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DCS Thyristor power converter

for DC drive systems

20 to 1000 A

9 to 522 kW

Manual

DCS 400

II K 1-1

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  DCS Thyristor power converter for DC drive systems 20 to 1000 A 9 to 522 kW Manual DCS 400 II K 1-1…
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  This manual is valid for DCS 400 Rev A including software version 108.0 List of contents ANUAL 1 DCS 400 — the compact-size DC drive ..II K 1-3 2 System overview of DCS 400 ….II K 2-1 2.1 Environmental conditions ……….
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  1 DCS 400 — the compact-size DC drive DCS 400 is a new generation of DC drives, which integrate more accessories within the same space. is rated from 9 to 522 KW and for use on all line The compact design has been partly achieved by supply voltages from 230 to 500 V.
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  DCS 400 — the compact-size DC drive Unit functions Activation and operator-control inputs outputs Drive functions analogue and digital • Speed ramp function generator (S-ramp, fieldbusses 2 accel / decel ramps) (man-machine communication) via: • Speed feedback via tacho, encoder, EMF •…
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  ‚ à y à ‚ … à ‡ ‚ †  ‚ ‚ ˆ ‘ à Q à i ‘ ‘ à ‡ optical fibre RS232 ‘ ‚ ‡ Fig. 2/1: System overview of DCS 400 II K 2-1…
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  2.1 Environmental conditions System overview of DCS 400 Mains supply — power part Environmental limit values Voltage, 3-phase: 230 to 500 V in acc. with IEC 38 Permissible ambient temp. with rated current I : +5 to +40°C Voltage deviation: ±10% permanent…
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  2.2 DCS 400 power converter modules System overview DCS 400 Sizes Size A2 Size A1 Size A4 Size A3 Size Current Dimensions Weight Min. Clearances Fan connection Fuses range H x W x D appr. top/butom/side [mm] [kg] [mm] 20…25 A…
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  2.3 DCS 400 overload withstand capability System overview of DCS 400 To match a drive system’s components as efficiently as possible to the driven machine’s load profile, the power converters can be dimensioned by means of the load cycle. Load cycles for driven machines have been defined in the IEC 146 or IEEE specifications, for example.
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  Control and Display Units of the DCS 400 System overview DCS 400 For operation, commissioning, diagnosis and for The coupling to an overriding system (PLC) takes controlling the drive, there are different possibil- place over a serial interface with a fibre-optic link ities available.
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  System overview of DCS 400 Operation by PC Drive Window Light Components : Drive Window Light is a PC tool for on-line start- • RS232 standard cable, 9-pin sub-D connector, up, diagnosis, maintenance and troubleshooting. male-female, non-crossing Functionality: System configuration display •…
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  Technical data 3 Technical Data 3.1 Module dimensions Module A1 DCS 401.0020 DCS 401.0045 DCS 401.0065 DCS 401.0090 DCS 401.0125 DCS 402.0025 DCS 402.0050 DCS 402.0075 DCS 402.0100 DCS 402.0140 Module A2 DCS 401.0180 DCS 401.0230 DCS 402.0200 DCS 402.0260 Module A3 DCS 401.0315 DCS 401.0405…
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  Technical data Module A4 DCS 401.0610 DCS 401.0740 for M6 DCS 401.0900 DCS 402.0680 DCS 402.0820 DCS 402.1000 Dimensions in mm for M12 Fig. 3.1/2: Dimension drawing A4-Module II K 3-2…
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  1 x 150 1 x 150 * Busbar connection 5 x 40 mm is recommended Table 3.2/1: Cross-sectional areas — tightening torques DCS 400 ❶ You will find instructions on how to calculate the PE conductor’s cross-sectional area in VDE 0100 or in equivalent national standards.
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  • The DCS 400 should be installed in an enclosure that is minimum 150% of the dimensions of con- verter. • The DCS 400 is suitable for use in a circuit capable of delivering not more than 18 kA rms Symetrical amperes, 500 V AC maximum. Recommended fuses must be used to provide short circuit protec- tion.
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  895 1416 1986 DCS402.1000 1000 1116 1786 2527 Table 3.3/1: DCS 400 Power losses of armature circuit Remarks on the table • The values stated are are maximum values ob- tained under the most unfavourable conditions. DCS 400 field supply 440V…
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  DCS 40x.0900…DCS 40x.1000 1x W2E250 (230 V) DCS 40x.0900. 2…DCS 40x.1000. 2 1x W2E250 (115 V) Configuration 1 Table 3.4/1: Fan assignment for DCS 400 Fan data for DCS 400 (data per fan) !»ÃWhp X99: Fan type CN2B2 W2E200 W2E200…
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  The control board SDCS-CON-3A has three serial communication channels: • X7: is a serial communication channel which is used for — DCS 400 PAN — Adapter (3AFE 10035368) • X6: is a standard RS232 serial communication channel. It is a 9-pin D-Sub female connector •…
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  Digital and analogue I/O connection of the SDCS-CON-3A Technical data Reso- Input/output Scaling Load Common Remarks 6’&6&21 Software lution values mode 90-270 V X1:1 [bit] Hardware range 30-90 V R115 100k 100k ±90…270 V 8-30 V AITAC ➀ ➁ 11 + sign ±30…90 V R 115/ ±20 V 100k…
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  Technical data 3.6 Power Interface Board SDCS-PIN-3A The power interface board SDCS-PIN-3A is used for all converter modules model A1…A4. Functions: — firing pulse circuits — power supply for complete converter electronics — measurement of the armature current — fuses for field supply. Fuse data F100…F102: — snubber circuit Bussmann KTK-15A (600V) — AC and DC voltage measurement…
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  3.7 Field exciter SDCS-FIS-3A Technical data The DCS 400 converter has an build-in three-phase field exciter with the following features: • smoothed field voltage — better commutation of the motor T100 — increased brush life SDCS-FIS-3A • less heat generation in the motor •…
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  Technical data System con- Field nection voltage range Line [V~] [V-] DCS 40x.0020…DCS 40x.0140 50…237 50…392 50…413 50…428 50…440 50…440 50…440 50…440 Table 3.7/1: Field voltage range related to 0,01 specified input voltage Fig. 3.7/3 Operating area of field exciter 0.1…6 A DCS 40x.0180…DCS 40x.1000 Fig.
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  3.8 Ciruit diagrams Technical data » » » » » » Ã Ã » » Ã Ã Ã Ã Ã » » Ã » Ã D & & Ã $ » » &…
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  Technical data » » » » » Ã Ã » Ã Ã Ã Ã Ã » » Ã » Ã D & & Ã $ » » & » » » » » Ã…
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  Technical data II K 3-14…
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  Overview of Software 4 Overview of software (The software delivered may contain minor changes to the product described here.) Parameter Function menu The parameters of the converter are subdivided into Special functions of the control panel are listed in the functional groups.
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  4.1 General information about application Macros Overview of Software Macros are pre-programmed parameter sets. During start-up, the analog outputs, which reference value sources are used, etc. is drive can be configured easily without changing individual parame- already defined in the macro. ters.
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  Overview of Software Overview of factory settings of macro-dependent parameters: Í Ï Macro Parameter Standard Man/Const Sp Hand/Auto Hand/MotPot Jogging Motor Pot ext Field Rev Torque Ctrl Cmd Location (2.02) Terminals Terminals Terminals Terminals Terminals Terminals Terminals Terminals Cur Contr Mode (3.14) Speed Contr Speed Contr Speed Contr…
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  4.2 Application Macros Overview of Software The following application macros are available: Macro 1: Standard Macro 5: Jogging Drive switch-on/switch-off and enable via 2 Drive switch-on/switch-off and enable via 2 di- digital inputs. gital inputs. Speed reference via analog input. Speed reference via analog input 1.
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  Overview of Software II K 4-5…
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  4.2.1 Macro 1 — Standard Overview of Software Description of I/O’s functionality Param Function Jog speed 1. Speed can be defined in parameter 5.13. Accel/Decel Ramp for Jogging can be defined in parameter 5.19/5.20. Jog speed 2. Speed can be defined in parameter 5.14. Accel/Decel Ramp for Jogging can be defined in parameter 5.19/5.20.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.02 5.03 Fault or Alarm 6.14 Zero-speed 6.13 Running 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  User alarm ‚ ‡…
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  4.2.2 Macro 2 — Man/Const Sp Overview of Software Description of I/O’s functionality Param Function Drive is started by closing digital input DI1 (DI=1). Switches the drive ON and START Drive is stopped by opening digital input DI2 (DI2=0). DI2 has a higher priority than DI1, i.e. if DI2 is open the drive can not be started.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Zero-speed 6.14 Fault 6.13 Running 6.12 Ready for ON 6.11 Fixed speed 2 Fixed speed 1 Main con- 6.15 tactor ON Reset Emergency stop 2.01 Ramp 1 / Ramp 2 Direction of rotation Stop Start…
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  4.2.3 Macro 3 — Hand/Auto Overview of Software Description of I/O’s functionality Param Function Start / Stop Hand. Start and stop the drive. DI1=0=STOP , DI1=1=START Start switches the drive ON and START. Stop the drive in according to parameter Stop-Mode and afterwards switch the drive off.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Zero-speed 6.14 Fault 6.13 Running 6.12 Ready for ON 6.11 Start/Stop Auto Direct. of rot. Auto Main con- 6.15 tactor ON Reset Emergency stop 2.01 Fixed speed / AI1 Direct.
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  4.2.4 Macro 4 — Hand/MotPot Overview of Software Description of I/O’s functionality Param Function Start / Stop. Start and stop the drive. DI1=0=STOP , DI1=1=START. Start switches the drive ON and START. Stop the drive in according to parameter Stop-Mode and afterwards switch the drive off and resets speed reference to zero.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Zero-speed 6.14 Fault 6.13 Running 6.12 Ready for ON 6.11 Decrease speed Main con- 6.15 tactor ON Increase speed Reset 2.01 Emergency stop AI1 / MotPot Direction of rotation Jogging Start/Stop…
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  4.2.5 Macro 5 — Jogging Overview of Software Description of I/O’s functionality Param Function Direction of rotation. DI1=0=forward , DI1=1=reverse Jog speed 1. Speed can be defined in parameter 5.13. Accel/Decel Ramp for Jogging can be defined in parameter 5.19/5.20. Jog speed 2.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Fault or Alarm 6.14 speed level reached 6.13 Zero-speed 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  ‚ ‡…
