
the master. It is also possible to use NDBU thus enabling peer-to-peer communication.
NDBU-95 DDCS Branching Unit has nine output channels where messages from the master are sent.
The reply message sent by one slave unit is delivered to the master and it can be delivered also to other
slaves if necessary. Several NDBU-95s can be used in parallel, in series or in any combination of these.
The maximum distance between the master and NDBU-95 as well as between two NDBU-95s, see
manual Branching units NDBU-95.
Technical specifications Layout of the NDBU-95 branching unit
Optical links:
Master channels 1 DDCS input and 1 DDCS output
Slave channels 9 DDCS inputs and 9 DDCS out- DBU
41
puts
Data rate 1 - 4 MBd, programmable
Driving current 20 mA, 30 mA, 50 mA + channel

94
disabling, programmable
Monitoring a green LED for each channel,
switched on when NDBU is receiv-
NDBU-95
ing messages DDCS
BRANCHING
Transmission device 10 Mb component for each channel V120
TXD
UNIT, 8+1 CH
CH8 RXD
Power supply: V119
Input voltage +24 VDC ± 10% V118

TXD
ADDRESS
8
Input current 300 mA CH7 RXD
Monitoring a green LED switched on when the V117 S1
output voltage is normal V116

TXD
1
1 0
CH6 RXD
Operating temperature: +0 ... +50 °C V115
PCB dimensions: s. diagram beside V114

TXD
MBIT/S
CH5 RXD
Remark: Only channels with the same components (e.g. V113
++ ++
+ + + + X12
1 2 4
10 Mb component) may be connected to each
other. TXD
V112
CH4 RXD
V111
For further information see Appendix D in the DriveWindow TXD

V110 264
User's Manual. CH3 RXD
V109
Note TXD
V108
For addressing and automatic node numbering of the CH2 RXD
drives and branching units see DriveWindow documentaion. V107
TRANSM
SETTING
TXD
+ + + + X2-
V106 + + + + X11
CH1 RXD
DIS
V105 LONG
MEDIUM
SHORT
TXD
V104
CH0 RXD
V103
TXD
V102
MSTR RXD
V101
+5V OK
1 24 V DC
X1
2 0V
Technical data
78
DSL Board
The DSL board provides a drive to drive communication. The communication hardware and protocol is
based on CAN bus.
This communication can be used 12-pulse operation, communication to field exciter either single phase
or three phase field exciter.
The communication hardware is equipped with an isolated supply and isolated transmitter. The
terminator can be set by Jumper S2 and S1selection of termination see chapter DSL wiring
77
SDCS-DSL-4
30
S1
X51 X52 X53 X54
3
1 2
4
2
S2
1 2 1 2 3 1 2 3 1 2 3 1
3
DSL-4_drw.dsf
Jumper coding
S1 Bus termination
3
2 120 Ohm
1
3
2 no termination, park position
1 *
S2 Ground termination
2 4 200 kOhm R-C ground
1 3 termination
2 4 0 Ohm R-C ground
3
1 termination
2 4
1 3 * no termination, park position
* default value
.
SDCS-DSL-4 Software Supply Remarks
X8: CON-4 24 V ≤ 200 mA 24 V grounded supply for FEX425
X51:1 24 V / 200 mA internal and DCF803-0035 field
2 exciter units; short circuit protected
X52:1 S1
250 mA
2 CANL
2 1 3
3
CANH
DSL communication Remarks
S1 GNDB Bus termination
X53:1 3 4 Termination 200 kOhm S1 1-2 120 ohm
1 2
2 2-3 no termination; park position
3 Ground termination
X54:1 S2 1-3 200 kOhm R-C ground termination
2
TxD 2-4 0 Ohm ground termination
RxD 3-4 no termination; park position
3
RS 485 communication Remarks
DSL-4_dia.dsf no isolation
Technical data
79
Digital I/O board SDCS-IOB-2
As described at the beginning of the chapter, there are I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
various options for configuring the inputs/outputs.
The board IOB-2x has 8 digital inputs and 8 digital

outputs.
X2: X1: X2: X1:
There are three different types existing, which differ at X3: X4: X5:
the input voltage level: X1: X2: X3: X1: X3: X1:

SDCS-IOB-21 24...48V DC
SDCS-IOB-22 115 V AC
SDCS-IOB-23 230 V AC
The inputs are filtered and galvanically isolated by

The cable length between X1:/X1: and X2:/X2: is max.
using optocouplers. Inputs can form two galvanically
1.7 m and between X1:/X3: is max. 0.5 m because of
separated groups by using either X7:1 or X7:2.
EMC reasons.
If these boards are in use, they have to be mounted

outside the DCS module. They must be mounted in a
way, that the conductive supports have a good con-
nection to ground of the installation.
Layout and jumper settings of the SDCS-IOB-2x board
233.5
S7
2
X3 X1 SDCS-IOB-2x
4
W16
3
W100 **
DO4 DO8
W10
W12
W14
1
W2
W4
W6
W8
2
DO1 DO2 DO3 DO5
3 4
DO6 DO7 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8
1
S8
K1 K2 K3 K4 K5 K8
97.5
4*
W11
W3
W5
W7
W1
W9
W13
W15
R1 R2 R3 R4 R5 R6 R7 R8
Line potential !
70
1 1 1 1
70
5 X4 X5 X6 X7 5
4 4
Jumper coding supports are conductive
time constant diameter of all supports: 4.3 mm

input 2ms 10ms
2 4 2 4
* this dimension may vary (4/5 mm)
S7 DI 7 1 3 1 3 * depending on revision
2 4 2 4 (** W100 as printed circuit ) ?
S8 DI 8 1 3 1 3 *
iob2x1_c.dsf
* default value
Technical data
80
Note:
When the SDCS-CON-4 control board with the SDCS-IOB-
2 I/O board is installed, terminals X6: and X7: on the
SDCS-CON-4 must not be used.
Output value Signal definition by Remarks
SDCS-IOB-2x Software
DOx
X4:1 DO1 K1...K5, K8 Firmware potential-isolated by relays
K1
2 (NO contact element)
3 DO2 Contact ratings:
K2
4 AC: ≤250 V~/ ≤3 A~
DO3 DC: ≤24 V-/ ≤3 A-
5
K3 or ≤115/230 V-/ ≤0.3 A-)
6
MOV-protected (275 V)
7 DO4
K4
8 K6, K7 Firmware potential-isolated by optocoupler
X5:1 DO5 Switching capacity: ≤50 mA
K5 external voltage: ≤24 V-
2
3 DO6 X4:, X5: are screw-clamp terminal types for leads up to 4 mm² cross-
66V
4 sectional area.
5 Default values are shown within the software diagrams.
DO7
66V The ground potential of the digital outputs may vary within ±100 V to
6
each other.
7 DO8
K8
8 Input value Signal definition by Remarks
Channel Firmware potential-isolated by optocoupler
681 +
X6:1 +
DIx
1...8 (24...48V-) R1...R8 = 4.7 kΩ
R1
100n 681
- DI1 IOB-21 -> "0 signal"
W1 W2
0...8 V -> "1 signal"
2 R2
18...60 V (115V~) R1...R8 = 22 kΩ
DI2
W3 W4
IOB-22 -> "0 signal"
3 R3 0...20 V -> "1 signal"
DI3
W5 W6 60...130 V (230 V~) R1...R8 = 47 kΩ
4 R4
IOB-23 Firmware -> "0 signal"
DI4 0...40 V -> "1 sig."
W7 W8
90...250 V including tolerance; absolute
5 R5
DI5 max. values
W9 W10
X6: / X7: are screw-clamp terminal types for leads up to 4 mm² cross-
6 R6
DI6 sectional area
W11 W12
Input resistance: see diagram.
7 R7 Input smoothing time constant: see diagram.
DI7
W13 W14 Smoothing time constant of channel 7 and 8 can be changed; see
8 R8
fig. before.
DI8
W15 W16
Power supply for digital inputs: 48V / ≤ 50mA; not galv. isolated
X7:1
W100
from the DCS electronics!
2
up to revision D
3 from If the inputs are supplied from the internal +48 V (X7:3 and/or X7:4) a
revision E on connection must be done from either X7:1 and/or X7:2 to ground of
4 +48V the DCS 500 module. In default condition ground is identical to the
conductive support converter's frame.
iob2x2_b.dsf If the inputs are supplied by any external source (+48 V DC, 115 V AC
or 230 V AC) the neutral line / - line must be connected to either X7:1
or X7:2. If the inputs should be controlled with the same voltage level,
but from two different voltage sources, having probably two different
ground levels, the first neutral line should be connected to X7:1 and
the second to X7:2. In this case the jumpers Wx connecting the inputs
to X7:2, but controlled by the source, connected to X7:1, must be cut
off.
The same method is needed for the other jumpers Wx.
High frequency grounding is done by 100 nF capacitor.
Technical data
81
Analogue and encoder I/O board SDCS-IOB-3
As described at the beginning of the chapter, there are I/O via SDCS-IOB-2x / IOB-3 and SDCS-CON-4
various options for configuring the inputs/outputs.
The board SDCS-IOB-3 consists of the 5 analogue

inputs, 3 analogue outputs, the galvanical isolated
pulse encoder interface and a current source for tem- X2: X1: X2: X1:
perature measuring devices. X6: X7:
X1: X2: X3: X1: X1: X2:
If these boards are in use, they have to be mounted

outside the DCS module. They must be mounted in a
way, that the conductive supports have a good con-
nection to ground of the installation.
The cable length between X1:/X1: and X2:/X2: is max.

