DCS800 Hardware Manual DCS800-E0 Panel Solution DCS800-E draw_3d.dsf DCS800 Drive Manuals Language ES F x x Public. number 3ADW000191 3ADW000211 E x x D x I x 3ADW000190 3ADW000192 3ADW000194 3ADW000194Z0301 3ADW000193 3ADW000032 3ADW000163 3ADW000195 3ADW000196 3ADW000136 3ADW000213 x x x x x x x x x p x x x x x x p x x x x p x Drive Tools DriveWindow 2.x - User's Manual DriveOPC 2.x - User's Manual Optical DDCS Communication Link DDCS Branching Units - User´s Manual 3BFE64560981 3BFE00073846 3AFE63988235 3BFE64285513 x x x x DCS800 Applications PLC Programming with CoDeSys 61131 DCS800 target +tool description - Application Program CoDeSys_V23 3ADW000199 x x DCS800 Crane Drive DCS800 Crane Drive Manual suppl. DCS800 Crane Drive Product note 3AST004143 PDC5 EN REVA x p DCS800 Winder ITC DCS800 Winder Product note DCS800 Winder description ITC Winder Questionnaire PDC2 EN 3ADW000308 3ADW000253z x x x DCS800-E Panel Solution Flyer DCS800-E Panel solution Hardware Manual DCS800-E 3ADW000210 3ADW000224 x x DCS800-A Enclosed Converters Flyer DCS800-A Technical Catalogue DCS800-A Installation of DCS800-A 3ADW000213 3ADW000198 3ADW000091 x x p DCS800-R Rebuild System Flyer DCS800-R DCS800-R Manual DCS500/DCS600 Size A5...A7, C2b, C3 and C4 Upgrade Kits 3ADW000007 3ADW000197 3ADW000256 x x x Extension Modules RAIO-01 Analogue IO Extension RDIO-01 Digital IO Extension AIMA R-slot extension 3AFE64484567 3AFE64485733 3AFE64661442 x x x Serial Communication Drive specific serial communication NETA Remote diagnostic interface 3AFE64605062 x 3AFE64504215 x Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3AFE64506005 x Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x Fieldbus Adapter with DC Drives RMBA (MODBUS) 3AFE64498851 x 3AFE64539736 x DCS800 Quick Guide DCS800 Tools & Documentation CD DCS800 Converter module Flyer DCS800 Technical Catalogue DCS800 Hardware Manual DCS800 Hardware Manual DCS800 update DCF503B/DCF504B Firmware Manual DCS800 Installation according to EMC Technical Guide Service Manual DCS800 12-Pulse Manual CMA-2 Board Flyer Hard - Parallel Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) Fieldbus Adapter with DC Drives RCAN-02 (CANopen) Fieldbus Adapter with DC Drives RETA (Ethernet) x -> existing p -> planned Status 10.2008 DCS800 Drive Manuals-List_h.doc CN RU x x x x x x x x x p x x x x x x 3 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 D7 and field exciter units DCF80x. 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 3ADW000224R0201 DCS800-E0 Hardware Manual e b 4 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 C+ and D- 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 C+ and D- cables are connected with the proper terminal. 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 and RDIO. • DCS800 with enclosure extension: Before working on the drive, isolate the whole drive from the supply. • Safety instructions 3ADW000224R0201 DCS800-E0 Hardware Manual e b 5 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. Use grounding strip: PE ABB order no.: 3ADV050035P0001 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 3ADW000224R0201 DCS800-E0 Hardware Manual e b 6 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 sizes D4...D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back. DCS800 sizes D5...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. 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 means); instead, use the control panel keys and , or commands via the I/O board of the drive. Safety instructions 3ADW000224R0201 DCS800-E0 Hardware Manual e b 7 • • • Mains connection You can use a disconnect switch (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 disconnect used must be a disconnect switch 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 disconnect 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 case of 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. Note: • When the control location is not set to Local (L not shown in the status row of the display), the stop key on the control panel will not stop the drive. To stop the drive using the control panel, press the LOC/REM key and then the stop key . Safety instructions 3ADW000224R0201 DCS800-E0 Hardware Manual e b 8 Table of contents Safety instructions 3 What this chapter contains..........................................................................................................3 To which products this chapter applies .......................................................................................3 Use of warnings and notes .........................................................................................................3 Installation and maintenance work..............................................................................................4 Grounding........................................................................................................................5 