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  4.2.6 Macro 6 — Motor Pot Overview of Software Description of I/O’s functionality Param Function Direction of rotation. DI1=0=forward , DI1=1=reverse Motor pot function „faster“.Accel Ramp 5.09 Motor pot function „slower“. Decel Ramp 5.10. Slower has precedence above faster. 2.01 Minimum speed.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Fault or Alarm 6.14 reached 6.13 reached 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  Min speed ‚ ‡…
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  4.2.7 Macro 7 — ext Field Rev with remanence contactor Overview of Software Short description Description of I/O’s functionality Param Function Non Field Reversal Mode: External field reversal with external field reversing switch. Only for 2Q application. • DI1 = 0 V (contact open), DI1=0=no field reversal only effective if drive is in DI1=1=field reversal…
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  Overview of Software field reversal K3 energized 1.03 / 1.04 no field reversal K3 de-energized 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Field reversal ON Fault or Alarm Field reversal OFF 6.14 Field reversal activ. 6.13 Running 6.12 Ready for Run 6.11 On/Off Main con-…
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  4.2.8 Macro 8 — Torque Ctrl Overview of Software Description of I/O’s functionality Param Funktion COAST. Closed-circuit principle, must be closed for operation. COAST is the fastest way to stop the current controller. The current controller will decrease the armature current to zero as fast as possible. This command will stop the drive so that the motor is left running and friction together with the load will decrease the speed to zero.
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  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Fault or Alarm 6.14 6.13 Running 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  User Alarm ‚ ‡ ‡…
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  4.3 Digital and analogue Inputs/Outputs Overview of Software Digital inputs DI1…DI8 Tachogenerator input (11 Bits + sign) The drive is controlled via the digital inputs DI1…DI8. The speed feedback with tachogenerator is set with The significance of the inputs are defined by a macro. the parameter Speed Meas mode (5.02) = Tacho.
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  80% of full resolution. A speed measure- ment up to 125% of nominal speed is possible. The accuracy is 0,06% related to nominal speed. Drive controlled by Serial Communication DCS 400 Speed reference Speed reference à $Ãiv‡†vt Fieldbus accuracy $È…
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  4.4 Drive Logic Overview of Software The drive logic controls the switching on and off of the Other behaviour during switching on and off converter and the motor and protects both in excep- Switching off modes other than the default setting can tional situations, in case of fault or emergency stop.
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  (5.15). When the drive starts again (RUN=1) the drive will switch over to nominal field current. Drive is in operation 9…v‰rÃv†Ã…ryrh†rq) 10sec 10sec AvryqÃurh‡vt Fig. 4.4/1: Switch-on sequence of DCS 400 Field current Fan On Zero Speed Programmable Fan Delay (2.13) II K 4-25…
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  Switch off fan 9…v‰rÃv†ÃPAA) AhÃP 2. Possible circuitry Since the requisite edges can Fig. 4.4/2: Switch-off sequence of DCS 400 be generated by means of a Reset Rdy On signal when the elec- Eme Stop tronics supply is switched on…
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  • the drive thus remains simple and safe. thresholds. This is not the case with the DCS 400, whose power section can be operated on a mains On the basis of the computed minimum permissible supply voltage of 230V…500V without any further…
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  Overview of Software 5% above this tripping threshold, an alarm signal Monitoring the Mains Voltage: A02-Mains Voltage Low will be generated. The alarm range shifts when the Net Underv Trip (1.10) e.g. Mains Supply Voltage = 400 V parameter is altered. Application = 4-Q Armature Voltage Nominal = 420 V…
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  Overview of Software Monitoring the Mains Voltage: Auto Reclosing In parameter Net Fail Time (1.11) the maximum e.g. Mains Supply Voltage = 400 V tolerated mains voltage failure time is set. In case of Application = 4-Q mains undervoltage the drive is blocked and alarm Armature Voltage Nominal = 420 V A02 is displayed during this time.
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  [217 A Correlation of Armature Voltage and EMF 440 V 390 V The DCS 400 drive calculates the true EMF and does not take the Armature Voltage instead. EMF is calculated by Ua actual Under full load condition, at full speed:…
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  Overview of Software Without speed-dependent current limiting 4.5.4 Overtemperature Protection The field weakening mode is selected or not selected as a function of the parameter values Base Speed Converter: (1.05) and Max Speed (1.06): DCS400 is equipped with an overtemperature protec- tion on the heat sinks of the thyristors.
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  Overview of Software 4.5.5 Armature current controller Second current limitation The motor’s maximum armature current is limited by The Arm Cur Nom (1.01), Arm Cur Max (3.04), the Arm Cur Max (3.04) parameter. This absolute Torque Lim Pos (3.07) and Torque Lim Neg (3.08) limitation is always active.
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  Overview of Software Armature current controller operating modes The speed of a DC motor is altered with the armature voltage. The range up to the point where the rated armature voltage is reached is referred to as the armature operating range. To enable the motor’s speed to be increased above these rated armature voltage, the field’s magnetic flux has to be reduced.
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  Overview of Software 1 = Speed Contr / 2 = Torque Contr 4 = Speed + Torque Depending on the application involved, however, a Depend on application in speed control mode a pre- constant torque is also required in the field weakening control of torque is required to have the drive more range (Torque-Controlled Mode (3.14) = Torque dynamic.
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  Overview of Software 6 = Lim Trq Ctr (Window Control Mode) t function The idea of Window Control Mode is to deactivate the The DCS400 is equiped with an I t-protection for the speed control as long as the speed deviation remains motor, which can be enabled if required.
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  Overview of Software The overload phase is set using parameters Arm Cur 4.5.8 Alternative Parameters for the Speed Max (3.04) and Overload Time (3.05). The recovery Controller phase is set using parameter Recovery Time (3.06). In order not to overload the Motor, the I t-plane of the A second parameter set is available for the speed two phases have to be identical:…
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  Overview of Software 4.5.9 Service Procedures, Contr Service (7.02) After successful autotuning the following controller parameters are set: Armature current controller Field Cur KP (4.03) (Motor does not turn) Field current controller proportional gain Field Cur TI (4.04) Autotuning Field current controller integral time constant •…
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  Overview of Software Speed controller After successful autotuning the following controller parameters are set: Attention: Motor will accelerate twice to 80% of Field Cur 40% (4.07) Base Speed now Field current for 40% flux Field Cur 70% (4.08) Autotuning Field current for 70% flux •…
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  Overview of Software This internal scaling does not apply to the transmis- 4.5.10 Internal Scaling sion of parameters via PLC. In this kind of transmis- You can display all parameters of the DCS400 in their sion, decimal values are simply transmitted in binary physical quantities by means of operating panel or the form i.e.
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  Overview of Software 4.5.11 Signal definitions Signal «Overtemp Mot» / «Overtemp DCS» Signal «At Set Point» in case of Alarm Speed reference reached. Speed actual value Speed Act (5.05) correspondes PTC (DCS / Motor-AI2) to speed reference value before ramp generator Digital Output DOx Ramp In Act (5.33).
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  Overview of Software 4.5.12 User events Adaptation of digital inputs for user events First four digital inputs DI1…DI4 are re-configurable in parameter group 9-Macro Adaptation for macro 1, 5, 6, 7 and 8. This functionality is not available for macro 2, 3 and 4. For some user specific application it’s helpful do assign these inputs to user events External Fault or External Alarm.
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  4.6 Software Structure Overview of Software DO1 Assign 9…v‰rÃG‚tvpÃhqÃT‡h‡ˆ†ÃQ…‚pr††vt 6.11 Eme Stop constant 0 Reset constant 1 DO2 Assign Macro depend 6.12 Rdy for On Start Rdy for Run DI Act Macro Select Stop Running DO3 Assign 6.28 2.01 6.13 Eme Stop act Fault Macro dep.
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  Overview of Software P‰r…‰vrÃ‚sÃhy‡r…h‡v‰rÃ9…v‰rÃ8‚‡…‚yyvt††vivyv‡vr† Srsr…rpr†Ã8‚‡…‚y 6p‡ˆhyÉhyˆr†ÃT‡h‡ˆ† ‚rÂsÇur†r v†Ãƒ‚††viyrÄ Fieldbus Fieldbus Adapter Module 7ˆ†Ã†’†‡r€ Adapter Module 7ˆ†Ã†’†‡r€ SHF DG D(N) D(P) SHF DG D(N) D(P) D‡r…hyÃ…‚pr††vt R XD R XD Nx xx -01 Fieldbus DS1.1 DS2.1 Nxxx-01 TX D Fieldbus TX D x xx xx x xx x xx xx x xx ADA PTER…
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  4.7 Parameter list Overview of Software Parameter overview 1 — Motor Settings 2 — Operation Mode 3 — Armature 4 — Field 1.01 Arm Cur Nom * 2.01 Macro Select * 3.01 Arm Cur Ref 4.01 Field Cur Ref 1.02 Arm Volt Nom * 2.02 Cmd Location 3.02 Arm Cur Act 4.02 Field Cur Act…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom setting Grp 1 Motor Settings 1.01 Arm Cur Nom 1000 Wizard Nominal motor current in amperes (indicated on the motor’s rating plate). 1.02 Arm Volt Nom Wizard Nominal motor voltage in volts (indicated on the motor’s rating plate).
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  Overview of Software ParNo. Parameter name and significance Default Unit custom setting Grp 1 Motor Settings (continued) 1.11 Net Fail Time 10.0 During this time the supply voltage must return to a value higher than Net Underv Trip (1.10). Otherwise an undervoltage trip will be generated.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 2 Operation Mode 2.01 Macro Select Text Wizard Selection of desired macro: 0 = Standard 1 = Man/Const Sp 2 = Hand/Auto 3 = Hand/MotPot 4 = Jogging 5 = Motor Pot 6 = ext FieldRev 7 = Torque Cntrl…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 2 Operation Mode (continued) 2.04 Eme Stop Mode Text Wizard Selection of the desired operating response to an Eme Stop command (controller blocking) 0 = Ramp Motor decelerates in acc. to Eme Stop Ramp (5.11). If Zero Speed Lev (5.15) is reached Main Contactor is switched off.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 2 Operation Mode (continued) 2.05 Main Ctrl Word Signal The Main Ctrl Word maps the control bits of the drive. This parameter indicates the control bits of the terminal block or of the bus communication.