1.7 m and between X1:/X3: is max. 0.5 m because of
EMC reasons.
Layout and jumper settings of the SDCS-IOB-3x board

233.5
conductive supports
V17
SDCS-IOB-3
X1 X2
2 14
S1*
T1
1 13
8 7 8 7
S5 * S10 *
S4
*
3 24 85
R110 1 2 1 2
2 1 2 1 2 23
3 4
1 22
70 S2* S3* 70
11 12
1 12 1 12 10
1
X3 X4 X5
5 5
4 iob3_c.dsf 4
Jumper coding
Functionallity of analogue inputs S4 Pulse encoder supply
activation of gain = 1 gain = 10 Sum I AC
S1 Ch 500 between * not equal 5V 12 V 24 V *
input terminal -10V..+10V -1V..+1V to 0
* 1 2 1 2 1 2
S2 AITAC S1:1-2 YES 3
5
7
4
6
8
3
5
7
4
6
8
3
5
7
4
6
8
AI1 S1:3-4 YES
S3 AI2 S1:5-6
9
11
10
12
9
11
10
12
9
11
10
12
S2 8 7 8 7
6 5 S2 6 5
4 3 4 3
2 1 2 1 S5 Temperature sensor supply
PTC PT100
AI3 S1:7-8 1.5 mA 5 mA *
S3 8 7 S3 8 7
6 5 6 5 1 2 1 2
4 3 4 3 3 4 3 4
2 1 2 1
AI4 S1:9-10 YES S1:11-12

S1:13-14
S10 Characteristics for pulse encoder inputs

single ended:
3
5V
*24 3
12/24 V
24
2 23 2 23
1 22 1 22
differential: 5V 12/24 V 13 mA
*
3 24 3 24 3 24
2 23 2 23 2 23
1 22 1 22 1 22
* default value
Technical data
82
Note:
X1:1 81-270V When the SDCS-CON-4 control board with the SDCS-IOB-3 I/O
-
2 25-90V board is installed, analogue tacho input at SDCS-CON-4 should
TG 3
8-33V
X2:3 be used:
+ 4 4
X2:3
5 R9 5
X2:4
6 6
7 7
PS5311
8 8 Terminals X3:, X4: and X5: on the SDCS-CON-4 must not be used.
Resolution Input/output Scaling Com- Remarks
[bit] values by mon
X2:
SDCS-IOB-3 SDCS-CON-x Software

- S1 100k 100k Hardware mode
X3:1
+
1 2
500
1n
100k 1n 100k AITAC range
2 15 + sign -10...0...+10 V Firmware ±20 V ➀➁➂➅
-
3 3 4
+ AI1
4 S2 3.3 ms 15 + sign -10...0...+10 V Firmware ±20 V ➀➁➂
-
5 5 6
+ x10 AI2
6
3.3 ms 15 + sign -10...0...+10 V Firmware ±40 V ➀➁➂➃➄
-
7 7 8
+ x10 AI3
8 15 + sign -10...0...+10 V Firmware ±40 V ➀➁➂➃➄
- S3 10 ms
9 9 10
AI4
10
+
12 14 10 ms
15 + sign -10...0...+10 V Firmware ±40 V ➀➁➂
S1
~ 11 13
11
100
12 ~
100 47.5
Power
X4:1 100n AO1 11 + sign -10...0...+10 V Firmware ≤ 5 mA*
2 0V
3 AO2 11 + sign -10...0...+10 V Firmware ≤ 5 mA*
4 0V
100
5 100n
47.5
x +/- I-act analogue -10...0...+10 V R110 ≤ 5 mA* gain: 0.5...5
3 V = I NDC
6 0V
R110
7 +10V Ri = 3 Ω ≤ 5 mA* for external use

8 0V ≤ 5 mA* e.g. reference pot.
9 1 2 -10V
100
10 S5
1.5 mA 1.5 mA Curr. source for
5 mA
3 4 5 mA PTC or PT100
11 0V
12
S10 S10 Encoder supply Remarks

X5:1 4 5 6 +24V 1 2 3 ChA +
Inputs not isolated
2 ChA -
Impedance = 120 Ω, if selected
3 10 11 12 +24V 7 8 9 ChB + max. frequence ≤300 kHz
4 ChB - 5V ≤ 250 mA * Sense lines for GND and supply to
5 16 17 18 +24V 131415 ChZ + 12 V / 24 V ≤ 200 mA * correct voltage drops on cable (only if
6 ChZ - 5V/12V enc. is in use)
V17
7 Power-
Sense Power + Source
8
Sense GND
9
10 S4 GND
iob3x2 e.dsf
➀ total smoothing time ≤2 ms ➆Residual current detection is selected as default. The jumpers S1:11-12 and S1:13-14 are set, inputs X3:9 and X3:10
➁ -20...0...+20 mA by setting S1 and jumper S1:9-10 must not be used and inputs X3:11 and X3:12 serve as input for the current signal taken from a
➂ 4...20 mA by ➁ + Software function current transformer. This detection is based on a sum current transformer where the secondary is connected through a
➃ -1...0...-1 V by setting S2/S3 (CMR ±10 V) diode bridge to 100 W resistor . Voltage will appear across the resistor, if the sum of the 3-phase current is not zero. In
-2...0...-2 mA by setting S2/S3 + S1 (CMR ±10 V) case AI4 should be used for a different purpose, use the inputs/jumpers accordingly and take the block diagram as a
➄ designated for PT100 evaluation per firmware and help.
hardware Restrictions using jumper S1, S2 or S3:
➅ If the input is used for tacho feedback and the tacho The selection for the burden resistor across the input terminals can be done independent from S2 or S3 settings for inputs
voltage needs to be scaled, the board PS5311 must be AITAC, AI1, AI2, AI3 and AI4.
ordered separate. If this input is used for feedback If the gain is set to 10 by using S2 or S3 and the 500 W burden resistor is activated, the input signal level is changed to -2
signals, there is a need for additional margin for mA...0...+2 mA.
overshoot measurement. This margin is set by software For input AI4 there are the following configurations available:
and results e.g. in the 8 to 33 volts at PS5311. - input range ”20mA” , or
* short circuit proof - input range ”10V”, or
- earth fault monitoring by Isum not equal to zero via X3:11 and X3:12
Technical data
83
Power Supply Board SDCS-POW-4

The SDCS-POW-4 board is designed for DCS800 converter modules D5...D7 and is mounted on the
electronic support. This board is used for all types of modules independent from current or voltage
range.
The SDCS-POW-4 works on a switched mode basis in fly back configuration. It generates all necessary
DC voltages for the SDCS-CON-4 and all other electronic boards. The input voltage automatically is
detected either to 230 V AC or to 115 V AC. The following figure shows the instructions for the selection
of the AC input voltage and for the selection of the encoder supply voltage.
Technical data
84
Interface Board SDCS-PIN-4
General
The SDCS PIN4 board is designed for DCS800 Converter modules sizes D1 up to size D4 (20 A...1000
A) the board has three different functions:
1. Power supply of CON-4 board and the connected options
2. Control of armature bridge and measurement
3. Control of on-board field exciter and field current measurement
The board is mounted conducting ground at points ( ) inside the module.
The board is used for supply voltages from 230 V up to 525 V, 600 V.
The converter identification is made by TYPECODE 97.01 (and not by hardware)!
The converter identification manages the burden resistor setting and 2-Q or 4-Q bridges operation.
Field current measurement Armature firing Power supply
High voltage
T100
X37
6A 5x
25A 1x
X18
X16
X13
X15
X17
X12
X95
SDCS-PIN-4 +
X5 X22
High voltage
Field firing
X12 X4
X3 S1 1
1-2 = 230 V
X31 2
2-3 = automatic
X1 X2 X7 3
X8 X9 K301
F100
F101
F102
K400
X10
F400 F300
W1 D1 X96 X99
- + C1 U1 V1
X24 X21 X25 X23 X20
conducting point
Pin4_layout.dsf
Different functional areas on SDCS-PIN-4
Technical data
85
Power supply
The power supply (X99:) operates on fly back configuration. The internal DC link voltage is 310 V.
The power supply automatically adapts the supply input voltage between 230 V and 115 V and switches
relays K301.
In case of oscillating 230 V input voltage (e.g. generator network) the operation must be clamped to
230 V by Jumper S1= 2-3 230 V operation
Technical data
AC Supply voltage Backup supply
Supply voltage 115 V AC 230 V AC The terminal X95 are used to add additional
capacitance to the existing ones to increase
Tolerence -15%/+10% -15%/+10% the mains buffering time. More detailed data
is available on request via your ABB
Frequency 45 Hz ... 65 Hz 45 Hz ... 65 Hz
representative.
Power con- 120 VA 120 VA
sumption
Power loss ≤60 W ≤60 W
Inrush current 20 A / 20 ms 10 A / 20 ms
Mains buffering min 30 ms min 30 ms
Powerfail 85 V 170 V
S1
2-3 -> 230 V operation fix
1-2 -> automatic detection of input voltage range (default)
X96: Output DO8