Mechanical installation ................................................................................................................6 Operation ....................................................................................................................................6 Table of contents 8 Mechanical Installation 10 How to use this manual .................................................................................................10 Associated publications .................................................................................................10 DCS800-E0 lifted by crane ............................................................................................11 Before installation ..........................................................................................................11 Cabinet installation ........................................................................................................12 Mounting TYRAK cabinet..........................................................................................................13 Preparations and considerations that can be done before the system shut down ........13 Preparing the cabinet ....................................................................................................13 Fixing the mounting supports ......................................................................................14 Inserting the sliding rails..............................................................................................15 Push the DCS800-E0 panel into the cabinet...............................................................16 Removing the Sliding Rails .........................................................................................16 Mounting of the CDP312 or DCS800 panel on the cabinet door (optional) ................17 Mounting Rittal cabinet .............................................................................................................18 Fixing the mounting supports ......................................................................................18 Preparing the backside ...............................................................................................19 Push the DCS800-E0 panel into the cabinet...............................................................19 Power loss...................................................................................................................19 Electrical installation 20 What this chapter contains ............................................................................................20 Checking the insulation of the assembly .......................................................................20 Supply voltage ...............................................................................................................21 Connecting the power cables ........................................................................................21 Supply transformer T2 for electronics and fan...............................................................21 Cross-sectional areas - Tightening torques...................................................................22 AC-connection ...............................................................................................................23 DC-connection...............................................................................................................23 Control cable connection ...............................................................................................24 Commissioning ..............................................................................................................24 Installation Checklist 25 Technical Data 27 Table of contents 3ADW000224R0201 DCS800-E0 Hardware Manual e b 9 Environmental Conditions..............................................................................................27 Harmonized Standards ...............................................................................................28 DCS800-E0 Panel Solution unit types...........................................................................29 Fuse switch OESA.........................................................................................................30 Drilling pattern for CDP 312...........................................................................................31 Drilling pattern for DCS800 control panel (door mounting kit ACS/H-EXT)...................32 Dimension of DCS800-E0 panel and fixing holes..........................................................33 Swing I/O unit, where the IOB-2x and IOB-3 are mounted in a vertical position ...........34 Lower mounting support ................................................................................................35 Upper mounting support ................................................................................................36 