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 2 Operation Mode (continued) Long Parameter Menu 2.07 Comm Fault Mode Text Selection of the desired operating response to a communication failure: 0 = Ramp Motor is decelerated in accord. to a ramp (5.10) 1 = Torque Lim Motor is decelerated in accord.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 3 Armature 3.01 Arm Cur Ref Signal Armature current reference value in amperes. 3.02 Arm Cur Act Signal Measured armature current actual value in amperes. 3.03 Arm Volt Act Signal Measured armature voltage actual value in volts.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 3 Armature (continued) 3.10 Arm Cur Reg TI 1000.0 50.0 auto- Integration time constant of the armature current tuning controller (PI controller) in milliseconds. 3.11 Cont Cur Lim auto- Armature current value at the limit between tuning…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 3 Armature (continued) Text 3.15 Torque Ref Sel Selection of the desired torque reference location: 0 = Macro depend / dependent on the select. macro 1 = AI1 / analog input 1 (X2:1-2) 2 = AI2 / analog input 2 (X2:3-4) 3 = Bus Main Ref / main fieldbus reference value 4 = Bus Aux Ref / auxiliary fieldbus reference value…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 4 Field 4.01 Field Cur Ref Signal Field current reference value in amperes. 4.02 Field Cur Act Signal Measured field current actual value in amperes. 4.03 Field Cur KP 0.000 13.499 0.300…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller 5.01 Speed Ref Sel Text Selection of the desired speed reference location: 0 = Macro depend / dependent on the selected macro 1 = AI1 / analog input 1 (X2:1-2) 2 = AI2 / analog input 2 (X2:3-4) 3 = Bus Main Ref / main fieldbus reference value 4 = Bus Aux Ref / auxiliary fieldbus reference value…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) Long Parameter Menu 5.12 Ramp Shape 0.00 10.00 0.00 0 = linear >0 = ramp shape time Setting the ramp shape: This parameter adds a filter to the output of the ramp generator to create a ramp shape.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) 5.15 Zero Speed Lev Wizard Zero speed signal. Speed level below which the signal is issued that the motor has reached zero speed. Is used for stall protection, as a standstill message to the drive logic and for the generation of the Zero Speed signal.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) 0.000 19.000 0.200 integer 5.22 Alt Speed KP Proportional gain of the speed controller (PI controller) for the alternative parameter set. 5.23 Alt Speed TI 6553.5 5000.0 Integration time constant of the speed controller…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) 5.30 Act Filt 2 Time 0.00 10.00 0.00 Filter time constant 2 for smoothing speed deviation at the input of the speed regulator. 5.31 Speed Lim Fwd 6500…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 6 Input / Output 6.01 AI1 Scale 100% 2.50 11.00 10.00 Scaling of analog input 1: input of a voltage value in volts, which correspond to 100% reference. 6.02 AI1 Scale 0% -1.00…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 6 Input / Output (continued) 6.11 DO1 Assign Text Wizard Desired assignment of digital output 1: 0 = none 0 constant (for test purposes) 1 = Constant 1 1 constant (for test purposes) 2 = Macro depend the output is defined by macro, see macro…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 6 Input / Output (continued) Text 6.12 DO2 Assign Wizard esired assignment of digital output 2: Assignment identical with DO1 (6.11). 6.13 DO3 Assign Text Wizard Desired assignment of digital output 3: Assignment identical with DO1 (6.11).
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 6 Input / Output (continued) 6.20 Dataset 2.2 Asn Text Selection of the desired assignment for fieldbus dataset 2.2: 0 = Speed Act / speed actual value (5.05) 1 = Speed Ref / speed reference value (5.04) 2 = Arm Volt Act / armature voltage act.
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 6 Input / Output (continued) 6.22 MSW Bit 11 Asn Text Function assignement for bit 11 in the main fieldbus status word (2.06): 0 = none 0 constant (for test purposes) 1 = Constant 1 1 constant (for test purposes) 2 = Macro depend…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 6 Input / Output (continued) 6.23 MSW Bit 12 Asn Text Function assignment for bit 12 in the main fieldbus status word (2.06): Assignment identical with MSW Bit 11 Asn (6.22) 6.24 MSW Bit 13 Asn Text…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 7 Maintenance 7.01 Language Text Wizard Selection of the panel language: 0 = English 1 = Deutsch 2 = Français 3 = Italiano 4 = Español 7.02 Contr Service Text Action…
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  = ShortcV13/26 = ShortcV14/21 = Ground Fault = NoThrConduc 7.04 SW Version integer Const. Display of the DCS 400 software version used. 7.05 Conv Type Text Const. Display of the converter type: 0 = DCS401 (2Q) 1 = DCS402 (4Q)
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 7 Maintenance (continued) 7.06 Conv Nom Cur Const. Display of the converter’s nominal current in amperes. 7.07 Conv Nom Volt Const. Display of the converter’s nominal voltage in volts. 7.08 Volatile Alarm Text…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 7 Maintenance (continued) 7.12 Alarm Word 1 Signal Alarm word 1. Significance of the individual bits: All the pending alarms are displayed if the corresponding bits are set to log. «1». Alarm definition 00 0001…
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  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 7 Maintenance (continued) 7.15 Commis Ref 1 -32768 32767 integer Commissioning reference value 1 Scaling: Field current 0…100%= 0…4096 Torque 0…100%= 0…4096 Armature current 0…100%= 0…4096 Speed 0…max = 0…max rpm 7.16 Commis Ref 2…
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  Overview of Software For detailed description see «Fieldbus Description» ParNo. Parameter name and significance Default Unit custom. setting Grp 8 Fieldbus Long Parameter Menu 8.01 Fieldbus Par 1 Text 0 = Disable no communication with PLC 1 = Fieldbus PLC communication via fieldbus adapter 2 = RS232-Port PLC communication via RS232 Port / Modbus protocol…
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  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 9 Macro Adaptation Long Parameter Menu 9.01 MacParGrpAction Text Before a new function can be assigned to a digital input or control bit, the actual function has to be disabled. This can be done in two ways.
• Page 97
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 9 Macro Adaptation (continued) 9.05 User Fault Text Fault function will be controlled from a binary signal which is assigned in this parameter: 0=Macro depend 1=Disable 2=DI1 3=DI2 4=DI3 5=DI4…
• Page 98
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 9 Macro Adaptation (continued) 9.10 MotPot Incr Text MotorPot Increase speed function will be controlled from a binary signal which is assigned in this parameter. Assignment identical with 9.05 only effective if MotPot Decr (9.11) is not set to 1 = Disable State of binary signal:…
• Page 99
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 9 Macro Adaptation (continued) 9.14 AlternativParam Text Alternative parameter set will be controlled from a binary signal which is assigned in this parameter. Assignment identical with 9.05 State of binary signal: 0= Standard parameter set for speed controller effective 5.07 Speed Reg KP…
• Page 100
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 9 Macro Adaptation (continued) 9.19 Disable Bridge1 Text Bridge 1 will be controlled from binary signal which is assigned in this parameter. Assignment identical with 9.05 State of binary signal: 0= Enable Bridge 1 1= Disable Bridge 1.
• Page 101
  If the consignment is incomplete or contains any incorrect items, please contact the supplier. The technical data and specifications are valid as of going to press. ABB reserves the right to make CAUTION! subsequent alterations. The thyristor power converter weighs quite a lot and should therefore not be held by the front cover.
• Page 102
  5.1 Safety instructions Installation in conformity with the low-voltage directive 73/23/EEC 1. General 4. Installation In operation, drive converters, depending on their degree of protec- The installation and cooling of the appliances shall be in accordance tion, may have live, uninsulated, and possibly also moving or rotating with the specifications in the pertinent documentation.
• Page 103
  Common Warnings Installation Warnings • The thyristor power converter possesses a number of automatic Warnings provide information on states which if the specified reset functions. When these functions are executed, the unit will procedure for the state concerned is not meticulously complied with be reset after an error and will then resume operation.
• Page 104
  (line filters, screened power cables) in the lower power range NOTE! The conformity procedure is matter of responsibility of ABB Automation Products GmbH and of the machine manufactur- ers or the plant builders corresponding to their share of the ex- tension of the electrical equipment.
• Page 105
  Installation Definitions Earth, earthing for safety Ground, grounding for EMC, connection with chassis or housing with low inductance Important instructions for plants with line fil- ters Filter in an earthed line (TN or TT Network) The filters are suitable for earthed lines only, for example in public European 400 V lines.
• Page 106
  Installation Classification Medium-voltage line Medium-voltage line Supply transformer of Supply transformer of a Converter an industry region residental region with light transformer (rated power normally industry (rated power with earthed ≤ 1.2 MVA) normally ≤ 1.2 MVA) Earthed star point iron core (and if Earthed…
• Page 107
  Europe for example with 400 V between the phases. Such lines have an earthed neutral conduc- tor. ABB offers suitable three — phase filters for 400 V and 25 A…600 A and 500 V filters for 440 V lines outside Europe (see Ap- pendix A).
• Page 108
  Installation Due to the maximum power of public 400 V transformers Õ = 1.2 MVA = 1732 A) and due to their relative short circuit voltage V of 6% or 4% the maximum AC current which is available for a ≤…
• Page 109
  Installation Separation A separation transformer makes line chokes unnecessary because transformers of its leakage inductance, and a grounded screen between its windings saves an EMC filter, see and 4. The screen and the iron core must be well connected with the mounting plate of the con- verter.
• Page 110
  Installation Screening Signal cables The cables for digital signals, which are longer than 3 m and all ca- bles for analogue signals, must be screened. Each screen must be connected at both ends by metal clamps (see figure 5.2-4) or comparable means directly on clean metal surfaces, if both earthing points belong to the same earth line.
• Page 111
  Installation Power cables If a screen is not necessary (see 13) the armature current cable without screens must be a four-wire cable because two wires are needed as con- ductors for the parasitic RF currents from the motor to the RF filter in the cubicle.