Isolated relay (NO contact)
X96:
Contact rating:AC: 230 V~/ <3 A~
DC: 24 V-/ <3 A-
or 115/230 V-/ <0.3 A-)
PIN4_in-output_circuit.dsf
Input circuit PIN-4 275 V Filtering
X99:
Technical data
86
Armature circuit interface

The function for armature circuit interface consist of:
• Firing the armature bridge of 6 or 12 thyristors.
• High ohmic measurement of DC and AC voltage.
• Interface for AC current transformer for current measurement.
• Snubber circuit for the thyristor protection together with resistor R1 on heatsink.
• Interface for heatsink temperature measurement with a PTC resistor.
• Fuses for overvoltage protection and field circuit.
The same board can be used for 3 phase field exciters without modification.
The current measurement is adjusted by TYPECODE parameter 97.01 and automatic adjusted by rated
motor current.
Field circuit interface

The On board fieldexciter is located internally. The firing pulses are synchronized from mains circuit
L1,L2,L3 and SDCS-CON-4 board. The pulses are amplified on PIN4 board. The hardware structure is
a three phase half controlled bridge supplied direct from mains circuit U1, V1 , W1 via fuses F100,
F101, F102.
If the On board field exciter is not needed it can be switched OFF by firmware.
The function of field circuit interface consists of:
• Firing the field bridge three phase half controlled bridge.
• Measurement of DC field current, the scaling is automatically selected via rated motor field current.
• Snubber circuit are shared with armature bridge.
• Fuses F101, F102, F103 for cable and motor field protection.
Ratings
AC voltage range 110...500 V (525 V)
AC insulation voltage 500 V
Frequency 50 Hz / 60Hz
AC input current < field current
Minimum Current ?300 mA
Size D1 D2 D3 D4
DC output current 6A 15A 20A 25A
max. cross sectional area 16 mm² 16 mm² 16 mm² 16 mm²
AWG 6 AWG 6 AWG 6 AWG 6
min. cross sectional area 1 mm² 2.5 mm² 4 mm² 6 mm²
AWG 16 AWG 12 AWG 10 AWG 8
Fuse type KTK - 25
Technical data
X12: Armature circuit interface POWER INTERFACE BOARD SDCS-PIN-4 PE U1 V1 W1
IDCM 11,12
X3: 1 T51 P2
Control board Armature current measuring resistances
3 S1
N/1
IDC 9,10 X4: 1 S2 P1 T53
25A...275A 1500:1
3 S1 276A...800A 3000:1
N/1
801A...1200A 4500:1
X5: 1 S2 P1
STWA 3 0V T52 P2
3 S1
GNDI 8,13 N/1
S2 P1
X22: 1 R57
ANTC 2 3
X20:
HWCOD3 5 NC D1
HWCDD5 7 NC X30:
R1
AC/DC voltage measuring circuits
5M / 6M
UA - 15 X31:
X1: F101
UU 4 X21:
U1
X2: F102
UV 14 V1
X7: F103 X23:
VW 16
W1
16A
UA + 6
X5: 25
X13: G
BZP1 1 1 27
1.1
K
9
G
BZP2 3 2 11 2.2

K
33 X24:
G C1
BZP3 5 3 35 1.3
K
1
G
BZP4 7 4 3 2.4 Field circuit G G
K 2.4 2.1
29
interface K K
G
BZP5 9 5 31 1.5
K G G
V24 V21
17 1.1 1.4
G K K
BZP6 11 6 19 2.6
V11 V14
REVERSE Firing pulse channels X6:
SR2 4,2 25
G G G
only in case of 4-Q converters
+48 V1 10 + 48 V1 27 2.1 2.6 2.3
K K K
SR1 8,6 FORWARD 9
G V1??
Typical armature circuit thyristor converter diagram with SDCS-PIN-4 board
GNDI 14 11 1.2 G V26 G V23

K 1.3 1.6
K K
33
G
35 2.3 T100
X13: K V13 V16
1
+24 V 2 G X12:1
G G
+48 V 4 3 1.4
K 2.2 2.5
K K
+24 V 6
29
+15 V 8 G
-15 V 12 31 2.5 G
K G V22 V25
GND 24, 22, 1.5 1.2
17 K K
20, 18, 10 G
19 1.6
K
X99: 1 2 X96: 1 2 X13: 13 15 16 12 X8: X9: V15 V12
Pin4.dsf
F- F+ C1 (+) D1 (-)
Technical data
87
88
Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x

The Power Interface of DCS converter modules model D5/D6/D7 from 900 A up to 5200 A consists of
two boards - the Measuring board SDCS-PIN-51 and the Pulse transformer board SCDS-PIN-41.
The following figures show the different connections between the SDCS-PIN-41 and SDCS-PIN-51
board depending on the application 2- or 4-quadrant and the construction type.
Converters delivered from middle 2005 will be equipped with SDCS-PIN-48, which is a full replacement
for converters already in use.
2-Quadrant application, no parallel thyristors - Construction type D5/D6/D7
SDCS-CON-x
X22 X122 X23 X24 X25 V14 V11 V16 V13 V12 V15
G G G G G G
U1
C C C C C C
V1
X413 S
X313 S
X12 S
X13 S
A B C D E F
X12
X12
W1
S2
S1
X113
X213
SDCS-PIN-5x
C1
SDCS-PIN-46/PIN-48
X513
X113
X213
X413
X313
2q_c34_b.dsf
X13
X13
D1
4-Quadrant application, no parallel thyristors - Construction type D5/D6/D7

SDCS-PIN-46/PIN-48
V25 V12 V23 V16 V21 V14
G G G G G G
SDCS-CON-x
X22 X122 X23 X24 X25 V24 V11 V26 V13 V22 V15
C C C C C C
G G G G G G
U1
C C C C C C
T4 T1 T6 T3 T2 F
V1
X413 S
X313 S
X12 S
X13 S
A B C D E F
X12
X12
X213
X113
W1
S2
S1
X113
X213
SDCS-PIN-5x
C1
SDCS-PIN-46/PIN-48
X513
X113
X213
X413
X313
4q_c3a_b.dsf
X13
X13
D1
Pulse transformer board SDCS-PIN-46/PIN-48

Layout of the SDCS-PIN-46/PIN-48 pulse transformer board
270
G G G G G G
Gate
C C C C C C Cathode
100
X1 X2 The board consists of six

A B C D E F pulse transformers with
amplifiers.
X113 X213
SDCS-PIN-4x
Pin4x.dsf
Technical data
89
Measuring board SDCS-PIN-51
This board is always used together with SDCS-PIN-41 board. On The voltage measurement uses 5 resistor:
this board there are the circuits located needed for current, voltage
and temperature measuring and for hardware coding. U1:W1 to W5
The current is measured by current transformers at the main AC V1:W6 to W11

inputs, rectified by a diode bridge and scaled with burden resistors.
The nominal current is adjusted by cutting out resistors (R1 ... R21) W1:W12 to W16
from the board according to the current coding table. The resistors
R22 ... R26 are used for the current equal to zero detection. These C1(+):W17 to W21
resistors must be cut off too, according to the current coding table.
D1(-):W22 to W26
Voltages (U1, V1, W1 and C1(+) and D1(-)) are measured by using
high ohm resistor chains. Scaling of AC and DC voltage is done by If there is a need for voltage adaptation, all 5 chains must be han-
activating 1 MΩ resistors (= cutting out short circuit wires, which are dled in the same way.
represented by low ohmic resistors).
Note! Actual voltage signals U1, V1, W1, C1(+) and D1(-) of the
main circuit are not galvanically isolated from the control board.
Because of that a current of less than 1 mA will flow to earth.
When galvanically isolated measurement is needed, please contact

your ABB representative..
Layout of the SDCS-PIN-51 board

see diagram Conductive
PTC power part
W5 line potential ! supports
R123 1 X23 2 1 X24 2 1 X25 2

U1 W5 W4 W3 W2 W1 X22 X122
3 4 Two PTC
S3 1 2 One PTC
R1 ....... R21
V1 W11 W9 W8 W7 W6
W10 W70 W71 W72 R22
X12
100
X12S X413S
W1 W16 W15 W14 W13 W12 W80 W81 W82 R26
W83
X13S X313S
C1 W21 W20 W19 W18 W17
S2 S1
X513
X113
X213
X413
X313
X13
Isolating D1 W26 W25 W24 W23 W22
supports
SDCS-PIN-51
305
Layout of the SDCS-PIN-52
U1 In the past some converters for