Table of contents 3ADW000224R0201 DCS800-E0 Hardware Manual e b 10 Mechanical Installation How to use this manual The purpose of this manual is to provide you with the information necessary to mount the DCS800-E0 Panel into an empty cabinet. As an example the mounting into an old ASEA TYRAK 8A cabinet is shown. However the given information and described procedures are also valid for other types of cabinets – mostly with only slight modifications. For that detailed dimension drawings are given for you to check the compatibility with your cabinet. The mounting is described using a mounting kit, consisting of mounting supports and sliding rails. These are optional available and not in the standard scope of delivery. You may check if you can use them for your cabinet by the dimension drawing given in the appendix This manual does not describe the commissioning of the DCS800 module itself. For that please refer to the documentation of the module Associated publications For the commissioning of the module please refer to the module’s documentation, that can be found on the DC Drives Documents CD-ROM which is part of the document binder delivered with every DCS800-E0 Unit. First information can be found in the DCS800 Quick guide (3ADW000191) which too is part of the enclosed documentation For mounting of the optional CDP312 Door Mounting kit please refer to the corresponding installation instruction. Basic information about the DCS800-E0 can be found in the DCS800-E0 Flyer, document no. 3ADW000210 Detailed Circuit Diagrams and a list of apparatus are part of the enclosed documentation of every DCS800-E0 panel. For installation of converters in accordance with EMC, see document no. 3ADW000032 Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 11 DCS800-E0 lifted by crane DCS800-E crane lift.dsf 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. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 12 Cabinet installation Preventing cooling air recirculation If the cabinet is equipped with filters the rated current of DCS800-E0 device must be reduced and air recirculation inside has to be prevented. Main air flow out Hot Air baffle plates COOL AREA Main air flow in prev recirc.dsf Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 13 Mounting TYRAK cabinet Preparations and considerations that can be done before the system shut down If the DCS800-E0 is used to revamp an existing DC-Drive, usually all work should be done as fast as possible to keep the system power down small. To decrease this time a lot of preparations and considerations can be done before the shut down. These are for example: • • • • • • • Check the dimensions of the DCS800-E0 and the clearance inside the cabinet to see if the DCS800-E0 panel fits. How will the DCS800-E0 panel will be brought into the cabinet? Check availability of a crane or a fork-lift. The DCS800-E0 panel offers handles for manual movement. The weights of the different DCS800-E0 types are given in the appendix. How will the Panel be fixed to the cabinet? Check if you can use the optional available mounting supports and sliding rails (Dimensions can be found in the appendix). If the mounting kit does not fit to your type of cabinet prepare the cabinet or a mounting aid according to the fastening holes on the DCS800-E0 panel. If you want to mount the CDP312 onto the cabinet door, you may do this before the system shut down. You can fix the panel either directly to the door by using the enclosed drilling pattern or you use the optional available CDP312 door mounting kit. Check AC and DC power cables. Is their length still sufficient for the DCS800-E0 panel? DC Output terminals at the very bottom of the Power unit are available as option, as well as AC connection cables. Take also into consideration if you will reuse components like load switches or chokes. Check also the control and tacho or encoder cables. Is their length still sufficient for the DCS800-E0 panel? If not you may purchase some optional available spare cables (check price list or flyer). Set T2 transformer tapping on correct input voltage. This list is intended to give you some useful hints to think about. It cannot be complete and you should consider the individual local situation. Preparing the cabinet Remove all old equipment that will not be re-used. For a typical TYRAK 8 Revamp you may re-use besides the cabinet and busbars the load switch and the main fuses. Note: Typically only line fuses were used in TYRAKs as incoming AC fuses. They can be left in the cabinet and re-used, but the DCS800-E0 has its own SCR-fuses to protect the DCS-module. The TYRAK line chokes may also be re-used. But It’s recommended to use also the 1% uk-chokes on the DCS800-E0 panel, as the TYRAK chokes typical have a very low inductance. But due to the low inductance the losses are very low, and so it may even be operated in serial to the DCS800-E0 chokes, they do not interfere. All external equipment, like Residual current detection or field transformer can be re-used, but it’s recommended to remove it from the cabinet for installation of the DCS800-E. Ensure that there is enough free space for mounting of the DCS800-E0 panel (check dimension drawings in the appendix). Consider also some free space for connecting the cables. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 14 Fixing the mounting supports Fix the upper and lower mounting support to the cabinet according to following pictures. Screws M6 are delivered together with the supports. The upper and lower mounting rails should be fixed into the cabinet with a distance of 1520 mm between their lower edges. If your cabinet’s grid of fixing holes in the mounting rail does not allow this distance, you may vary the distance by some mms due to the elongated fixing holes in the panel. The total position of the two mounting supports in the cabinet depends on its clearance and the height of its base. It’s useful to install the supports in a way that the lower mounting support is at the same height of the cabinet's base. For a Standard TYRAK 8 cabinet a height of 122 mm from the floor is recommended. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 1520 mm from bottom to bottom 15 from 12 2 mm * gr ound * for Tyrak 8 standard cabinets Inserting the sliding rails The sliding rails are designed for easily sliding the DCS800-E0 into the cabinet until its weight is carried fully by the lower mounting support. The rails are put onto the upper mounting support. Their construction prevents the rails from slipping off. In the front the sliding rails are put onto the cabinet base. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 16 Push the DCS800-E0 panel into the cabinet. When using a crane, put the DCS800-E0 onto the front part of the sliding rails. When using a fork lift, bring the panel to the same level of the sliding rails. Then push the DCS800-E0 panel into the cabinet against the support in the back of the cubicle. To put the DCS800-E0 panel onto the lower mounting support, it has to be lifted slightly in the back. For that it’s useful to throw it a little bit in direction outside the cubicle at the top front edge. Now the DCS800-E0 panel can be fixed to the upper and lower mounting support with the enclosed M10-srews (17mm-size nut or wrench needed). Removing the Sliding Rails When the DCS800-E0 panel is fixed to the cabinet, the sliding rails can be removed. First, remove the sliding rail below the power unit. Then move the remaining sliding rail also below the power unit, so that it can be easily removed. The sliding rails now can be re-used for mounting of another DCS800-E0 panel. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 17 Mounting of the CDP312 or DCS800 panel on the cabinet door (optional) CDP312 The control panel CDP312 can be easily mounted onto the cabinet door by fixing it with two screws. For that 3 holes have to be put into the cabinet door: 2 holes (5 mm Ø) for the screws and one hole 14x16 mm (wxh) for the connection cable. Drilling pattern see appendix. Following items are needed in addition (not in the standard scope of delivery) • 2 pc. screws (M4x10) • 1 pc. control cable COM-8 board Æ CDP312, 3 m long, Id-No. DCA0021499P0001 (refer to pricelist) • SDCS-COM-8 board DCS800 control panel 2 holes (4 mm Ø) for the screws and one hole (24 mm Ø) for the connection cable. Drilling pattern see appendix. Following items are needed in addition (not in the standard scope of delivery) • 2 pc. screws (M3x10) • control cable set ACS/H-EXT kit 3AFE68294673 The picture shows an example of CDP 312 mounted directly onto an old TYRAK cabinet door. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 18 Mounting Rittal cabinet The DCS800-E0 can be mounted in all Rittal TS 8-cabinets starting from size 600x2000x600 mm whatever there is a mounting plate or not. For the mounting four punched sections are required (TS8612.560) (if there is no mounting plate, four more for the backside) and three support rails (TS4396.500). The total position of the mounting supports and the fixing holes depend on the cabinet’s height. The following recommends depend on a standard Rittal TS 8 (600x2000x600 mm). Fixing the mounting supports Fix on each side of the cabinet two punched sections directly on top of each other, so that the upper edge is located 200 mm above the floor. 