• Page 112
  Installation Others Earthed public The rated voltages of a public European low voltage line are 400 V low voltage between the 3 phases and 230 V between a phase and the neutral lines conductor. These voltages are provided by a transformer with its 3- phase secondary winding in star connection.
• Page 113
  Installation Industrial low Industrial low voltage lines are local lines in plants or factories. voltage lines They have own supply transformers (see 6). In most cases they are insulated (IT network / no earthed star point) and their voltages are often higher than 400 V. The loads tolerate higher noise levels. Therefore and because industrial lines are decoupled from public lines by their transformers and distances, converters do not need EMC filters at industrial low-voltage lines (see 6).
• Page 114
  Installation Connection exam- See figure 5.2 — 7. ple in accordance with EMC Armature and See figure 5.2 — 7. field cables with screens for “first environ- ment” Armature and See figure 5.2 — 7. field cables without screens for “second en- vironment”…
• Page 115
  Installation Mounting plate Filter Field supply unit Mounting plate with PE DC motor bar and terminals Armature and field cables with A1 A2 screens for «first environment» 6FUHHQV 7DFKR Contact to the motor PE bar housing at the whole screen perimeter The armature current cable must contain a third wire for a PE c Cv‡)Ã…
• Page 116
  Installation Important hint The example shows the principle structure of a DC drive and its connections. It is not a binding recommendation, and it cannot re- spect all conditions of a plant. Therefore each drive must be con- sidered separately and with respect to the special application. Addi- tionally the general installation and safety rules must be taken into account.
• Page 117
  Connection examples Installation Installation 5.3.1 Connection example for digital and analogue coupling of a PLC 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 2.01 Remark The drive is controlled via digital inputs/outputs. Speed 6.08 / 6.09 / 6.10 reference is given via analogue input AI1.
• Page 118
  Installation Installation 5.3.2 Connection example for serial communication of a PLC 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark The drive is controlled serial via MainControlWord 6.08 / 6.09 / 6.10 and MainStatusWord.
• Page 119
  Installation Installation 5.3.3 Connection example for Emergeny Off (valid for all macros) General situation 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark In cases of Emergency Off it is necessary to have an 6.08 / 6.09 / 6.10 OFF-delay relais (K22) in the Emergency Off circuit 6.05 / 6.06 / 6.07…
• Page 120
  Installation Installation 5.3.4 Connection example with DC breaker and controlled deceleration 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark In cases of Emergency Off it is necessary to have an 6.08 / 6.09 / 6.10 OFF-delay relais (K22) in the Emergency Off circuit 6.05 / 6.06 / 6.07…
• Page 121
  Installation Installation 5.3.5 Connection example with DC breaker and drive coasting 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark Switch Main Contactor (K1) On and Off is controlled 6.08 / 6.09 / 6.10 by digital output DO5.
• Page 122
  Installation 5.3.6 Connection example for Motor fan and Converter fan (useful for all macros) General situation 0 a 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 Fan On Fan Delay 2.13 6.11 6.15 Emergency Stop 2.01 6.08 / 6.09 / 6.10…
• Page 123
  • basic knowledge of physics and electrical engi- Panel link neering, electrical wiring principles, components The DCS 400 PAN is connected to the drive via a and symbols used in electrical engineering, and serial interface and is removable under power.
• Page 124
  6.1 Panel Operating Instructions Panel mode: Menu selection 2XWSXW GLVSOD 0HQX VHOHFWLRQ 0(18 440V 368A 1500rpm 1 Motor Settings 1500rpm 0(18 OUTPUT MENU AUTO OFF HAND REM LOC <RUN> OUTPUT MENU AUTO OFF HAND REM LOC <RUN> 2 Operation Mode 3 Armature 4 Field 5 Speed Controller…
• Page 125
  Operating Instructions Panel mode: Parameter programming Pˆ‡ƒˆ‡Ãqv†ƒyh’ HrˆÃ†ryrp‡v‚ Qh…h€r‡r…Æryrp‡v‚ Qh…h€r‡r…Ãpuhtvt 0(18 (17(5 (17(5 440V 368A 1500rpm 1 Motor Settings 1.01 Arm Cur Nom 1.01 Arm Cur Nom 200A 200A 1500rpm 0(18 0(18 0(18 OUTPUT MENU AUTO OFF HAND REM LOC <RUN> OUTPUT MENU AUTO OFF HAND REM LOC <RUN>…
• Page 126
  Operating Instructions Set Typecode Read Faultlogger Only visible in Long Par List. Disabled if the drive is in ON-state. Non-volatile memory — 16 Set Typecode Read Faultlogger entries. Use only for replacement of SDCS-CON-3A. OUTPUT MENU AUTO OFF HAND REM LOC <RUN> OUTPUT MENU AUTO OFF HAND REM LOC <RUN>…
• Page 127
  Operating Instructions Factory Setting Panel Lock Disabled if the drive is in ON-state. Before any change in the Panel Lock mode can Enter PIN Code become effective, the PIN number (“400“) first has to Factory Setting Resets all parameters to be entered.
• Page 128
  Panel mode: Drive control Operating Instructions 440V 368A 1500rpm Actual value display 1500rpm Reference display OUTPUT MENU AUTO OFF HAND REM LOC <RUN> Status display 440V 368A 1500rpm (17(5 0(18 Activate reference 1500rpm OUTPUT MENU AUTO OFF HAND REM LOC <RUN> /2&…
• Page 129
  Guided Commissioning Operating Instructions The DCS 400 converters of ABB offer the possibility This section describes the guided commissioning to have a guided commissioning by means of interac- with the panel. The necessary dialogue, also Panel tive dialogue through the parameter programming.
• Page 130
  Operating Instructions Parameter entries The entries required during the guided commission- ing procedure are divided into selection parameters and value parameters. Selection parameters are selected from a prede- fined text list and confirmed. The control panel display only shows one line of this text list at a time.
• Page 131
  Operating Instructions Start of guided commissioning Commissioning step Comments Unexpected trouble during guided commissioning can be eliminated easily. Find in the following chapters the reason and carry out the measures described there. For faults, alarms and diagnosis messages, see chapter 6.4 Troubleshooting . For other reasons, see chapter 6.3 Useful hints for commssioning .
• Page 132
  Operating Instructions Commissioning step Comments Fieldweakening? Field weakening Yes/No OUTPUT MENU AUTO OFF HAND REM <RUN> 1.06 Max Speed Maximum speed for field- 1.06 Max Speed is set to the value of weakening operation 100rpm 1.05 Base Speed see motor name plate OUTPUT MENU AUTO OFF HAND REM…
• Page 133
  Operating Instructions Commissioning step Comments Field Autotuning? Field current controller opti- mization OUTPUT MENU AUTO OFF HAND REM <RUN> CAUTION CAUTION Field voltage of the motor will be Observe safety energized. instructions Start Drive Press key on panel to apply Press (I) field voltage to the motor.
• Page 134
  Operating Instructions Commissioning step Comments Armature Autotuning? Armature current controller optimization OUTPUT MENU AUTO OFF HAND REM <RUN> CAUTION CAUTION Motor will be energized. Observe safety instructions Press key on panel to apply Start Drive Press (I) field voltage armature voltage to the motor.
• Page 135
  Operating Instructions Commissioning step Do not use this path, if speed Speed Meas Adjust? controller adjustment is already done! OUTPUT MENU AUTO OFF HAND REM <RUN> Speed measurement mode 5.02 Speed Meas Mode Select and confirm. Depending on the selection made, EMF or Tacho or Encoder commission- Analogue Tacho OUTPUT…
• Page 136
  Operating Instructions Commissioning step Comments Speed Autotuning? Speed controller optimization Select and confirm. OUTPUT MENU AUTO OFF HAND REM <RUN> CAUTION CAUTION Observe safety Motor will accelerate twice up to instructions 80% of Base Speed! Press key on panel to switch Start Drive Press (I) on and enable the drive.
• Page 137
  Operating Instructions Commissioning step Comments Flux Adaptation? Flux optimization only available in Field weaken- OUTPUT MENU AUTO OFF HAND REM <RUN> ing Mode. CAUTION CAUTION Observe safety Motor will accelerate up to 50% instructions of Base Speed! Press key on panel to switch Start Drive Press (I) on and enable the drive.
• Page 138
  Operating Instructions Commissioning step Comments Stall Protection? Stall protection OUTPUT MENU AUTO OFF HAND REM <RUN> 3.17 Stall Torque Stall torque 100% OUTPUT MENU AUTO OFF HAND REM <RUN> 3.18 Stall Time 0.0s Stall time OUTPUT MENU AUTO OFF HAND REM <RUN>…
• Page 139
  Arm Autotun Switch the drive ON and increase speed reference slowly up to the value of Base Speed (1.05) by using a reference potentiometer or by using the DCS 400 operating panel in LOCal mode. Read parameter Speed Ref (5.04); same as Base Speed! Tacho Speed Act (5.06);…
• Page 140
  Operating Instructions with EMF feedback Set parameters Arm Cur Nom (1.01): see motor name plate Arm Volt Nom (1.02): see motor name plate Field Cur Nom (1.03): see motor name plate Field Volt Nom (1.04): see motor name plate Base Speed (1.05): see motor name plate Max Speed (1.06): same as Base Speed…
• Page 141
  Operating Instructions with Encoder feedback Set parameters Arm Cur Nom (1.01): see motor name plate Arm Volt Nom (1.02): see motor name plate Field Cur Nom (1.03): see motor name plate Field Volt Nom (1.04): see motor name plate Base Speed (1.05): see motor name plate Armature control range Field weakening range…
• Page 142
  Useful hints for commissioning Operating Instructions F12 — Field Undercurrent Field Autotuning failed F09 — Mains Undervoltage Check parameter Diagnosis (7.03) and read chapter 6.4.7 Diagnostic Messages A02 — Mains Voltage Low Drive doesn’t start Armature Autotuning failed DCS400 is suitable for main supply of 230…500V Check parameter Diagnosis (7.03) and read chapter without any parameter settings.
• Page 143
  Operating Instructions Hints for speed controller autotuning Drive accelerates to overspeed Only successfully commissioned selftuning will change With default parameter values (defaults: KP=0.200 / parameters of the speed controller Speed Reg KP TI=5000.0 ms) and slow ramps it may happen, that (5.07) and Speed Reg TI (5.08), other-wise parame- the drive accelerates to overspeed limit bypassing ters remain unchanged.
• Page 144
  Eliminate speed offset via Tacho Offset (5.34) fieldweakening • switch drive OFF If a DCS 400 is intended to be used in regenrative • read Speed Actual from panel mode including field-weakening we recommend the • set Tacho Offset (5.34) to this value incl. polarity following sequence to switch the drive on: •…
• Page 145
  A compromise is provided by two series- Then DCS 400 is using automatic field weakening connected fuses, as used in the power supply. to achieve full speed but will lose torque in field weakening range.
• Page 146
  Reserved for External FPROM checksum error In addition to the seven segment display, the LCD of the control panel DCS 400 PAN will be able to show COMM LOSS Internal error in even address of the fault and alarm signals as well as the diagnostic messages as clear text.
• Page 147
  After Reset, switch ON and RUN off and on again. DCS 400 Initialisation phase initialisation phase After the electronics supply has been switched on, both LEDs light up briefly during the initialisation phase of the DCS 400. Flashes Flashes DCS 400 Hardware problem with the power supply…
• Page 148