S3
V1 line voltages lower/equal 500 V
had been equipped with SDCS-
X12
W1
PIN-52 boards. The SDCS-PIN-
C1 51 board serves as a spare part
D1 for those converters.
SDCS-PIN-52
Technical data
90
Settings of the SDCS-PIN-51 board if a DCS converter is equipped with it by ABB

Current coding
Construction type D5 D6 D7
Current transf. ratio 2500:1 2500:1 4000:1
Rated current [A DC] 900 1200 1500 2000 1900 2050 2500 3000 2050 2600 3300 4000 4800 5200
R1-R4 18
R5 18
R6 18
R7 18
Rated current scaling
R8 18
R9 18
R10 18
R11 18
R12 18
R13 18
R14 18
R15 18
R16 18
R17 33
R18 68
R19 120
R20 270
R21 560
R22 47
Zero current
detection
R23 47
R24 47
R25 47
R26 100
code_tab_PIN1_PIN20_PIN51_d.dsf
Voltage coding
Construction type D5 D6 / D7 D7 D7
Conv. nom. voltage [V] Y=4 (400V) Y=6 (600V) Y=7 (690V) Y=4 (400V) Y=6 (600V) Y=7 (690V) Y=8 (790V) Y=9 Y=1
➀ U1 [V AC] Y=5 (500V) Y=5 (500V) (990V) (>1000V)
Value f. conv. nom. volt
0 = HW type coding 500 600 690 800 1000
at SET(TINGS) block
Measuring board SDCS PIN-51 PIN-51 PIN-51 PIN-51 PIN-51 PIN-51 PIN-51 PIN-51 see
chapter
W1, 6, 12, 17, 22
Galvanic
W2, 7, 13, 18, 23 isolation
W3, 8, 14, 19, 24
W4, 9, 15, 20, 25
W5, 11, 16, 21, 26
➀ the converters can be used at lower line voltage then specified by the y-value without hardware modifications, if
the nominal line voltage applied to the converter is not lower than 45% for y=5...9 and not lower than 55% for y=4.
Temp. sensor coding 2 Q - 4 Q coding

R 57 as a temp. sensor for D5, D6, D7
2-Q 4-Q
S3 4 3
W10
2 1
Board used as a spare part: indicates a removed jumper
• default: all jumpers Wxx, Rxx are in condition

• ensure the correct converter type related settings
Technical data
PE U1 V1 W1
T51 P2
X12: X12: POWER INTERFACE BOARD SDCS-PIN-51 S1
IDCM 11,12 A3,B3 4000/1
S2 P1
X23: 1
Armature current measurement 2
R25 47R
R24 47R
R23 47R
R22 47R
T52 P2
R26 100R
IDC 9,10 A4,B4 X24: 1
2 S1 4000/1
S2 P1
X25: 1
R18 68R
R17 33R
R16 18R
R15 18R
R14 18R
R13 18R
R12 18R
R11 18R
R10 18R
R9 18R
R8 18R
R7 18R
R6 18R
R5 18R
R4 18R
R3 18R
R2 18R
R1 18R
R21 560R
R20 270R
R19 120R
GNDI 8,13 A5,B2
STWA 3 B7 101 W1 W2 W3 W4 W5
0V 100
UU 4 A7 U1
5M
201 W6 1M W7 1M W8 1M W9 1M W11 1M
200
UV 14 A2 V1
AC/DC voltage measurement 301 W12 W13 W14 W15 W16

300
VW 16 A1 W1
W17 W18 W19 W20 W21

400 401
UA + 6 A6 C1
4-Quadrant D7 type converter
500 W22 W23 W24 W25 W26

501
UA - 15 B1 D1
X22: 1 R57
0V
ANTC 2 A8 3
Fast-on
2.4 1.1 2.6 1.3 2.2 1.5 G G
Control board S1
2.4 K 1.4 K
GA CA GB CB GC CC GD CD GE CE GF CF
X13: X13: Firing pulse channels X113: X113: X213:

BZP1 1 B8 1 A10,B10 A10,B10 A5,B5 G V24 G V14
A5,B5 A5,B5 1.1 K 2.1 K
BZP2 3 B7 2 A10,B10 F11 F14
BZP3 5 B6 3 A9,B9 A9,B9 A6,B6

R11 V11 R14 V21
BZP4 7 B5 4 A7,B7 A7,B7 A8,B8
C11 C14
BZP5 9 B4 5 A8,B8 A8,B8 A7,B7
C24 C21
BZP6 11 B3 6 A6,B6 A6,B6 A9,B9 R24 R21
G G
GNDI 12,14 A2,A3 0V A4,B4 A4,B4 A4,B4
*
2.6 K 1.6 K
SR2 4,2 A7,A8 REV A3,B3 A3,B3 A3,B3
SR1 8,6 A5,A6 FWD A1,B1 A1,B1 A1,B1 G V26 G V16

A2 A2 1.3 K 2.3 K
+48 V1 10 A4 + 48 V1 SDCS-PIN-48 A2 F13 F16
2.5 1.2 2.3 1.6 2.1 1.4 V13

R13 R16 V23
GA CA GB CB GC CC GD CD GE CE GF CF C13 C16
HW-coding jumpers
X213: X213: X113: C26 C23
0V A10,B10 A10,B10 A5,B5 R26 R23
W70 W71 W72 G G
1k5 A5,B5 A5,B5 A10,B10 K K
ACOD1 13 B2 2.2 1.2
A9,B9 A9,B9 A6,B6
820R 1k5 3k3
W80 W81 W82 W83 A7,B7 A7,B7 A8,B8 G V22 G V12
1.5 K 2.5 K
ACOD2 15 B1 A8,B8 A8,B8 A7,B7 F15 F12
1k5 820R 1k5 3k3 8k2 A6,B6 A6,B6 A9,B9

R15 V15 R12 V25
X12: X12: A4,B4 A4,B4 A4,B4
HWCOD3 5 B6 NC C15 C12
A3,B3 A3,B3 A3,B3
C22 C25
HWCDD5 7 B5 A1,B1 A1,B1 A1,B1 R22 R25
W10
HWCIN4 1 B8 A2 A2 SDCS-PIN-48 A2
p41_51_A7.dsf C1 (+) D1 (-)

Typical armature circuit thyristor converter diagram with SDCS-PIN-48 and SDCS-PIN-51 boards for a
Technical data
91
92
Galvanic isolation - T90, A92
The Galvanic isolation is an option for converters in

the current range 2050...5200 A and rated voltages
≤1000 V. For converters with a rated voltage of
1190 V and 12-pulse serial > 2x 500 V the galvanic
isolation is a standard equipment. It is used to
replace the high-ohmic resistance voltage
measurement and gives the advantage of a total
isolation from power part to electronic part.
The transformer T90 and the DC transducer A92 are
located outside the converter module. The internal AC
and DC voltage measurement channels are opened and
connected to the T90 and A92 units.
Hard and software settings:

Voltage coding on measuring board
Construction type D5 / D6 / D7
Conv. nom. voltage [V] * Y=4 (400V) Y=6 (600V) Y=7 (690V) Y=8 (790V) Y=9 (1000V) Y=1 (1190V)
Y=5 (500V)
Rated mains voltage [V AC] 220…500 270…600 300…690 350…790 450…1000 530…1190
Value f. conv. nom. volt at 500 600 690 800 1000 1200
SET(TINGS) block *
Measuring board SDCS- PIN-51 PIN-51 PIN-51 PIN-51 PIN-51 PIN-51
Resistors W1…W26
all resistors are 0 Ω
Galvanic isolation
Resistors Rx on PIN51 27.4 kΩ 27.4 kΩ 27.4 kΩ 27.4 kΩ 27.4 kΩ 27.4 kΩ
DC-DC transducer A92 8680A1

Switch position RG * 7 (675 V) 6 (810 V) 5 (945 V) 4 (1080 V) 2 (1350 V) 1 (1620 V)
Transformer T90 3ADT 745047