200 mm Support rails Punched sections 120 mm On top of the punched sections the support rails must be fixed in a clearance of Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 19 120 mm to each other and 15 mm to the front. The support rails are needed for easily sliding the DCS800-E0 into the cabinet. Preparing the backside When using a mounting plate prepare the fixing holes (see the drilling pattern page 33). When using the punched sections fix also two of them in top of each other. The lower supporting surface 250 mm from the floor, the upper 1800 mm from the floor. Push the DCS800-E0 panel into the cabinet When using a crane, put the DCS800E0 onto the front of the support rails. When using a fork lift, bring the panel to the same level of the support rails. Then push the DCS800-E0 panel into the cabinet. If the panel should be mounted in a cabinet with the width of 600mm the panel first must be turned a little and then pushed into the cabinet because the opening is a bit too small. Now the DCS800-E0 panel can be fixed with either self tapping M5-screws or cage nuts (TS 4164.000) with M6screws (SZ 2504.500). When using a 600 mm deep Rittal cabinet remove the square-cut pipe frame. Power loss The power loss (see page 29) cannot be dissipated only by free convection. Use extra cooling see Rittal brochure “System Climate Control”. Mechanical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 20 Electrical installation What this chapter contains 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+, FPE ohm Electrical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 21 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. contactor, 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 Fan AC voltage for field circuit AC voltage for armature circuit X99, tapping of T2 transformer Terminals U1, V1, W1 (if used) U1, V1, W1 Connecting the power cables Grounding and screening of power cables see manual Technical Guide, see Reference Cross sectional areas and tightening torques of power cable see chapter Planning the electrical installation Supply transformer T2 for electronics and fan Aux transformer setting F2 0 115 230 0 380 400 415 450 500 525 575 600 660 690 T2 230 V 115 V T2_a.dsf 0V Electrical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 22 Application hint: 230 V F2 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 tapping according to the left picture. T2 230 V 115 V T2_a.dsf 0V Cross-sectional areas - Tightening torques Recommended cross-sectional area to DINVDE 0276-1000 and DINVDE 0100540 (PE) trefoil arrangement, up to 50°C ambient temperature Converter type U1, V1, W1(AK1, AK3, AK5) Connection at DC fuse holder DCS800-E01-0020-04/05-960t DCS800-E02-0025-04/05-960t DCS800-E01-0045-04/05-960t DCS800-E02-0050-04/05-960t DCS800-E01-0065-04/05-960t DCS800-E02-0075-04/05-960t DCS800-E01-0090-04/05-960t DCS800-E02-0100-04/05-960t DCS800-E01-0125-04/05-960t DCS800-E02-0140-04/05-960t DCS800-E01-0180-04/05-960t DCS800-E02-0200-04/05-960t DCS800-E01-0230-04/05-960t DCS800-E02-0260-04/05-960t DCS800-E01-0315-04/05-960t DCS800-E02-0350-04/05-960t DCS800-E01-0405-04/05-960t DCS800-E02-0450-04/05-960t DCS800-E01-0470-04/05-960t DCS800-E02-0520-04/05-960t DCS800-E01-0290-06-960t DCS800-E02-0320-06-960t PE stud M12 Field WDU 4 / 10 [mm²] max. [mm²] IDC Iv [A~] 15 18 34 37 50 55 67 73 95 103 132 147 172 184 234 266 300 332 328 369 213 233 C1, D1 (AM1, KM1) Connection at ABB fuse switch XLP... / [mm²] / stud 1 x 10 / M8 00 1 x 25 / M8 1 x 25 / M10 1 x 35 / M10 1 1 x 95 / M10 1 x 95 / M10 2 2 x 70 / M12 2 x 95 / M12 3 2 x 95 / M12 2 1 x 95 / M12 [A-] 18 22 41 45 61 67 81 90 115 125 160 180 210 225 285 300 365 405 400 450 260 285 OFAX... / [mm²] / stud 1 x 6 / M10 2 x00S1L 1x6 6 1 x 25 / M10 2 x 1S1 1 x 35 / M10 1 x 25 1 x 95 / M10 1 x 95 / M10 1 x 25 2 x 2S1 2 x 50 / M10 16 1 x 50 2 x 3P1 2 x 95 / M10 2 x 2S1 1 x 95 / M10 Tightening torques: M6 => 6 Nm; M8 => 13 Nm; M10 => 25 Nm; M12 => 50 Nm Electrical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 1 x 50 16 23 AC-connection The AC-connection point is at the top of the power unit, at the in-coming terminals of the fuse-holder / fuse-switch. AC-connection cables with cable lugs are available as option. DC-connection The DC-connection point is at the DC output terminals of the DCS module, or at the secondary side of the DC-fuse-holder, if ordered. If the existing motor cables are too short, a DC block terminal at the very bottom of the DCS800-E0 panel is available as option. The block terminals are capable for one cable, if double armature cables are used a short 3-hole-busbar (not in the scope of delivery) has to be used. DCS module output terminal DC fuse output terminal DC connection extension (option) Electrical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 24 Control cable connection The control cables usually are connected to the I/O-cards on the I/O unit. Rails for fixing the cable shields are included for every I/O card. 4x2x0.5 mm² shielded cable for IOB-3, pulse transmitter, etc. and 4 m long cable 7x1 mm² unshielded control cable, all with cable lugs are available as option. Commissioning After all electrical connections are done the installation will be completed with the commissioning of the DCS-Module. Therefore please refer to the DCS-ModuleDocumentation Further parts of electrical installation e.g. • • • • • • • Location R-Extension and Interface Modules