  SDCS-CON-3A as codes F . . as well as on the LCD Fault no. of the control panel DCS 400 PAN as plain text. Auxiliary Voltage Fault All fault signals — with the exception of F1 to F6 — can be reset by Aux Voltage Fault 7.09…
• Page 149
  Operating Instructions Definition / Definition / Possible source Possible source Fault message Fault message Fault no. Fault no. Converter Over Temperature Mains Synchronization Fault Converter Overtemp 7.09 F 11 Mains Sync Fault 7.09 Temperature of the converter too The synchronization to the mains bit 6 bit 10 high.
• Page 150
  Operating Instructions Definition / Definition / Possible source Possible source Fault message Fault message Fault no. Fault no. Field Overcurrent Tacho Polarity Fault F 13 Field Overcurrent 7.09 F 17 Tacho Polarity Fault 7.10 Field current has reached a limit Polarity of feed back signal from bit 12 bit 0…
• Page 151
  Operating Instructions Definition / Possible source Fault message Fault no. Local Control Lost F 21 Local Control Lost 7.10 During operation in Local control bit 4 mode no message has been received for a time longer than the value that has been set in Parameter Comm Fault Time (2.08).
• Page 152
  Possible source Alarm message control board SDCS-CON-3 as codes A . . as well as on the LCD of Alarm no. the control panel DCS 400 PAN as clear text. Alarm signals will only Parameters Added Alarm Parameters Added 7.12 be displayed, if there is no fault signal active.
• Page 153
  Wizard. Then Mains Drop Out Alarm Main Voltage Drop Out 7.12 read out parameter Diag- DCS 400 is equipped with an bit 7 nosis (7.03) manually and „Auto Reclosing“ that allows for also the Fault Logger for a continous operation after more information.
• Page 154
  Operating Instructions Definition / Definition / Possible source Possible source Alarm message Alarm message Alarm no. Alarm no. A 14 Up/Download Failed Alarm Upload Download Fai- 7.12 A 18 Parameter Restored Parameter Restored 7.13 bit 13 To enable data loss in the bit 1 The checksum verification failed FlashProm to be detected, the…
• Page 155
  None Actually no problems Internal software causes. Reference list of Diagnostic messages Please contact your ABB local — sorted by alphabetical order service center. Tune Aborted Procedure aborted by FAULT or switching off the RUN command.
• Page 156
  Field R Meas Not enough measurement for the de- Upload or Download start timeout. tection of field resistance. The value of Please contact your ABB local “Field R” is used for calculation the service center. Parameter 4.04 (Field Cur TI).
• Page 157
  Operating Instructions Definition / Definition / Possible source Possible source 7.03 Diagnosis 7.03 Diagnosis Diagn. message Diagn. message AI2 vs PTC AI2 is set as PTC evaluation and Ref- 3bbbb 3bbbb 3bbbb faulty thyristor diagnosis erence value source. (b=bridge) If PTC is allocated to AI2 this input will 3bbbb 1…6 = thyr.
• Page 158
  Operating Instructions II K 6-36…
• Page 159
  Drive configuration with serial communication The drive can be operated (ON / RUN / Reset / Emergency Stop) The DCS 400 is equipped with the following serial interfaces: according to parameter Cmd Location (2.02) via terminal X4: or • Panel-Port (standard, built-in) one out of three serial interfaces (Panel-Bus or RS232-Bus or •…
• Page 160
  Serial Interfaces T‡h‡rÂs 6p‡ˆhy 6p‡ˆhy 9…v‰r ‰hyˆr ‰hyˆr DataSet 2.1 DataSet 2.2 DataSet 2.3 HhvÃT‡h‡ÃX‚…q 6p‡ˆhyÃWhyˆrà 6p‡ˆhyÃWhyˆrÃ! SHF DG D(N) D(P) R XD Nxxx-01 TX D x xx xx x xx ADA PTER XM I T BU S TE R M I N A TI O N R EC ER R O R +2 4 V…
• Page 161
  Serial Interfaces DataSet 3.1 DataSet 3.2 DataSet 3.3 DataSet 4.1 DataSet 4.2 DataSet 4.3 9vtv‡hyÃSrs 6hy‚tÃSrs 6hy‚tÃSrs AyqÃ8ˆ…Ã6p‡ Q‚r…Ã6 p‡ U‚…„ˆrÃ6 p‡ SHF DG D(N) D(P) R XD Nx xx -01 TX D x xx xx x xx ADA PTER XM I T BU S TE R M I N A TI O N…
• Page 162
  Serial Interfaces Communcation Parameters Necessary parameter-settings for fieldbus communication Parameter Parameter name possible settings recommended The following communication paramters are relevant 2.02 Cmd Location 0=Macro depend in case of external drives control. 1=Terminals 2=Bus 2=Bus Cmd Location (2.02) 3=Key Purpose: Determines whether Drive is externally con- 2.07 Comm Fault Mode 0=Ramp…
• Page 163
  Irrespective of the bus protocol, these ports main control word (2.05) and main status word communicate with the DCS400 software via specified (2.06) of the DCS 400 converter. The allocation is as data sets. Four data sets are available with three 16- follows: bit words each.
• Page 164
  Serial Interfaces Status word allocation Panel-Port 4 bits of the status word (data set 2.1) can be param- The Panel Port is normally used for connection of the eterized. The signals are selected in the parameters control panel. The default settings of this interface are MSW bit 11 Ass (6.22), MSW bit 12 Ass (6.23), MSW as follows: bit 13 Ass (6.24) and MSW bit 14 Ass (6.25).
• Page 165
  Serial Interfaces RS232-Port The RS232 interface is normally used for setting parameter in the drive via the PC Tool Drive Window Light. The default settings of this interface are as follows: Signal level: RS232 (+12V / -12V) Description Data format: UART not connected Message format:…
• Page 166
  Several fieldbus protocol specific adapters are avail- Fieldbus cable able as options for the DCS 400. The following de- scription is an overview. Detailed information is avail- able from the specific adapter descriptions. DG D( N ) D( P )
• Page 167
  Data Set Offset 0…255 0 = no Offset 8.07 Cut Off Timeout 0…255 (20ms grid) between NPBA-02 and 30 = 600ms Master 8.08 Comm Profile 0 = ABB DRIVES 0 = ABB DRIVES 1 = CSA 2.8/3.0 II K 7-9…
• Page 168
  Serial Interfaces Modbus (including parameter transfer) Parameter Meaning Alternative settings Typical settings 8.01 Module Type 0 = Disable 1 = Fieldbus Fieldbus 2 = RS232-Port 3 = Panel-Port 4 = Res Feldbus 8.02 Modbus Mode 0 = RTU wdg:flt 0 = RTU wdg:flt 1 = RTU wdg:rst 8.03 Station Number…
• Page 169
  0 = Disable 1 = Fieldbus Fieldbus 2 = RS232-Port 3 = Panel-Port 4 = Res Feldbus 8.02 Protocol 1 = ABB CS31 8.03 Modul ID 0 = Word 0 = Word 1 = Binary 8.04 Station Number 0… 5 (Word Mode) 0…57 (Binary Mode)
• Page 170
  Parameter settings for the most commonly used fieldbus adapters For detailed information please refer to the related fieldbus adapter description. In the case you need a fieldbus other than shown, please contact your local ABB sales office. ABB is continuously developing on new solutions. II K 7-12…
• Page 171
  Serial Interfaces DCS 400 Fieldbus parameter PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 1 — Motor Settings 40101 3065 Arm Cur Nom 40102 3066 Arm Volt Nom 40103 3067 Field Cur Nom 40104 3068 Field Volt Nom…
• Page 172
  Serial Interfaces PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 4 — Field 40401 3191 Field Cur Ref 40402 3192 Field Cur Act 40403 3193 Field Cur KP 40404 3194 Field Cur TI 40405 3195 Fld Ov Cur Trip 40406 3196 Field Low Trip…
• Page 173
  Serial Interfaces PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 6 — Input/Output 40601 3259 AI1 Scale 100% 40602 325A AI1 Scale 0% 40603 325B AI2 Scale 100% 40604 325C AI2 Scale 0% 40605 325D AO1 Assign 40606 325E AO1 Mode…
• Page 174
  Serial Interfaces PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 8 — Fieldbus 40801 3321 Fieldbus Par 1 40802 3322 Fieldbus Par 2 40803 3323 Fieldbus Par 3 40804 3324 Fieldbus Par 4 40805 3325 Fieldbus Par 5 40806 3326 Fieldbus Par 6…
• Page 175
  Appendix A Appendix Appendix A — Accessories Line chokes L1 DCS type Type of Fig. 500V reactor 2-quadrant converter DCS401.0020 ND01 DCS401.0045 ND02 DCS401.0065 ND04 DCS401.0090 ND05 DCS401.0125 ND06 DCS401.0180 ND07 DCS401.0230 ND07 DCS401.0315 ND09 DCS401.0405 ND10 DCS401.0500 ND10 DCS401.0610 ND12 DCS401.0740 ND12…
• Page 176
  Appendix A Line chokes type ND Type Choke Weight Power loss peak [mH] [kg] ND 01 ND 02 ND 04 ND 05 ND 06 ND 07 12.6 ND 09 37.5 16.0 ND 10 25.0 22.2 ND 12 18.8 36.0 ND 13 18.2 1047 46.8…
• Page 177
  Appendix A Line chokes type ND 07…ND 12 H ±2 C ±1 ±0.3 3 AST 4 7 8 2 2 3 D5 3AFE 10014603 0 . 0 1 8 8 mH 4 9 0 A I ma x 7 3 4 A Max D F ±0.3 B ±1…
• Page 178
  Appendix A Fuses and fuse holders for armature- circuit supply The semiconductor fuses used are blade fuses. The relevant data are listed in the table below. The fuses’ construction requires special fuse holders. Fuse hold- er of the OFAX and OFAS type series are available for this purpose.
• Page 179
  Appendix A L1 L2 L3 Manufacturer/ Type Loss [W] Resistance [mW] Fuse F1 Size Fuse holder Caliper [mm] Bussman 170M 1564 50A 660V UR OFAX 00 S3L 78.5 Bussman 170M 1566 80A 660V UR OFAX 00 S3L 78.5 Bussman 170M 1568 125A 660V UR OFAX 00 S3L 78.5…
• Page 180
  Grids of this kind DCS401.0020 NF3-500-25 250x150x65 have an earthed neutral conductor. For DCS401.0045 NF3-500-50 250x150x65 these cases, ABB offers its three-phase DCS401.0065 NF3-500-64 250x150x65 DCS401.0090 NF3-500-80 450x170x90 mains filters for 500 V and 25 A … 1000 A.
• Page 181
  Appendix B — Declaration of conformity II K B-1…
• Page 182
  Appendix C — Quick Installation & Commissioning guide II K C-1…
• Page 183
  Appendix C II K C-2…
• Page 184
  Appendix D — Examples for basic parameter programming The experience has shown that certain parameters must be adapted in most applications. These parameters show the following tables. Table 1: Operation for armature control mode Table 2: Operation for field control mode Table 3: Operation for field control mode with speed-dependent current limitation Table 4:…
• Page 185
  Appendix D Operation for field control mode Armature control range Field control range norm Base Speed Max Speed Table 2 Parameter Parameter Significance Contents Entry number name Arm Cur Nom Nominal armature current Arm Volt Nom Nominal armature voltage Field Cur Nom Nominal field current Field Volt Nom Nominal field voltage…
• Page 186
  Appendix D Operation for field control mode with speed-dependent current limiting Armature Field control range norm control range Speed-dependent current limiting Base Speed Cur Lim Speed Max Speed Table 3 Parameter Parameter Significance Contents Entry number name Arm Cur Nom Nominal armature current Arm Volt Nom Nominal armature voltage…
• Page 187
  Appendix D Common parameters for the three operating modes Table 4 Parameter Parameter Significance Contents Entry number name Arm Cur Max Maximum current limit Overload Time Overload time Recovery Time Recovery time Torque Lim Pos Positive torque limit Torque Lim Neg Negative torque limit Stall Torque Stall torque…
• Page 188
  Index Symbole 7-Segment display 2-5, 3-7, 6-24, 6-26, 6-30 Factory Setting 6-5 Fan data 3-6 Fault Signals (F) 6-26 Alarm Signals (A) 6-30 Faultlogger 6-4 Alternative parameters for speed controller Field current controller 3-10, 4-37, 4-54 4-2, 4-36 Field Exciter Board SDCS-FIS-3A 3-10 Analogue Tacho feedback 6-17 Field heating 4-25 Application Macros 4-2…
• Page 189
  Index Operating Instructions 6-1 Overload 2-4 Overtemperature Protection 4-31 Overview of software 4-1 Paint finish 2-2 Panel DCS400PAN 1-4, 2-5, 6-1, 6-7, 6-24, 6-25, 7-6 Panel LEDs 6-25 Panel Lock 6-5 Panel mode 6-2 Drive control 6-6 Function selection 6-3 Menu selection 6-2 Parameter programming 6-3 Panel-Port 7-6…
• Page 190
  Notices…
• Page 191
  Notices…
• Page 192
  ABB Automation Products GmbH Postfach 1180 D-68619 Lampertheim Telefon +49(0) 62 06 5 03-0 Telefax +49(0) 62 06 5 03-6 09 www.abb.com/motors&drives…