Secondary Terminals * 2U1 2U2 2U3 2U4 2U5 2U6
2V1 2V2 2V3 2V4 2V5 2V6
2W1 2W2 2W3 2W4 2W5 2W6
2N 2N 2N 2N 2N 2N
* 12-pulse serial and sequential have a different selection between S CONV NOM VOLT (42.08) and
the scaling of measurement channel. See 12-pulse manual for DCS 600.
Technical data
T90 F90
removed wires
Rx
resistors, to be soldered in parallel to 5 M hybrid; values see table before S
2N PE U1 V1 W1
T51 P2
X12: X12: POWER INTERFACE BOARD SDCS-PIN-51 S1
IDCM 11,12 A3,B3 4000/1
S2 P1
X23: 1
Armature current measurement 2
R25 47R
R24 47R
R23 47R
R22 47R
X24: 1 T52 P2
R26 100R
IDC 9,10 A4,B4
2 S1 4000/1
S2 P1 aux. supply
X25: 1
230 V AC
2
R18 68R
R17 33R
R16 18R
R15 18R
R14 18R
R13 18R
R12 18R
R11 18R
R10 18R
R9 18R
R8 18R
R7 18R
R6 18R
R5 18R
R4 18R
R3 18R
R2 18R
R1 18R
R21 560R
R20 270R
R19 120R
GNDI 8,13 A5,B2
STWA 3 B7 Rx W1 W2 W3 W4 W5
0V 100 101
U1
SDCS-POW-1
UU 4 A7
5M
Rx201 W6 1M W7 1M W8 1M W9 1M W11 1M X99:1
200
UV 14 A2 V1 X99:2
Rx W12 W13 W14 W15 W16
AC/DC voltage measurement 300 301
VW 16 A1 W1
Rx W17 W18 W19 W20 W21

400 401
UA + 6 A6 C1
500
Rx W22 W23 W24 W25 W26
501
UA - 15 B1 D1
4-Q D7 type converter with galvanic isolation
X22: 1 R57
0V
ANTC 2 A8 3
Fast-on
2.4 1.1 2.6 1.3 2.2 1.5 G G
Control board S1

2.4 K 1.4 K
GA CA GB CB GC CC GD CD GE CE GF CF
X13: X13: Firing pulse channels X113: X113: X213:
BZP1 1 B8 1 A10,B10 A10,B10 A5,B5 G V24 G V14
A5,B5 A5,B5 1.1 K 2.1 K
BZP2 3 B7 2 A10,B10 F11 F14
BZP3 5 B6 3 A9,B9 A9,B9 A6,B6
R11 V11 R14 V21
BZP4 7 B5 4 A7,B7 A7,B7 A8,B8
C11 C14
BZP5 9 B4 5 A8,B8 A8,B8 A7,B7
C24 C21
BZP6 11 B3 6 A6,B6 A6,B6 A9,B9 R24 R21
G G
GNDI 12,14 A2,A3 0V A4,B4 A4,B4 A4,B4
*
2.6 K 1.6 K
SR2 4,2 A7,A8 REV A3,B3 A3,B3 A3,B3
SR1 8,6 A5,A6 FWD A1,B1 A1,B1 A1,B1 G V26 G V16

10 9 1 2
A2 A2 1.3 K 2.3 K
+48 V1 10 A4 + 48 V1 SDCS-PIN-48 A2
F13 F16 = ~
2.5 1.2 2.3 1.6 2.1 1.4 V13
R13 R16 V23
GA CA GB CB GC CC GD CD GE CE GF CF C13 C16 = =
HW-coding jumpers
X213: X213: X113: C26 C23
0V R26 R23 20 17 A92
W70 W71 W72 A10,B10 A10,B10 A5,B5
G G
1k5 A5,B5 A5,B5 A10,B10 K K
ACOD1 13 B2 2.2 1.2
A9,B9 A9,B9 A6,B6
820R 1k5 3k3
W80 W81 W82 W83 A7,B7 A7,B7 A8,B8 G V22 G V12
1.5 K 2.5 K
A8,B8 A8,B8 A7,B7 F15 F12
ACOD2 15 B1
A6,B6 A6,B6 A9,B9
1k5 820R 1k5 3k3 8k2
R15 V15 R12 V25
X12: X12: A4,B4 A4,B4 A4,B4
HWCOD3 5 B6 NC C15 C12
A3,B3 A3,B3 A3,B3
C22 C25
HWCDD5 7 B5 A1,B1 R22 R25
A1,B1 A1,B1
W10
HWCIN4 1 B8 A2 A2 SDCS-PIN-48 A2
p41_51_A7.dsf C1 (+) D1 (-)
F11
Typical armature circuit thyristor converter diagram with SDCS-PIN-48 and SDCS-PIN-51 boards for a
Technical data
93
94
DC-DC transducer A92

Principle circuit diagram of the DC-DC transducer A92
17 6M appr. 280nF 9
Input 10nF Output
voltage OPAMP
RG voltage
20 6M 10
appr. 3.9 k TRANSDUCER
1:1 GAIN
7 STEPS
POWER SUPPLY
1 +15V
230 V AC 0V 0V
2 -15V
Data
Selectable voltage gains: 675 810 945 1080 1215 1350 1620 V DC
Switch position 7 6 5 4 3 2 1
Output voltage: 9,84 V / 5 mA
Auxiliary power: 230 V ± 15 %; 50/60 Hz; 3 W
Clearance in air: Auxiliary power to Output: >13 mm
Input/Output to Auxiliary power: >14 mm
Insulation voltage: 2000 V
Insulation test voltage: 5000 V
Ambient temperature range: - 10 …+ 70 °C
Weight: appr. 0.4 kg
The voltage gain and frequency response is especially designed for

DCS800 converters.
Dimensions in mm Location of terminals

Side view Buttom view
112.0 2.0
76.0
10.0 70.0
7.0
Snap-on mounting on DIN 46277 rail
20 17
100.0
80.0
Gain selector
RG
50.0 1 2 9 10
5.0 60.0
Technical data
95
Transformer T90
Principle diagram of the transformer T90
1U 2N 2U6 2U5 2U4 2U3 2U2 2U1
1V 2V6 2V5 2V4 2V3 2V2 2V1
1W 2W6 2W5 2W4 2W3 2W2 2W1
1N
S
Data
Selectable transfer ratios Uprim: 502, 601, 701, 800,1000, 1200 V AC rms
Output voltage: 7.3 V AC rms
Insulation voltage: 1200 V
Isolation test voltage: 3500 V
Ambient temperature range: - 10 …+ 70 °C
Weight: - 10 …+ 70 °C
Weight: 2.1 kg
Dimensions in mm Remark
max 116
The terminals on the primary side of the
transformer are in special design (lug termi-
nals).
Handling hints: First turn the screw counter-

max 110
clockwise to the end stop, then swing out the

shrowding cover. Put in the cable lug, swing
in the shrowding cover and fasten the con-
nection by turning the screw clockwise.
5.2 x 7.7
130
80
118....120
130
Technical data
96
Technical data
97
Dimensional drawings of the DCS800 are shown below. The dimensions are given in
milllimeters.
Module D1 for size D1

for size D2...D3
DCS800-S01-0020 direction of air flow
DCS800-S01-0045
DCS800-S01-0065
DCS800-S01-0090 screw M6
fan terminal
DCS800-S01-0125
DCS800-S02-0025
DCS800-S02-0050
DCS800-S02-0075
DCS800-S02-0100
DCS800-S02-0140
Module D2
DCS800-S01-0180
DCS800-S01-0230 earthing
point screw
DCS800-S02-0200
DCS800-S02-0260 Size Weight
Module D3
DCS800-S01-0315
T1 = 250mm for size D2/D3
DCS800-S01-0405
T1 = 150mm for size D1
DCS800-S01-0500
Top clearance
Minimum
DCS800-S02-0350
DCS800-S02-0450
Mounting direction
DCS800-S02-0550
310 for size D1/D2
400 for size D3
Signal terminals
Field and power supply terminals
Power connection
T2 = 150mm for size D2/D3
T2 = 100mm for size D1
Bottom clearance
Minimum
D1toD3_dim_a.dsf
98
Module D4
for size D4
DCS800-S01-0610
DCS800-S01-0740
DCS800-S01-0900
DCS800-S02-0680
DCS800-S02-0820
DCS800-S02-1000
Weight appr. 38 kg
D4_dim_a.dsf
99
Module D5
Minimum Top
510
DCS800-S0x-0900
clearance
400
250
450
DCS800-S0x-1200 127.5 125 125 17 26
85.5
DCS800-S0x-1500 for M10
U1 V1 W1
DCS800-S0x-2000
22
17
26
55
Ø 14 34
Weight appr. 110 kg
1005
820
775
773
Support Support
> 510
min. 480
69
Ø 14 cable tray
earthing M12 with = 40 mm
102
earthing height =39 mm

44.5
80
M12
C1 276 D1
Bottom clearance
17.75 fan terminals
fan terminals
Minimum
65.5 25 50 50 50
400
100
461 325.5
483
A5_dim_a.dsf
Mounting the converter module A5 inside an