I/O Board Configuration Pulse encoder connection Pulse encoder receiver Connecting the signal and control cables Routing the cables DCS Link Wiring see Hardware manual publication no. 3ADW000194 Electrical Installation 3ADW000224R0201 DCS800-E0 Hardware Manual e b 25 Installation Checklist The mechanical and electrical installation of the DCS800-E0 should be checked before start-up. It is advisable to go through the checklist below together with another person. Study carefully the Safety Instructions on the first pages of this manual before attempting any work on, or with, the unit. MECHANICAL INSTALLATION (see chapter Mechanical Installation) The ambient operating conditions are acceptable (e.g. environmental conditions in the chapter Technical data, fan data in the DCS800 hardware manual and free space requirements in chapter - Mechanical Installation) The unit is mounted properly Cooling air will flow freely: • the lifting bars or sliding rails (if used) are removed • the cabinet roof is attached properly • the finger protections are mounted properly Installation Checklist 3ADW000224R0201 DCS800-E0 Hardware Manual e b 26 ELECTRICAL INSTALLATION (see chapter Electrical Installation) The AC busbars and PE busbars are properly connected (see chapter Mechanical Installation) The internal control cables are properly connected The converter unit and cabinets are earthed properly The mains voltage matches the DC converter nominal input voltage The setting of the internal 220/115 V transformer T2 corresponds to the supply voltage The mains (input power) connections at U, V and W are OK The appropriate mains fuses are installed for units D1, D2, D3, D4 (see chapter Technical Data) Motor cable routing (armature and excitation) is OK Check that the screens are properly installed at the motor and in the drive cabinet The connections at L+, L-, F+ and F- are OK The control connections are OK If pulse encoder is used, check the encoder cables and correct direction of rotation (see chapter Technical Data) PT 100, PTC, Klixon cables: Check that the connections are appropriate for the type of sensor used in the motor Check the prevention of unexpected start-up (on inhibit, coast stop) cables Check the emergency stop cables For all external cables make sure that both ends of the cables are connected and the cables do not cause any damage or danger when power is being switched on Cleanliness of the cabinets and surroundings, e.g.: • there are no tools or other foreign objects inside the cabinets or waste left from installation e.g. cable trimmings • there is no garbage under the cabinets (the cooling air fan will draw the garbage inside the cabinets) • use a vacuum cleaner to remove any dirt. Do not use compressed air! Installation Checklist 3ADW000224R0201 DCS800-E0 Hardware Manual e b 27 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 Hardware extension RDIO Digital I/O Extension DCS800 1131 Programming target Branching units NDBU-95 publ.no.:3AFE64484567 publ.no.:3AFE64485733 publ.no.:3ADW000199 publ.no.:3ADW000100 Environmental Conditions System connection Voltage, 3-phase: Voltage deviation: Rated frequency: Static frequency deviation: 230 to ≤ 1000 V acc. to IEC 60038 ±10% continuous; ±15% short-time * 50 Hz or 60 Hz 50 Hz ±2 %; 60 Hz ±2 % Environmental limit values Permissible cooling air temperat. - at converter module air inlet: with rated DC current: w. different DC curr. acc. Fig. below: - Options: Relative humidity (at 5...+40°C): Relative humidity (at 0...+5°C): Change of the ambient temp.: Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz df/dt: 17 % / s * = 0.5 to 30 cycles. Please note: Special consideration must be taken for voltage deviation in regenerative mode. Degree of protection Converter Module and options (line chokes, fuse holder, field supply unit, etc.): IP 00 / NEMA TYPE OPEN Enclosed converters: IP 20/21/31/41 Paint finish Converter module: light grey RAL 9002 Site elevation <1000 m above M.S.L.: Enclosed converter: >1000 m above M.S.L.: Size D1 D2 D3 D4 D5 D6 D7 light grey RAL 7035 Sound pressure level LP (1 m distance) as module 55 dBA 55 dBA 60 dBA 66...70 dBA, depending on fan 73 dBA 75 dBA 82 dBA Vibration enclosed conv. 54 dBA 55 dBA 73 dBA 77 dBA Shock Transport in original package 1.5 mm, 2...9 Hz 0.5 g, 9...200 Hz 7 g / 22 ms 0.3 mm, 2...9 Hz 0.1 g, 9...200 Hz 4 g / 22 ms Effect of the site elevation above sea level on the converter’s load capacity 0 to +40°C 5 to 95%, no condensation 5 to 50%, no condensation < 0.5°C / minute Storage temperature: Transport temperature: Pollution degree (IEC 60664-1, IEC 60439-1): Vibration class as module 1.2 m 78 dBA 73 dBA 80 dBA 0 to +55°C 0 to +40°C +30 to +55°C -40 to +55°C -40 to +70°C 2 3M3 - D1...D4 3M1 - D5...D7 100%, without current reduction with curr. reduct., see Fig. below Short circuit withstand rating The DCS800 is suitable for use in a circuit capable of delivering