Quick Links

DCS Thyristor power converter

for DC drive systems

20 to 1000 A

9 to 522 kW

Manual

DCS 400

II K 1-1

• Page 1
  DCS Thyristor power converter for DC drive systems 20 to 1000 A 9 to 522 kW Manual DCS 400 II K 1-1…
• Page 2
  This manual is valid for DCS 400 Rev A including software version 108.0 List of contents ANUAL 1 DCS 400 — the compact-size DC drive ..II K 1-3 2 System overview of DCS 400 ….II K 2-1 2.1 Environmental conditions ……….
• Page 3
  1 DCS 400 — the compact-size DC drive DCS 400 is a new generation of DC drives, which integrate more accessories within the same space. is rated from 9 to 522 KW and for use on all line The compact design has been partly achieved by supply voltages from 230 to 500 V.
• Page 4
  DCS 400 — the compact-size DC drive Unit functions Activation and operator-control inputs outputs Drive functions analogue and digital • Speed ramp function generator (S-ramp, fieldbusses 2 accel / decel ramps) (man-machine communication) via: • Speed feedback via tacho, encoder, EMF •…
• Page 5
  ‚ à y à ‚ … à ‡ ‚ †  ‚ ‚ ˆ ‘ à Q à i ‘ ‘ à ‡ optical fibre RS232 ‘ ‚ ‡ Fig. 2/1: System overview of DCS 400 II K 2-1…
• Page 6
  2.1 Environmental conditions System overview of DCS 400 Mains supply — power part Environmental limit values Voltage, 3-phase: 230 to 500 V in acc. with IEC 38 Permissible ambient temp. with rated current I : +5 to +40°C Voltage deviation: ±10% permanent…
• Page 7
  2.2 DCS 400 power converter modules System overview DCS 400 Sizes Size A2 Size A1 Size A4 Size A3 Size Current Dimensions Weight Min. Clearances Fan connection Fuses range H x W x D appr. top/butom/side [mm] [kg] [mm] 20…25 A…
• Page 8
  2.3 DCS 400 overload withstand capability System overview of DCS 400 To match a drive system’s components as efficiently as possible to the driven machine’s load profile, the power converters can be dimensioned by means of the load cycle. Load cycles for driven machines have been defined in the IEC 146 or IEEE specifications, for example.
• Page 9
  Control and Display Units of the DCS 400 System overview DCS 400 For operation, commissioning, diagnosis and for The coupling to an overriding system (PLC) takes controlling the drive, there are different possibil- place over a serial interface with a fibre-optic link ities available.
• Page 10
  System overview of DCS 400 Operation by PC Drive Window Light Components : Drive Window Light is a PC tool for on-line start- • RS232 standard cable, 9-pin sub-D connector, up, diagnosis, maintenance and troubleshooting. male-female, non-crossing Functionality: System configuration display •…
• Page 11
  Technical data 3 Technical Data 3.1 Module dimensions Module A1 DCS 401.0020 DCS 401.0045 DCS 401.0065 DCS 401.0090 DCS 401.0125 DCS 402.0025 DCS 402.0050 DCS 402.0075 DCS 402.0100 DCS 402.0140 Module A2 DCS 401.0180 DCS 401.0230 DCS 402.0200 DCS 402.0260 Module A3 DCS 401.0315 DCS 401.0405…
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  Technical data Module A4 DCS 401.0610 DCS 401.0740 for M6 DCS 401.0900 DCS 402.0680 DCS 402.0820 DCS 402.1000 Dimensions in mm for M12 Fig. 3.1/2: Dimension drawing A4-Module II K 3-2…
• Page 13
  1 x 150 1 x 150 * Busbar connection 5 x 40 mm is recommended Table 3.2/1: Cross-sectional areas — tightening torques DCS 400 ❶ You will find instructions on how to calculate the PE conductor’s cross-sectional area in VDE 0100 or in equivalent national standards.
• Page 14
  • The DCS 400 should be installed in an enclosure that is minimum 150% of the dimensions of con- verter. • The DCS 400 is suitable for use in a circuit capable of delivering not more than 18 kA rms Symetrical amperes, 500 V AC maximum. Recommended fuses must be used to provide short circuit protec- tion.
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  895 1416 1986 DCS402.1000 1000 1116 1786 2527 Table 3.3/1: DCS 400 Power losses of armature circuit Remarks on the table • The values stated are are maximum values ob- tained under the most unfavourable conditions. DCS 400 field supply 440V…
• Page 16
  DCS 40x.0900…DCS 40x.1000 1x W2E250 (230 V) DCS 40x.0900. 2…DCS 40x.1000. 2 1x W2E250 (115 V) Configuration 1 Table 3.4/1: Fan assignment for DCS 400 Fan data for DCS 400 (data per fan) !»ÃWhp X99: Fan type CN2B2 W2E200 W2E200…
• Page 17
  The control board SDCS-CON-3A has three serial communication channels: • X7: is a serial communication channel which is used for — DCS 400 PAN — Adapter (3AFE 10035368) • X6: is a standard RS232 serial communication channel. It is a 9-pin D-Sub female connector •…
• Page 18
  Digital and analogue I/O connection of the SDCS-CON-3A Technical data Reso- Input/output Scaling Load Common Remarks 6’&6&21 Software lution values mode 90-270 V X1:1 [bit] Hardware range 30-90 V R115 100k 100k ±90…270 V 8-30 V AITAC ➀ ➁ 11 + sign ±30…90 V R 115/ ±20 V 100k…
• Page 19
  Technical data 3.6 Power Interface Board SDCS-PIN-3A The power interface board SDCS-PIN-3A is used for all converter modules model A1…A4. Functions: — firing pulse circuits — power supply for complete converter electronics — measurement of the armature current — fuses for field supply. Fuse data F100…F102: — snubber circuit Bussmann KTK-15A (600V) — AC and DC voltage measurement…
• Page 20
  3.7 Field exciter SDCS-FIS-3A Technical data The DCS 400 converter has an build-in three-phase field exciter with the following features: • smoothed field voltage — better commutation of the motor T100 — increased brush life SDCS-FIS-3A • less heat generation in the motor •…
• Page 21
  Technical data System con- Field nection voltage range Line [V~] [V-] DCS 40x.0020…DCS 40x.0140 50…237 50…392 50…413 50…428 50…440 50…440 50…440 50…440 Table 3.7/1: Field voltage range related to 0,01 specified input voltage Fig. 3.7/3 Operating area of field exciter 0.1…6 A DCS 40x.0180…DCS 40x.1000 Fig.
• Page 22
  3.8 Ciruit diagrams Technical data » » » » » » Ã Ã » » Ã Ã Ã Ã Ã » » Ã » Ã D & & Ã $ » » &…
• Page 23
  Technical data » » » » » Ã Ã » Ã Ã Ã Ã Ã » » Ã » Ã D & & Ã $ » » & » » » » » Ã…
• Page 24
  Technical data II K 3-14…
• Page 25
  Overview of Software 4 Overview of software (The software delivered may contain minor changes to the product described here.) Parameter Function menu The parameters of the converter are subdivided into Special functions of the control panel are listed in the functional groups.
• Page 26
  4.1 General information about application Macros Overview of Software Macros are pre-programmed parameter sets. During start-up, the analog outputs, which reference value sources are used, etc. is drive can be configured easily without changing individual parame- already defined in the macro. ters.
• Page 27
  Overview of Software Overview of factory settings of macro-dependent parameters: Í Ï Macro Parameter Standard Man/Const Sp Hand/Auto Hand/MotPot Jogging Motor Pot ext Field Rev Torque Ctrl Cmd Location (2.02) Terminals Terminals Terminals Terminals Terminals Terminals Terminals Terminals Cur Contr Mode (3.14) Speed Contr Speed Contr Speed Contr…
• Page 28
  4.2 Application Macros Overview of Software The following application macros are available: Macro 1: Standard Macro 5: Jogging Drive switch-on/switch-off and enable via 2 Drive switch-on/switch-off and enable via 2 di- digital inputs. gital inputs. Speed reference via analog input. Speed reference via analog input 1.
• Page 29
  Overview of Software II K 4-5…
• Page 30
  4.2.1 Macro 1 — Standard Overview of Software Description of I/O’s functionality Param Function Jog speed 1. Speed can be defined in parameter 5.13. Accel/Decel Ramp for Jogging can be defined in parameter 5.19/5.20. Jog speed 2. Speed can be defined in parameter 5.14. Accel/Decel Ramp for Jogging can be defined in parameter 5.19/5.20.
• Page 31
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.02 5.03 Fault or Alarm 6.14 Zero-speed 6.13 Running 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  User alarm ‚ ‡…
• Page 32
  4.2.2 Macro 2 — Man/Const Sp Overview of Software Description of I/O’s functionality Param Function Drive is started by closing digital input DI1 (DI=1). Switches the drive ON and START Drive is stopped by opening digital input DI2 (DI2=0). DI2 has a higher priority than DI1, i.e. if DI2 is open the drive can not be started.
• Page 33
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Zero-speed 6.14 Fault 6.13 Running 6.12 Ready for ON 6.11 Fixed speed 2 Fixed speed 1 Main con- 6.15 tactor ON Reset Emergency stop 2.01 Ramp 1 / Ramp 2 Direction of rotation Stop Start…
• Page 34
  4.2.3 Macro 3 — Hand/Auto Overview of Software Description of I/O’s functionality Param Function Start / Stop Hand. Start and stop the drive. DI1=0=STOP , DI1=1=START Start switches the drive ON and START. Stop the drive in according to parameter Stop-Mode and afterwards switch the drive off.
• Page 35
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Zero-speed 6.14 Fault 6.13 Running 6.12 Ready for ON 6.11 Start/Stop Auto Direct. of rot. Auto Main con- 6.15 tactor ON Reset Emergency stop 2.01 Fixed speed / AI1 Direct.
• Page 36
  4.2.4 Macro 4 — Hand/MotPot Overview of Software Description of I/O’s functionality Param Function Start / Stop. Start and stop the drive. DI1=0=STOP , DI1=1=START. Start switches the drive ON and START. Stop the drive in according to parameter Stop-Mode and afterwards switch the drive off and resets speed reference to zero.
• Page 37
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Zero-speed 6.14 Fault 6.13 Running 6.12 Ready for ON 6.11 Decrease speed Main con- 6.15 tactor ON Increase speed Reset 2.01 Emergency stop AI1 / MotPot Direction of rotation Jogging Start/Stop…
• Page 38
  4.2.5 Macro 5 — Jogging Overview of Software Description of I/O’s functionality Param Function Direction of rotation. DI1=0=forward , DI1=1=reverse Jog speed 1. Speed can be defined in parameter 5.13. Accel/Decel Ramp for Jogging can be defined in parameter 5.19/5.20. Jog speed 2.
• Page 39
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Fault or Alarm 6.14 speed level reached 6.13 Zero-speed 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  ‚ ‡…
• Page 40
  4.2.6 Macro 6 — Motor Pot Overview of Software Description of I/O’s functionality Param Function Direction of rotation. DI1=0=forward , DI1=1=reverse Motor pot function „faster“.Accel Ramp 5.09 Motor pot function „slower“. Decel Ramp 5.10. Slower has precedence above faster. 2.01 Minimum speed.
• Page 41
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Fault or Alarm 6.14 reached 6.13 reached 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  Min speed ‚ ‡…
• Page 42
  4.2.7 Macro 7 — ext Field Rev with remanence contactor Overview of Software Short description Description of I/O’s functionality Param Function Non Field Reversal Mode: External field reversal with external field reversing switch. Only for 2Q application. • DI1 = 0 V (contact open), DI1=0=no field reversal only effective if drive is in DI1=1=field reversal…
• Page 43
  Overview of Software field reversal K3 energized 1.03 / 1.04 no field reversal K3 de-energized 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Field reversal ON Fault or Alarm Field reversal OFF 6.14 Field reversal activ. 6.13 Running 6.12 Ready for Run 6.11 On/Off Main con-…
• Page 44
  4.2.8 Macro 8 — Torque Ctrl Overview of Software Description of I/O’s functionality Param Funktion COAST. Closed-circuit principle, must be closed for operation. COAST is the fastest way to stop the current controller. The current controller will decrease the armature current to zero as fast as possible. This command will stop the drive so that the motor is left running and friction together with the load will decrease the speed to zero.
• Page 45
  Overview of Software 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 Fault or Alarm 6.14 6.13 Running 6.12 Ready for Run 6.11 On/Off Main con- 6.15 tactor ON Reset Emergency stop 2.01  User Alarm ‚ ‡ ‡…
• Page 46
  4.3 Digital and analogue Inputs/Outputs Overview of Software Digital inputs DI1…DI8 Tachogenerator input (11 Bits + sign) The drive is controlled via the digital inputs DI1…DI8. The speed feedback with tachogenerator is set with The significance of the inputs are defined by a macro. the parameter Speed Meas mode (5.02) = Tacho.
• Page 47
  80% of full resolution. A speed measure- ment up to 125% of nominal speed is possible. The accuracy is 0,06% related to nominal speed. Drive controlled by Serial Communication DCS 400 Speed reference Speed reference à $Ãiv‡†vt Fieldbus accuracy $È…
• Page 48
  4.4 Drive Logic Overview of Software The drive logic controls the switching on and off of the Other behaviour during switching on and off converter and the motor and protects both in excep- Switching off modes other than the default setting can tional situations, in case of fault or emergency stop.
• Page 49