Busbars in mm: enclosure
AC 80 x 10
DC 60 x 5 Two supports should be mounted inside the
enclosure in such a way, that they can carry the
converter's weight when placing the converter
later on. The minimum distance between the
supports should not be less then 480 mm
because of electrical clearance (DC busbars).
A L-shape support as indicated will allow to

place the converter temporarily close to the front
end of the support (weight still taken by a lifting
device) and then push it back to the back plate
of the enclosure. The upper and lower holes in
the back plate of the converter should be used
to fix the converter in that position.
100
Module D6
458.2
DCS800-S0x-1900 425
DCS800-S0x-2050 375
DCS800-S0x-2500 250 409 Air outlet
DCS800-S0x-3000 10x20
20
Weight appr. 180 kg
C C
200
D D
225
M12
40
50
U U
62
200
*
V
V
1750
200
1725
W
W
1079.5
759.5
Pressure switch
10x20
63
15
72 100
M10 355
385
Air entry
445 A6_dim.dsf
from the front, right, left and
468.2
back
136
101
Module D7
230 530
left-hand 350 for M10
25
DCS800-S0x-2050-xxL
DCS800-S0x-2600-xxL
DCS800-S0x-3300-xxL
DCS800-S0x-4000-xxL
DCS800-S0x-4800-xxL 200
DCS800-S0x-5200-xxL
Weight appr. 315 kg

*
225
200
1725
200
Pressure switch
759.5
for M10
A7_dim_a.dsf
Busbars in mm:
AC and DC 100 x 10
93
80 80 80 80
102
Module D7
right-hand for M10
25
DCS800-S0x-2050-xxR
DCS800-S0x-2600-xxR
DCS800-S0x-3300-xxR
DCS800-S0x-4000-xxR
DCS800-S0x-4800-xxR
200
DCS800-S0x-5200-xxR
Weight appr. 315 kg
225
*
200
1725
200
Pressure switch
759.5
for M10
A7_dim_a.dsf
Busbars in mm:
AC and DC 100 x 10
103
Fuses installed inside the converter

Converter type Model Fuse F1 Size Type
400 V / 500 V L1 L2 L3
DCS800-S0x-1200-04/05 D5 800A 660V UR 5 170M 6162

DCS800-S0x-1500-04/05 D5 1250A 660V UR 5 170M 6166
F1x F1x
DCS800-S0x-2000-04/05 D5 1600A 660V UR 5 170M 6169
F1x F1x
DCS800-S0x-2050-51 D6 1500A 660V UR 5 170M 6168
900A 660V UR ➀
F1x F1x
DCS800-S0x-2500-04/05 D6 5 170M 6163
DCS800-S01-3000-04/05 D6 1500A 660V UR ➀ 5 170M 6168
DCS800-S02-3000-04/05 D6 1250A 660V UR ➀ 5 170M 6166
DCS800-S0x-3300-04/05 D7 2500A 660V UR 7 170M 7026
DCS800-S0x-4000-04/05 D7 3000A 660V UR 7 170M 7028
DCS800-S0x-5200-04/05 D7 3500A 660V UR 7 170M 7057
600 V / 690 V
DCS800-S0x-0900-06/07 D5 630A 1250V UR 6 170M 6144
DCS800-S0x-1500-06/07 D5 1100A 1250V UR 6 170M 6149
DCS800-S01-2000-06/07 D5 1400A 1100V UR 6 170M 6151
DCS800-S0x-2050-06/07 D6 700A 1250V UR ➀ 6 170M 6145
DCS800-S0x-2500-06/07 D6 1000A 1250V UR ➀ 6 170M 6148
DCS800-S01-3000-06/07 D6 1100A 1250V UR ➀ 6 170M 6149
DCS800-S02-3000-06/07 D6 1000A 1250V UR ➀ 6 170M 6148
DCS800-S0x-3300-06/07 D7 2500A 1000V UR 8 170M 7036
DCS800-S0x-4000-06/07 D7 3000A 1000V UR 8 170M 7156
DCS800-S0x-4800-06/07 D7 3000A 1000V UR 8 170M 7156
790 V
DCS800-S0x-1900-08 D6 700A 1250V UR ➀ 6 170M 6145
DCS800-S0x-2050-08 D6 700A 1250V UR ➀ 6 170M 6145
DCS800-S0x-2500-08 D6 1000A 1250V UR ➀ 6 170M 6148
DCS800-S01-3000-08 D6 1100A 1250V UR ➀ 6 170M 6149
DCS800-S02-3000-08 D6 1000A 1250V UR ➀ 6 170M 6148
DCS800-S0x-3300-08 D7 2500A 1000V UR 8 170M 7036
DCS800-S0x-4000-08 D7 3000A 1000V UR 8 170M 7156
DCS800-S0x-4800-08 D7 3000A 1000V UR 8 170M 7156
1000 V
DCS800-S0x-2050-10 D7 1800A 1250V UR 9 170M 7976
DCS800-S0x-2600-10 D7 1800A 1250V UR 9 170M 7976
DCS800-S0x-3300-10 D7 2500A 1250V UR 9 170M 7978
DCS800-S0x-4000-10 D7 2500A 1250V UR 9 170M 7978
➀ 12 fuses per bridge (2x per F1x)
104
Size 5, 6 Size 7...10
Indicator 15
max 105
4xM10
max d min 10 deep
11
max 105
c
Ø 56
33
Ø
11
67.5
82.5
14 17
108 max d Ø 11
139
b a b
8 25 25
A
100
Size A
6
7 62
8 90
9 105
Size a b c d 10 120
5 50 29 30 76
Remark:
6 80 14 30 76
Given dimensions may be exceeded in some
cases. Please take them only for information.
105
Accessories
DCF803-0035 and FEX 425 internal

The field exciter DCF803 0035 and FEX425intern are half controlled three-phase field converter. Both
field converters are based on the same controller board SDCS FEX4. The board is equipped with own
synchronization and current control. The current measurement circuit is automatic scaled based on
rated motor field current. The field exciter is fully controlled and monitored via serial communication
from armature converter.
The field exciter is prepared to operate as three phase or single phase converter. Single phase
operation is provided with terminals U and W
measurement channel
IFact 5A
35 A
Setting of switchable burden
resistors by rated field current
U
V Field
W
Fex4x1.dsf
Layout of the SDCS-FEX-4 board

240
1 2
X1
X110
P2 P1
35A
T110
1
T113
5A
X100
2
T112 X2
D1
S800
T111
115
X5
D800 U730
S801
U731
R106
S2
1
U1
V110
X71
S1100
V1
X101
2
R107
W1
X6 X4
3
2 3
X3
R108 X7
1
Fex4_layout.dsf
Accessories
106
Electrical data
Power circuit
AC Field input voltage 110 V -15%...500 V +10% single or three-phase
AC input current < DC output current
Frequency same as DCS Converter module
AC isolation voltage 600 V
Line reactor external or shared with D5 armature converter
Line fuses KTK25 for FEX425 internal; external for DCF803-0035
DC output current 300 mA (min)...25 A= FEX425 internal; ...35 A = DCF803-0035
Powerloss < 130 W ( at rated current)
Auxiliary supply
DC input voltage 24 V DC
Input current < 200 mA supplied from SDC-DSL-4 X51
Buffering 10ms
Control unit
The control includes the following main blocks:
• Micro controller H8 for current control synchronization and fault handling.
• Two channel actual field current measurement of DC circuit.
• H8 controller for serial communication based on CAN standard.
• Driver circuit for firing of half control bridge.
• The software is stored in the flash PROM memory. This software contains
PI current control for field circuit
Fault reset logic
Synchronization and PLL function
setting of current measurement channel
The setting and updating of all control parameters are set from armature converter via DCS link serial
communication. Actual field current reference, current control and status bits are cyclic sent via DCS
link serial communication.
The field exciter is equipped with an autoscaling function of burden resistor based on nominal field
current of motor.
Power section
The power section is a three-phase half controlled bridge with free-wheeling diode.
The external field exciter DCF803-0035 is the three-phase half controlled bridge including snubbers
based on SDCS-FEX-4 board. Line fuses and the line choke and transformer must be located outside
the housing.
The internal field exciter FEX425 is a ready installed field exciter in a D5 armature converter. The unit is
based on a SCDS-FEX-4 board and contains also line fuses and three-phase connection to armature
bridge. This internal supply can be removed and connected to an independent AC field supply.
The snubbers are designed to operate in parallel with armature bridge and shared the armature line
choke.
If the unit is used as a single phase supply the terminal U and W must be used. For single-phase supply
an autotransformer for voltage adaption is recommended.
Please see comparison of output voltage ripple between single-phase and three phase-supply.
Accessories
107
Voltage ripple of UDC voltage depending on operation modes
0,75 single-phase half-controlled

Voltage ripple Vsec
0,5
0,25
three-phase half-controlled
0
0,1 0,4 0,7 1
U dc field
three-phase full-controlled
DCS LINK communication

The field converter is controlled from armature converter via DCS link serial communication based on
CAN hardware.
.
Fex4_DCSLink.dsf Supply Remarks
X1:1 24 V / 200 mA 24 V ≤ 200 mA 24 V grounded supply f. SDCS-FEX-4
2
DSL communication Remarks
X3:1
S1100:1 CANL Bus termination
2 S1100 :1 = ON 120 ohm
CANH
3 :1 = OFF no termination
GNDB Ground termination
S1100:3 S1100:2 S1100 :2 = ON 200 kOhm R-C ground termination
:3 = ON 0 Ohm ground termination
:2,:3 = OFF no termination
Termination 200 kOhm
Node address is set by: S800 digit 0 (node adress 00 is not possible!)
S801 digit 10
Same node address must be selected in the corresponding armature converter.
example: node adress=13 ==> S800 = 3 and S801 = 1
Selection of communication speed is set by S1100