not more than: 65 kA rms symmetrical amps at maximum 600 VAC 1.0 m 0.25 m Shock monitor 100 kA rms symmetrical amps at maximum 600 VAC Effect of the ambient temperature on the converter module load capacity 110 100 90 100 80 90 70 80 60 50 1000 70 2000 3000 Current reduction to (%) 4000 5000 m 30 35 40 45 50 55°C Current reduction to (%) for converter modules Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 28 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 Machinery Directive 98/37/EEC 93/68/EEC Low Voltage Directive 73/23/EEC 93/68/EEC EMC Directive 89/336/EEC 93/68/EEC Enclosed converter Declaration of Incorporation EN 60204-1 [IEC 60204-1] EN 60204-1 [IEC 60204-1] Declaration of Conformity EN 61800-1 [IEC 61800-1] EN 60204-1 [IEC 60204-1] EN 60204-1 [IEC 60204-1] EN 60204-1 [IEC 60204-1] Declaration of Conformity EN 61800-3 ➀ [IEC 61800-3] EN 61800-3 ➀ [IEC 61800-3] ➀ in accordance with 3ADW 000 032 ➀ in accordance with 3ADW 000 032/3ADW 000 091 (Provided that all installation instructions concerning cable selection, cabling and EMC filters or dedicated transformer are followed.) 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 • see UL Listingwww.ul.com / certificate no. E196914 UL types: on request Approval: cULus The spacings in the modules were evaluated to table 36.1 of UL 508 C. Spacings also comply with table 6 and table 40 of C22.2 No. 14-05. >600 V to 990 V • or on request EN / IEC xxxxx see table above. Available for converter modules including field exciter units. EN / IEC types: on request (for details see table above) Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 29 DCS800-E0 Panel Solution unit types DC I ➀ [A] Unit type 400 V / 525 V DCS800-E01-0020-04/05-960t DCS800-E02-0025-04/05-960t DCS800-E01-0045-04/05-960t DCS800-E02-0050-04/05-960t DCS800-E01-0065-04/05-960t DCS800-E02-0075-04/05-960t DCS800-E01-0090-04/05-960t DCS800-E02-0100-04/05-960t DCS800-E01-0125-04/05-960t DCS800-E02-0140-04/05-960t DCS800-E01-0180-04/05-960t DCS800-E02-0200-04/05-960t DCS800-E01-0230-04/05-960t DCS800-E02-0260-04/05-960t DCS800-E01-0315-04/05-960t DCS800-E02-0350-04/05-960t DCS800-E01-0405-04/05-960t DCS800-E02-0450-04/05-960t DCS800-E01-0470-04/05-960t DCS800-E02-0520-04/05-960t 600 V DCS800-E01-0290-06-960t DCS800-E02-0320-06-960t t=1 Standard type P&P type t=2 Voltage class: (example: DCS800-E02-0025-04-960t) 4 400V 5 525V 6 600V DCS800-E0 Panel Solution unit types Up to DCS800-E02-0350-04/05-960t From DCS800-E01-0405-04/05-960t Power loss ➁ [kW] 18 22 41 45 61 67 81 90 115 125 160 180 210 225 285 300 365 405 400 450 <0.58 <0.58 <0.65 <0.65 <0.72 <0.72 <0.90 <0.95 <1.10 <1.15 <1.50 <1.55 <1.60 <1.60 <1.85 <1.90 <2.47 <2.55 <2.57 <2.70 260 285 <1.85 <1.85 Weight Air volume [kg] [m³/h] 90 91 95 103 360 103 121 126 141 720 144 126 360 ➀ Given Ratings are typical values for mounting in IP 21 cabinets; actual values may differ and are strongly depending on the cabinet and its cooling, especially with higher protection classes ➁ Values are valid for Standard Scope of delivery without options Air flow [m3/h] freely blowing 312(50Hz)/360(60Hz) 624(50Hz)/720(60Hz) Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 30 Fuse switch OESA M6 Bolt and nut M6 Bolt M6 Fuse switch OESA_a.dsf Mounting the fuse switch (option) Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 31 Drilling pattern for CDP 312 Ø5 6 6 15 11 1 2 16 14 166 Silhuette of panel CDP 312 in full-scale Holes to be made: 1 Ø 5mm holes for fixing screws (M4) 2 Hole for cable 1 6 6 Ø5 80 Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 32 Drilling pattern for DCS800 control panel (door mounting kit ACS/H-EXT) Mounting Template scale 1:1 Ø 3.5 (2x) Ø 24 22.5 (outline of the connector) 30.6 70.5 (outline of the panel) 87.1 56 Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 33 Dimension of DCS800-E0 panel and fixing holes Clearance min. 200 mm air exit 515 25 195 320 1597 1523 1519 +9,5mm -15,5mm air entry A (grid) 32 515 30 40 125 13 35 DCS800-E_dimensions.dsf 35 250 air entry B air exit 320 x 350 mm air entry 320 x 350 mm Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 34 Swing I/O unit, where the IOB-2x and IOB-3 are mounted in a vertical position Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 35 548 14 80 35 10 46.5 125 246.5 °12.7 250 14 70 45 10 40 9 9 18 45 M6 45 15 lower_mounting_support.dsf Lower mounting support Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 20 27 14 46.5 125 246.5 548 520 °12.7 548 °12.7 250 20 20 7 45 100 80 10 9 18 7 M6 upper_mounting_support.dsf 45 36 Upper mounting support Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b 37 Technical data 3ADW000224R0201 DCS800-E0 Hardware Manual e b Ident. No.: 3ADW000224R0201 Rev B 01_2009 ABB Automation Products Wallstadter-Straße 59 68526 Ladenburg • Germany Tel: +49 (0) 6203-71-0 Fax: +49 (0) 6203-71-76 09 www.abb.com/motors&drives *224R0201A9070000* *224R0201A9070000*