  (5.15). When the drive starts again (RUN=1) the drive will switch over to nominal field current. Drive is in operation 9…v‰rÃv†Ã…ryrh†rq) 10sec 10sec AvryqÃurh‡vt Fig. 4.4/1: Switch-on sequence of DCS 400 Field current Fan On Zero Speed Programmable Fan Delay (2.13) II K 4-25…
• Page 50
  Switch off fan 9…v‰rÃv†ÃPAA) AhÃP 2. Possible circuitry Since the requisite edges can Fig. 4.4/2: Switch-off sequence of DCS 400 be generated by means of a Reset Rdy On signal when the elec- Eme Stop tronics supply is switched on…
• Page 51
  • the drive thus remains simple and safe. thresholds. This is not the case with the DCS 400, whose power section can be operated on a mains On the basis of the computed minimum permissible supply voltage of 230V…500V without any further…
• Page 52
  Overview of Software 5% above this tripping threshold, an alarm signal Monitoring the Mains Voltage: A02-Mains Voltage Low will be generated. The alarm range shifts when the Net Underv Trip (1.10) e.g. Mains Supply Voltage = 400 V parameter is altered. Application = 4-Q Armature Voltage Nominal = 420 V…
• Page 53
  Overview of Software Monitoring the Mains Voltage: Auto Reclosing In parameter Net Fail Time (1.11) the maximum e.g. Mains Supply Voltage = 400 V tolerated mains voltage failure time is set. In case of Application = 4-Q mains undervoltage the drive is blocked and alarm Armature Voltage Nominal = 420 V A02 is displayed during this time.
• Page 54
  [217 A Correlation of Armature Voltage and EMF 440 V 390 V The DCS 400 drive calculates the true EMF and does not take the Armature Voltage instead. EMF is calculated by Ua actual Under full load condition, at full speed:…
• Page 55
  Overview of Software Without speed-dependent current limiting 4.5.4 Overtemperature Protection The field weakening mode is selected or not selected as a function of the parameter values Base Speed Converter: (1.05) and Max Speed (1.06): DCS400 is equipped with an overtemperature protec- tion on the heat sinks of the thyristors.
• Page 56
  Overview of Software 4.5.5 Armature current controller Second current limitation The motor’s maximum armature current is limited by The Arm Cur Nom (1.01), Arm Cur Max (3.04), the Arm Cur Max (3.04) parameter. This absolute Torque Lim Pos (3.07) and Torque Lim Neg (3.08) limitation is always active.
• Page 57
  Overview of Software Armature current controller operating modes The speed of a DC motor is altered with the armature voltage. The range up to the point where the rated armature voltage is reached is referred to as the armature operating range. To enable the motor’s speed to be increased above these rated armature voltage, the field’s magnetic flux has to be reduced.
• Page 58
  Overview of Software 1 = Speed Contr / 2 = Torque Contr 4 = Speed + Torque Depending on the application involved, however, a Depend on application in speed control mode a pre- constant torque is also required in the field weakening control of torque is required to have the drive more range (Torque-Controlled Mode (3.14) = Torque dynamic.
• Page 59
  Overview of Software 6 = Lim Trq Ctr (Window Control Mode) t function The idea of Window Control Mode is to deactivate the The DCS400 is equiped with an I t-protection for the speed control as long as the speed deviation remains motor, which can be enabled if required.
• Page 60
  Overview of Software The overload phase is set using parameters Arm Cur 4.5.8 Alternative Parameters for the Speed Max (3.04) and Overload Time (3.05). The recovery Controller phase is set using parameter Recovery Time (3.06). In order not to overload the Motor, the I t-plane of the A second parameter set is available for the speed two phases have to be identical:…
• Page 61
  Overview of Software 4.5.9 Service Procedures, Contr Service (7.02) After successful autotuning the following controller parameters are set: Armature current controller Field Cur KP (4.03) (Motor does not turn) Field current controller proportional gain Field Cur TI (4.04) Autotuning Field current controller integral time constant •…
• Page 62
  Overview of Software Speed controller After successful autotuning the following controller parameters are set: Attention: Motor will accelerate twice to 80% of Field Cur 40% (4.07) Base Speed now Field current for 40% flux Field Cur 70% (4.08) Autotuning Field current for 70% flux •…
• Page 63
  Overview of Software This internal scaling does not apply to the transmis- 4.5.10 Internal Scaling sion of parameters via PLC. In this kind of transmis- You can display all parameters of the DCS400 in their sion, decimal values are simply transmitted in binary physical quantities by means of operating panel or the form i.e.
• Page 64
  Overview of Software 4.5.11 Signal definitions Signal «Overtemp Mot» / «Overtemp DCS» Signal «At Set Point» in case of Alarm Speed reference reached. Speed actual value Speed Act (5.05) correspondes PTC (DCS / Motor-AI2) to speed reference value before ramp generator Digital Output DOx Ramp In Act (5.33).
• Page 65
  Overview of Software 4.5.12 User events Adaptation of digital inputs for user events First four digital inputs DI1…DI4 are re-configurable in parameter group 9-Macro Adaptation for macro 1, 5, 6, 7 and 8. This functionality is not available for macro 2, 3 and 4. For some user specific application it’s helpful do assign these inputs to user events External Fault or External Alarm.
• Page 66
  4.6 Software Structure Overview of Software DO1 Assign 9…v‰rÃG‚tvpÃhqÃT‡h‡ˆ†ÃQ…‚pr††vt 6.11 Eme Stop constant 0 Reset constant 1 DO2 Assign Macro depend 6.12 Rdy for On Start Rdy for Run DI Act Macro Select Stop Running DO3 Assign 6.28 2.01 6.13 Eme Stop act Fault Macro dep.
• Page 67
  Overview of Software P‰r…‰vrÃ‚sÃhy‡r…h‡v‰rÃ9…v‰rÃ8‚‡…‚yyvt††vivyv‡vr† Srsr…rpr†Ã8‚‡…‚y 6p‡ˆhyÉhyˆr†ÃT‡h‡ˆ† ‚rÂsÇur†r v†Ãƒ‚††viyrÄ Fieldbus Fieldbus Adapter Module 7ˆ†Ã†’†‡r€ Adapter Module 7ˆ†Ã†’†‡r€ SHF DG D(N) D(P) SHF DG D(N) D(P) D‡r…hyÃ…‚pr††vt R XD R XD Nx xx -01 Fieldbus DS1.1 DS2.1 Nxxx-01 TX D Fieldbus TX D x xx xx x xx x xx xx x xx ADA PTER…
• Page 68
  4.7 Parameter list Overview of Software Parameter overview 1 — Motor Settings 2 — Operation Mode 3 — Armature 4 — Field 1.01 Arm Cur Nom * 2.01 Macro Select * 3.01 Arm Cur Ref 4.01 Field Cur Ref 1.02 Arm Volt Nom * 2.02 Cmd Location 3.02 Arm Cur Act 4.02 Field Cur Act…
• Page 69
  Overview of Software ParNo. Parameter name and significance Default Unit custom setting Grp 1 Motor Settings 1.01 Arm Cur Nom 1000 Wizard Nominal motor current in amperes (indicated on the motor’s rating plate). 1.02 Arm Volt Nom Wizard Nominal motor voltage in volts (indicated on the motor’s rating plate).
• Page 70
  Overview of Software ParNo. Parameter name and significance Default Unit custom setting Grp 1 Motor Settings (continued) 1.11 Net Fail Time 10.0 During this time the supply voltage must return to a value higher than Net Underv Trip (1.10). Otherwise an undervoltage trip will be generated.
• Page 71
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 2 Operation Mode 2.01 Macro Select Text Wizard Selection of desired macro: 0 = Standard 1 = Man/Const Sp 2 = Hand/Auto 3 = Hand/MotPot 4 = Jogging 5 = Motor Pot 6 = ext FieldRev 7 = Torque Cntrl…
• Page 72
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 2 Operation Mode (continued) 2.04 Eme Stop Mode Text Wizard Selection of the desired operating response to an Eme Stop command (controller blocking) 0 = Ramp Motor decelerates in acc. to Eme Stop Ramp (5.11). If Zero Speed Lev (5.15) is reached Main Contactor is switched off.
• Page 73
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 2 Operation Mode (continued) 2.05 Main Ctrl Word Signal The Main Ctrl Word maps the control bits of the drive. This parameter indicates the control bits of the terminal block or of the bus communication.
• Page 74
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 2 Operation Mode (continued) Long Parameter Menu 2.07 Comm Fault Mode Text Selection of the desired operating response to a communication failure: 0 = Ramp Motor is decelerated in accord. to a ramp (5.10) 1 = Torque Lim Motor is decelerated in accord.
• Page 75
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 3 Armature 3.01 Arm Cur Ref Signal Armature current reference value in amperes. 3.02 Arm Cur Act Signal Measured armature current actual value in amperes. 3.03 Arm Volt Act Signal Measured armature voltage actual value in volts.
• Page 76
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 3 Armature (continued) 3.10 Arm Cur Reg TI 1000.0 50.0 auto- Integration time constant of the armature current tuning controller (PI controller) in milliseconds. 3.11 Cont Cur Lim auto- Armature current value at the limit between tuning…
• Page 77
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 3 Armature (continued) Text 3.15 Torque Ref Sel Selection of the desired torque reference location: 0 = Macro depend / dependent on the select. macro 1 = AI1 / analog input 1 (X2:1-2) 2 = AI2 / analog input 2 (X2:3-4) 3 = Bus Main Ref / main fieldbus reference value 4 = Bus Aux Ref / auxiliary fieldbus reference value…
• Page 78
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 4 Field 4.01 Field Cur Ref Signal Field current reference value in amperes. 4.02 Field Cur Act Signal Measured field current actual value in amperes. 4.03 Field Cur KP 0.000 13.499 0.300…
• Page 79
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller 5.01 Speed Ref Sel Text Selection of the desired speed reference location: 0 = Macro depend / dependent on the selected macro 1 = AI1 / analog input 1 (X2:1-2) 2 = AI2 / analog input 2 (X2:3-4) 3 = Bus Main Ref / main fieldbus reference value 4 = Bus Aux Ref / auxiliary fieldbus reference value…
• Page 80
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) Long Parameter Menu 5.12 Ramp Shape 0.00 10.00 0.00 0 = linear >0 = ramp shape time Setting the ramp shape: This parameter adds a filter to the output of the ramp generator to create a ramp shape.
• Page 81
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) 5.15 Zero Speed Lev Wizard Zero speed signal. Speed level below which the signal is issued that the motor has reached zero speed. Is used for stall protection, as a standstill message to the drive logic and for the generation of the Zero Speed signal.
• Page 82
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) 0.000 19.000 0.200 integer 5.22 Alt Speed KP Proportional gain of the speed controller (PI controller) for the alternative parameter set. 5.23 Alt Speed TI 6553.5 5000.0 Integration time constant of the speed controller…
• Page 83
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 5 Speed Controller (continued) 5.30 Act Filt 2 Time 0.00 10.00 0.00 Filter time constant 2 for smoothing speed deviation at the input of the speed regulator. 5.31 Speed Lim Fwd 6500…
• Page 84
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 6 Input / Output 6.01 AI1 Scale 100% 2.50 11.00 10.00 Scaling of analog input 1: input of a voltage value in volts, which correspond to 100% reference. 6.02 AI1 Scale 0% -1.00…
• Page 85
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 6 Input / Output (continued) 6.11 DO1 Assign Text Wizard Desired assignment of digital output 1: 0 = none 0 constant (for test purposes) 1 = Constant 1 1 constant (for test purposes) 2 = Macro depend the output is defined by macro, see macro…
• Page 86
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 6 Input / Output (continued) Text 6.12 DO2 Assign Wizard esired assignment of digital output 2: Assignment identical with DO1 (6.11). 6.13 DO3 Assign Text Wizard Desired assignment of digital output 3: Assignment identical with DO1 (6.11).
• Page 87
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 6 Input / Output (continued) 6.20 Dataset 2.2 Asn Text Selection of the desired assignment for fieldbus dataset 2.2: 0 = Speed Act / speed actual value (5.05) 1 = Speed Ref / speed reference value (5.04) 2 = Arm Volt Act / armature voltage act.
• Page 88
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 6 Input / Output (continued) 6.22 MSW Bit 11 Asn Text Function assignement for bit 11 in the main fieldbus status word (2.06): 0 = none 0 constant (for test purposes) 1 = Constant 1 1 constant (for test purposes) 2 = Macro depend…
• Page 89
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 6 Input / Output (continued) 6.23 MSW Bit 12 Asn Text Function assignment for bit 12 in the main fieldbus status word (2.06): Assignment identical with MSW Bit 11 Asn (6.22) 6.24 MSW Bit 13 Asn Text…
• Page 90
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 7 Maintenance 7.01 Language Text Wizard Selection of the panel language: 0 = English 1 = Deutsch 2 = Français 3 = Italiano 4 = Español 7.02 Contr Service Text Action…
• Page 91
  = ShortcV13/26 = ShortcV14/21 = Ground Fault = NoThrConduc 7.04 SW Version integer Const. Display of the DCS 400 software version used. 7.05 Conv Type Text Const. Display of the converter type: 0 = DCS401 (2Q) 1 = DCS402 (4Q)