S1100:6 S1100:5 S1100:4 Baudrate Selection of armature
kBaud * converter
OFF OFF OFF 20 0
OFF OFF ON 50 1
OFF ON OFF 125 2
OFF ON ON 250 3
ON OFF OFF 500 4
ON OFF ON 800 5
ON ON OFF 888 6
ON ON ON 1000 7
* see Parameter 94.08, 94.09
Accessories
108
Diagnosis
All messages are sent to armature converter and displayed by armature converter control panel. If
communication is broken or node numbers are mixed up a simple fault display on SDCS-FEX-4 board
can be used. Therefore the unit is equipped with two small LED.
U730 = Green
U731 = Yellow
Following messages are displayed:
both OFF no 24V supply
green and yellow continues No firmware
green blinking 25 A / 35 A output active, waiting for DCSLINK communication
green continues 25 A / 35 A output active, DCSLINK communication OK
yellow blinking 5A output active (X100:2), waiting for DCSLINK communicat.
yellow continues 5A output active (X100:2), DCSLINK communication OK
green and yellow toggling:
X times yellow Y times green
X=1 Y=1 Alarm phase missed
Y=2 Alarm maximum temperature heatsink
X=2 Y=1 Fault DCS link serial communication failed

Y=2 Fault Synchronization fault
Y=3 Fault Overcurrent
Y=5 Fault Field AC supply voltage < 30V
Y=6 Fault Field AC supply voltage < 650V
Y=9 Fault maximum temperature heatsink
Y=12 Fault Auxiliary voltage
Y=14 Fault general hardware No RESET
Y=15 Fault general software No RESET
Accessories
109
RS232-Port
The RS232 interface is used for download the 'Field exciter firmware package'.
The default settings of this interface are as follows:
Signal level: RS232 (+12V / -12V)
Data format: UART
Message format: Modbus-Protocol
Transmission method: half-duplex
Baudrate: 9.600 Baud
Number of Data bits: 8
Number of Stop bits: 1
Parity-Bit: odd
X2: Description
1 not connectedßtext1
2 TxD
3 RxD
4 not connected
5 SGND Signal ground
6...9 not connected
5 1
9 6
The programming procedure is activated by setting S1:1-2 during auxiliary voltage is switched ON.
Setting for field exciter mode is S1:3-4 (default).
Accessories
110
Fuses and fuse holders

Type Resistance [mΩ] Fuse F1 Size Fuse holder
170M 1558 30 10A 660V UR 0 OFAX 00 S3L
170M 1559 21 21A 660V UR 0 OFAX 00 S3L
L1 L2 L3
170M 1561 15 25A 660V UR 0 OFAX 00 S3L
170M 1564 6 50A 660V UR 0 OFAX 00 S3L F1
170M 1565 4 63A 660V UR 0 OFAX 00 S3L
170M 1566 3 80A 660V UR 0 OFAX 00 S3L
170M 1568 1.8 125A 660V UR 0 OFAX 00 S3L
170M 3815 0.87 200A 660V UR 1 OFAX 1 S3
170M 3816 0.59 250A 600V UR 1 OFAX 1 S3
170M 3817 0.47 315A 660V UR 1 OFAX 1 S3
170M 3819 0.37 400A 660V UR 1 OFAX 1 S3
170M 5810 0.30 500A 660V UR 2 OFAX 2 S3
170M 6811 0.22 700A 660V UR 3 OFAX 3 S3
170M 6813 0.15 900A 660V UR 3 OFAX 3 S3
170M 6163 0.15 900A 660V UR 4 170H 3006
170M 6166 0.09 1250A 660V UR 4 170H 3006
Dimensions [mm] Size 0...4

Size a b c d e
0 78,5 50 35 21 15
Size 0...3 1 135 69 45 45 20
Indicator
2 150 69 55 55 26
3 150 68 76 76 33
a c
b
10
2
6
Fuse1_a.dsf
d
e
Size 4 Indicator
30
11
76
11
14 17
108 76
139
29 50 29
6
fuse2_a.dsf
Main dimensions of fuse holders

Fuse holder HxWxD [mm] Protection OFAX ...
OFAX 00 S3L 148x112x111 IP20
OFAX 1 S3 250x174x123 IP20
OFAX 2 S3 250x214x133 IP20 H
OFA X 2 S3
OFAX 3 S3 265x246x160 IP20
W D
170H 3006 (IP00)

110
A-A
M8
M10
M8
77
64
A
27
A 60
205 85
180
9
Ø
40
170H3006_a.dsf
M10
Accessories
111
Line chokes
Line chokes type ND 01...ND 16

Line chokes for use in industrial environment (minimum requirements), low inductive voltage drop, deep
commutation notches.
Line chokes ND01...ND06 are equipped with cables. The bigger ones ND07...ND16 are equipped with
busbars. When connecting them to other components, please take relevant standards into account in
case the materials are different. Don't use choke terminals as cable or busbar support!
Type Choke rated Weight Power loss recommended
L Irms Ipeak Voltage Fe Cu for armature
[µH] [A] [A] [UN] [kg] [W] [W] converter type
ND 01 512 18 27 500 2.0 5 16 DCS...-0025

ND 02 250 37 68 500 3.0 7 22 DCS...-0050
ND 03 300 37 68 600 3.8 9 20 DCS...-0050
ND 04 168 55 82 500 5.8 10 33 DCS...-0075
ND 05 135 82 122 600 6.4 5 30 DCS...-0110
ND 06 90 102 153 500 7.6 7 41 DCS...-0140
ND 07 50 184 275 500 12.6 45 90 DCS...-0250
ND 08 56.3 196 294 600 12.8 45 130 DCS...-0270
ND 09 37.5 245 367 500 16.0 50 140 DCS...-0350
ND 10 25.0 367 551 500 22.2 80 185 DCS...-0520
ND 11 33.8 326 490 600 22.6 80 185 DCS...-0450
ND 12 18.8 490 734 500 36.0 95 290 DCS...-0680
ND 13 18.2 698 1047 690 46.8 170 160 DCS...-0820
ND 14 9.9 930 1395 500 46.6 100 300 DCS...-1200
ND 15 10.9 1163 1744 690 84.0 190 680 DCS...-1500
ND 16 6.1 1510 2264 500 81.2 210 650 DCS...-2000

3
A X
B Y X, Y, Z
C Z A, B, C
A B C 60
A, B, C 0
0 100
X Y Z X, Y, Z
c
a
a1 b
ND1_to_6_a.dsf
d
Type a1 a b c d e f g
mm²
ND 01 120 100 130 48 65 116 4 8 6
e
ND 02 120 100 130 58 65 116 4 8 10

ND 03 148 125 157 63 80 143 5 10 10
ND 04 148 125 157 78 80 143 5 10 16
ND 05 148 125 157 78 80 143 5 10 25
ND 06 178 150 180 72 90 170 5 10 35
g
Accessories
112
H ±2
I (6x)
C ±1
15
G ±4
conduction to the mounting plate

F ±0.3
min 30 without varnish for

A
E±2
L C1
E ±2
A ±2
K
3 AST4 78 2 23 D5
3AFE 10014603
0 .0 1 88 mH
4 90 A
I ma x 7 34 A
A
7
A-A
15
ND7_to_12_c.dsf
F ±0.3
B ±1
Type A B C C1 E F G H I K L busbar
ND 07, 08 285 230 86 100 250 176 65 80 9x18 385 232 20x4
ND 09 327 250 99 100 292 224 63 100 9x18 423 280 30x5
ND 10, 11 408 250 99 100 374 224 63 100 11x18 504 280 60x6
ND 12 458 250 112 113 424 224 63 100 13x18 554 280 40x6
Line chokes type ND 13, 14 Line chokes type ND 15, 16

all busbars 40x10 all busbars 60x10
140 ±2 151±2
18x13(3x)
100 100 90
45 45 45
140 30
20
18
30
154 ±4
176 ±5
40
224 ±0.3
conduction to the mounting plate
A-A
316 ±0.3
ø13
A-A
min 30 without varnish for
min 30 without varnish

for conduction to the
10
342 ±2
440 ±2
13
123 ±2
mounting plate
147
ø13 15 ø13
40
30
60
50
80
15 15
290 ±1 150 ±2 40 30 140
ND13_14_c.dsf 147 48
A A
A A
(6x) 10x18
181±2 ND15_16_c.dsf
390±1
Accessories
113

Line chokes for use in light industrial/residential environment, high inductive voltage drop, reduced
commutation notches.
These chokes are designed for drives which usually operate in speed control mode at 400 V or 500 V
networks. Because of that a duty cycle has been taken into account. The percentage taken into account
for that duty cycle is different for 400 V and 500 V networks:
- for Urated supply = 400 V, DC curr. 1 = 90% of nominal current
- for Urated supply = 500 V, DC curr. 1 = 72% of nominal current
For easier reading the maximum average DC load current is listed instead of the percentage in the next
table.
Line chokes ND401...ND402 are equipped with terminals. The bigger ones ND403...ND413 are
equipped with busbars. When connecting them to other components, please take relevant standards
into account in case the materials are different.
Type Choke rated Weight Power loss Load Load
L Irms Ipeak Voltage Fe Cu DC curr. 1 DC curr.2
[mH] Line AC [A] [A] [UN] [kg] [W] [W] (f. Usupply=400V) (f. Usupply=500V)
ND 401 1000 18.5 27 400 3.5 13 35 22.6 18
ND 402 600 37 68 400 7.5 13 50 45 36
ND 403 450 55 82 400 11 42 90 67 54
ND 404 350 74 111 400 13 78 105 90 72
ND 405 250 104 156 400 19 91 105 127 101
ND 406 160 148 220 400 22 104 130 179 143
ND 407 120 192 288 400 23 117 130 234 187
ND 408 90 252 387 400 29 137 160 315 252
ND 409 70 332 498 400 33 170 215 405 324
ND 410 60 406 609 400 51 260 225 495 396
ND 411 50 502 753 400 56 260 300 612 490
ND 412 40 605 805 400 62 280 335 738 590
ND 413 35 740 1105 400 75 312 410 900 720

Type A B C D E F ØG ØH
ND 401 160 190 75 80 51 175 7 9
ND 402 200 220 105 115 75 200 7 9
Terminals: WAGO Type 202

170 UL File E45172
A X B Y C Z
øH
tin-coated
X Y Z
A
A B C
øG ø G+5
F±1 E±2
B C
Accessories
114

Type A B C D E F ØG ØH ØK
ND 403 220 230 120 135 100 77.5 7 9 6.6
ND 404 220 225 120 140 100 77.5 7 9 6.6
ND 405 235 250 155 170 125 85 10 9 6.6
ND 406 255 275 155 175 125 95 10 9 9
ND 407 255 275 155 175 125 95 10 9 11
ND 408 285 285 180 210 150 95 10 9 11
øH
tin-coated
X Y Z
øK AL
A
A B C
ø G+5
50 45 10 E ±2
F ±2 C

Type A B C D E F ØG ØH ØK
ND 409 320 280 180 210 150 95 10 11 11
ND 410 345 350 180 235 150 115 10 13 14
ND 411 345 350 205 270 175 115 12 13 2x11
ND 412 385 350 205 280 175 115 12 13 2x11
ND 413 445 350 205 280 175 115 12 13 2x11
øH
tin-coated
A B C
X Y Z
øK AL
A
A B C
X Y Z
øG+6
12 E ±2
F ±2 C
D
Accessories
115
Autotransformer T3
Type for Field curr. Transformer's Weight Power loss Fuse F3
secondary current
IF Isec [kg] PV [W] [A]
Uprim = 500 V; 50/60Hz
T 3.01 ≤6 A ≤7 A 15 65 10
T 3.02 ≤12 A ≤13 A 20 100 16
T 3.03 ≤16 A ≤17 A 20 120 25
T 3.04 ≤30 A ≤33 A 36 180 50
T 3.05 ≤50 A ≤57 A 60 250 63
Uprim = 690 V; 50/60Hz
T 3.11 ≤6 A ≤7 A ➀ 15 80 10
T 3.12 ≤12 A ≤13 A ➀ 20 125 16
T 3.13 ≤16 A ≤17 A ➀ 30 150 20
T 3.14 ≤30 A ≤33 A 60 230 50
T 3.15 ≤50 A ≤57 A 60 320 63
➀ 690 V transformer input cannot be used for the field converters SDCS-FEX-1 and SDCS-FEX-2 (isolation only 600
V max.)
A
F3 F3
T3 T3
h
Type A B C D h e G
T 3.01 / T 3.11 210 110 112 75 240 10x18 95
T 3.02 / T 3.12 210 135 112 101 240 10x18 95
T 3.03
T 3.13 230 150 124 118 270 10x18 95
T 3.04 260 150 144 123 330 10x18 95
G
T 3.14 295 175 176 141 380 12x18 95
T 3.05 / T 3.15
C D e
B
Line choke L3 for SDCS-FEX-2
2 1 3 4
1000
1 2
3 4
Type line choke data L3

Weight Pow
max70
er
L Irms Ipeak loss
[µH] [A] [A] [kg] [W] [mm²]
ND30 2x >500 16 16 1.1 8 2
4.5 Ø 55 37
max 80 52
Accessories
116
Supply transformer T2 for electronics and fan

The supply transformer T2 has been re-designed. The new power and current rating allows to supply
then 2-phase fans and the electronics by one transformer only in case A5 converters are used in a 12-
pulse configuration.
They differ in their electrical data and therefore can be identified by their name plate.
Input voltage: 230/380...690 V/1~; ±10%
F2 Frequency: 50...60 Hz
Output voltage: 115/230 V/1~
T2
Type Power Weight Fuse F2 Isec Power loss
[VA] [kg] [A] [A] [W]
T2 1400 15 16 6 (0...230 V) 100
230 V 115 V T2_a.dsf 0V
12 (0...115 V)
6.3 mm Faston
150
115
230
380
400
415
450
500
525
575
600
660
690
0
35
106 128
125 148
T2_dim.dsf 100 +-5
Application hint:
230 V The transformer is designed to work as a 230 V / 230 V transformer to open/

avoid ground loops. This is done via the 380 V and 600 V taping according to
F2
the left picture.
T2
230 V 115 V T2_a.dsf 0V
Accessories
117
Optical cables
For the bus communication of the DCS converters there are different optical cables available.
Kind of cable Connector cable length Ident. no. Fig.
plastic fibre optic single cable plug 0.5...20 m 3ADT 693324 1
plastic fibre optic double cable plug 0.5...20 m 3ADT 693318 2
HCS silica (double) without plastic jacket plug 30...50 m 3ADT 693355 3
HCS silica (double) with plastic jacket plug 50...200 m 3ADT 693356 4
Figure 1
L
blue black
for DCS 400

DCS 500
DCS 600
Figure 2
L
blue black
black blue
Figure 3
see manual NDBU 3ADW 000 100 R0201

L
for DCS 600 selected channels.

orange orange
5 mm
black black
Figure 4
L
blue blue
red
8 mm red
Accessories
118
Accessories
3ADW000194R0201_Rev B
10_2005
ABB Automation Products GmbH

Postfach 1180
68619 Lampertheim • GERMANY
Telefon: +49 (0) 62 06 5 03-0
Telefax: +49 (0) 62 06 5 03-6 09
www.abb.com/dc
*194R0201A5400000*
*194R0201A5400000*

Hardware Manual DCS800 Drives (20 To 5200 A)

Uploaded by

Copyright:

Available Formats

Hardware Manual DCS800 Drives (20 To 5200 A)

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hardware Manual DCS800 Drives (20 To 5200 A)

Uploaded by

Copyright:

Available Formats

DCS800

Tools + optical link

DCS800 00A Enclosed

DCR 500 rebuild system

Serial interfaces vdB

Fieldbus Adapter with DC Drives RCAN-02 (CANopen) vdB

Fieldbus Adapter with DC Drives RETA (Ethernet) vdB

¤ 2005 ABB Automation Products GmbH. All rights reserved.served.

3ADW000194R0201 DCS800 Hardware Manual e b

What this chapter contains

To which products this chapter applies

Use of warnings and notes

Dangerous voltage warning warns of high voltage which can cause

General warning warns about conditions, other than those caused by

Installation and maintenance work

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)

WARNING! The printed circuit boards contain components sensitive to electrostatic

• Make sure that grounding conductors are adequately sized as required by

• In a multiple-drive installation, connect each drive separately to protective

• Minimize EMC emission and make a 360° high frequency grounding of

• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

Fibre optic cables

• Ensure sufficient cooling.

• Do not fasten the drive by riveting or welding.

• Do not activate automatic fault reset functions of the Standard Application

DCS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Planning the electrical installation

What this chapter contains

Size D1...D4 Size D5

Position Plus code

3ADW000194R0201 DCS800 Hardware Manual e b

X51X52 DSL X53

DCS link twisted pair

X51X52 DSL X53

3ADW000194R0201 DCS800 Hardware Manual e b

3ADW000194R0201 DCS800 Hardware Manual e b

DCS link twisted pair

Unpacking the unit

Type designation label

Requirements for the installation site

Main air flow out

Air baffle plates

Air baffle plate

Main air flow in

Mounting the converter module D6 inside an enclosure

Top view Top view

Cooling air outlet

tion can be made.

When mounting the right angle busbars or connecting

Example right side connection

Mounting the converter module D7 inside an enclosure

electronics power supply

converter fan control cables

View from bottom

Free space around the conerter module

Air entry through bottom plate

Planning the electrical installation

What this chapter contains