• Page 92
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 7 Maintenance (continued) 7.06 Conv Nom Cur Const. Display of the converter’s nominal current in amperes. 7.07 Conv Nom Volt Const. Display of the converter’s nominal voltage in volts. 7.08 Volatile Alarm Text…
• Page 93
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 7 Maintenance (continued) 7.12 Alarm Word 1 Signal Alarm word 1. Significance of the individual bits: All the pending alarms are displayed if the corresponding bits are set to log. «1». Alarm definition 00 0001…
• Page 94
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 7 Maintenance (continued) 7.15 Commis Ref 1 -32768 32767 integer Commissioning reference value 1 Scaling: Field current 0…100%= 0…4096 Torque 0…100%= 0…4096 Armature current 0…100%= 0…4096 Speed 0…max = 0…max rpm 7.16 Commis Ref 2…
• Page 95
  Overview of Software For detailed description see «Fieldbus Description» ParNo. Parameter name and significance Default Unit custom. setting Grp 8 Fieldbus Long Parameter Menu 8.01 Fieldbus Par 1 Text 0 = Disable no communication with PLC 1 = Fieldbus PLC communication via fieldbus adapter 2 = RS232-Port PLC communication via RS232 Port / Modbus protocol…
• Page 96
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 9 Macro Adaptation Long Parameter Menu 9.01 MacParGrpAction Text Before a new function can be assigned to a digital input or control bit, the actual function has to be disabled. This can be done in two ways.
• Page 97
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 9 Macro Adaptation (continued) 9.05 User Fault Text Fault function will be controlled from a binary signal which is assigned in this parameter: 0=Macro depend 1=Disable 2=DI1 3=DI2 4=DI3 5=DI4…
• Page 98
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 9 Macro Adaptation (continued) 9.10 MotPot Incr Text MotorPot Increase speed function will be controlled from a binary signal which is assigned in this parameter. Assignment identical with 9.05 only effective if MotPot Decr (9.11) is not set to 1 = Disable State of binary signal:…
• Page 99
  Overview of Software custom. ParNo. Parameter name and significance Default Unit setting Grp 9 Macro Adaptation (continued) 9.14 AlternativParam Text Alternative parameter set will be controlled from a binary signal which is assigned in this parameter. Assignment identical with 9.05 State of binary signal: 0= Standard parameter set for speed controller effective 5.07 Speed Reg KP…
• Page 100
  Overview of Software ParNo. Parameter name and significance Default Unit custom. setting Grp 9 Macro Adaptation (continued) 9.19 Disable Bridge1 Text Bridge 1 will be controlled from binary signal which is assigned in this parameter. Assignment identical with 9.05 State of binary signal: 0= Enable Bridge 1 1= Disable Bridge 1.
• Page 101
  If the consignment is incomplete or contains any incorrect items, please contact the supplier. The technical data and specifications are valid as of going to press. ABB reserves the right to make CAUTION! subsequent alterations. The thyristor power converter weighs quite a lot and should therefore not be held by the front cover.
• Page 102
  5.1 Safety instructions Installation in conformity with the low-voltage directive 73/23/EEC 1. General 4. Installation In operation, drive converters, depending on their degree of protec- The installation and cooling of the appliances shall be in accordance tion, may have live, uninsulated, and possibly also moving or rotating with the specifications in the pertinent documentation.
• Page 103
  Common Warnings Installation Warnings • The thyristor power converter possesses a number of automatic Warnings provide information on states which if the specified reset functions. When these functions are executed, the unit will procedure for the state concerned is not meticulously complied with be reset after an error and will then resume operation.
• Page 104
  (line filters, screened power cables) in the lower power range NOTE! The conformity procedure is matter of responsibility of ABB Automation Products GmbH and of the machine manufactur- ers or the plant builders corresponding to their share of the ex- tension of the electrical equipment.
• Page 105
  Installation Definitions Earth, earthing for safety Ground, grounding for EMC, connection with chassis or housing with low inductance Important instructions for plants with line fil- ters Filter in an earthed line (TN or TT Network) The filters are suitable for earthed lines only, for example in public European 400 V lines.
• Page 106
  Installation Classification Medium-voltage line Medium-voltage line Supply transformer of Supply transformer of a Converter an industry region residental region with light transformer (rated power normally industry (rated power with earthed ≤ 1.2 MVA) normally ≤ 1.2 MVA) Earthed star point iron core (and if Earthed…
• Page 107
  Europe for example with 400 V between the phases. Such lines have an earthed neutral conduc- tor. ABB offers suitable three — phase filters for 400 V and 25 A…600 A and 500 V filters for 440 V lines outside Europe (see Ap- pendix A).
• Page 108
  Installation Due to the maximum power of public 400 V transformers Õ = 1.2 MVA = 1732 A) and due to their relative short circuit voltage V of 6% or 4% the maximum AC current which is available for a ≤…
• Page 109
  Installation Separation A separation transformer makes line chokes unnecessary because transformers of its leakage inductance, and a grounded screen between its windings saves an EMC filter, see and 4. The screen and the iron core must be well connected with the mounting plate of the con- verter.
• Page 110
  Installation Screening Signal cables The cables for digital signals, which are longer than 3 m and all ca- bles for analogue signals, must be screened. Each screen must be connected at both ends by metal clamps (see figure 5.2-4) or comparable means directly on clean metal surfaces, if both earthing points belong to the same earth line.
• Page 111
  Installation Power cables If a screen is not necessary (see 13) the armature current cable without screens must be a four-wire cable because two wires are needed as con- ductors for the parasitic RF currents from the motor to the RF filter in the cubicle.
• Page 112
  Installation Others Earthed public The rated voltages of a public European low voltage line are 400 V low voltage between the 3 phases and 230 V between a phase and the neutral lines conductor. These voltages are provided by a transformer with its 3- phase secondary winding in star connection.
• Page 113
  Installation Industrial low Industrial low voltage lines are local lines in plants or factories. voltage lines They have own supply transformers (see 6). In most cases they are insulated (IT network / no earthed star point) and their voltages are often higher than 400 V. The loads tolerate higher noise levels. Therefore and because industrial lines are decoupled from public lines by their transformers and distances, converters do not need EMC filters at industrial low-voltage lines (see 6).
• Page 114
  Installation Connection exam- See figure 5.2 — 7. ple in accordance with EMC Armature and See figure 5.2 — 7. field cables with screens for “first environ- ment” Armature and See figure 5.2 — 7. field cables without screens for “second en- vironment”…
• Page 115
  Installation Mounting plate Filter Field supply unit Mounting plate with PE DC motor bar and terminals Armature and field cables with A1 A2 screens for «first environment» 6FUHHQV 7DFKR Contact to the motor PE bar housing at the whole screen perimeter The armature current cable must contain a third wire for a PE c Cv‡)Ã…
• Page 116
  Installation Important hint The example shows the principle structure of a DC drive and its connections. It is not a binding recommendation, and it cannot re- spect all conditions of a plant. Therefore each drive must be con- sidered separately and with respect to the special application. Addi- tionally the general installation and safety rules must be taken into account.
• Page 117
  Connection examples Installation Installation 5.3.1 Connection example for digital and analogue coupling of a PLC 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 2.01 Remark The drive is controlled via digital inputs/outputs. Speed 6.08 / 6.09 / 6.10 reference is given via analogue input AI1.
• Page 118
  Installation Installation 5.3.2 Connection example for serial communication of a PLC 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark The drive is controlled serial via MainControlWord 6.08 / 6.09 / 6.10 and MainStatusWord.
• Page 119
  Installation Installation 5.3.3 Connection example for Emergeny Off (valid for all macros) General situation 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark In cases of Emergency Off it is necessary to have an 6.08 / 6.09 / 6.10 OFF-delay relais (K22) in the Emergency Off circuit 6.05 / 6.06 / 6.07…
• Page 120
  Installation Installation 5.3.4 Connection example with DC breaker and controlled deceleration 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark In cases of Emergency Off it is necessary to have an 6.08 / 6.09 / 6.10 OFF-delay relais (K22) in the Emergency Off circuit 6.05 / 6.06 / 6.07…
• Page 121
  Installation Installation 5.3.5 Connection example with DC breaker and drive coasting 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 6.11 6.15 Emergency Stop 2.01 Remark Switch Main Contactor (K1) On and Off is controlled 6.08 / 6.09 / 6.10 by digital output DO5.
• Page 122
  Installation 5.3.6 Connection example for Motor fan and Converter fan (useful for all macros) General situation 0 a 1.03 / 1.04 1.05 / 1.06 1.01 / 1.02 5.03 5.02 6.14 6.13 6.12 Fan On Fan Delay 2.13 6.11 6.15 Emergency Stop 2.01 6.08 / 6.09 / 6.10…
• Page 123
  • basic knowledge of physics and electrical engi- Panel link neering, electrical wiring principles, components The DCS 400 PAN is connected to the drive via a and symbols used in electrical engineering, and serial interface and is removable under power.
• Page 124
  6.1 Panel Operating Instructions Panel mode: Menu selection 2XWSXW GLVSOD 0HQX VHOHFWLRQ 0(18 440V 368A 1500rpm 1 Motor Settings 1500rpm 0(18 OUTPUT MENU AUTO OFF HAND REM LOC <RUN> OUTPUT MENU AUTO OFF HAND REM LOC <RUN> 2 Operation Mode 3 Armature 4 Field 5 Speed Controller…
• Page 125
  Operating Instructions Panel mode: Parameter programming Pˆ‡ƒˆ‡Ãqv†ƒyh’ HrˆÃ†ryrp‡v‚ Qh…h€r‡r…Æryrp‡v‚ Qh…h€r‡r…Ãpuhtvt 0(18 (17(5 (17(5 440V 368A 1500rpm 1 Motor Settings 1.01 Arm Cur Nom 1.01 Arm Cur Nom 200A 200A 1500rpm 0(18 0(18 0(18 OUTPUT MENU AUTO OFF HAND REM LOC <RUN> OUTPUT MENU AUTO OFF HAND REM LOC <RUN>…
• Page 126
  Operating Instructions Set Typecode Read Faultlogger Only visible in Long Par List. Disabled if the drive is in ON-state. Non-volatile memory — 16 Set Typecode Read Faultlogger entries. Use only for replacement of SDCS-CON-3A. OUTPUT MENU AUTO OFF HAND REM LOC <RUN> OUTPUT MENU AUTO OFF HAND REM LOC <RUN>…
• Page 127
  Operating Instructions Factory Setting Panel Lock Disabled if the drive is in ON-state. Before any change in the Panel Lock mode can Enter PIN Code become effective, the PIN number (“400“) first has to Factory Setting Resets all parameters to be entered.
• Page 128
  Panel mode: Drive control Operating Instructions 440V 368A 1500rpm Actual value display 1500rpm Reference display OUTPUT MENU AUTO OFF HAND REM LOC <RUN> Status display 440V 368A 1500rpm (17(5 0(18 Activate reference 1500rpm OUTPUT MENU AUTO OFF HAND REM LOC <RUN> /2&…
• Page 129
  Guided Commissioning Operating Instructions The DCS 400 converters of ABB offer the possibility This section describes the guided commissioning to have a guided commissioning by means of interac- with the panel. The necessary dialogue, also Panel tive dialogue through the parameter programming.
• Page 130
  Operating Instructions Parameter entries The entries required during the guided commission- ing procedure are divided into selection parameters and value parameters. Selection parameters are selected from a prede- fined text list and confirmed. The control panel display only shows one line of this text list at a time.
• Page 131
  Operating Instructions Start of guided commissioning Commissioning step Comments Unexpected trouble during guided commissioning can be eliminated easily. Find in the following chapters the reason and carry out the measures described there. For faults, alarms and diagnosis messages, see chapter 6.4 Troubleshooting . For other reasons, see chapter 6.3 Useful hints for commssioning .
• Page 132
  Operating Instructions Commissioning step Comments Fieldweakening? Field weakening Yes/No OUTPUT MENU AUTO OFF HAND REM <RUN> 1.06 Max Speed Maximum speed for field- 1.06 Max Speed is set to the value of weakening operation 100rpm 1.05 Base Speed see motor name plate OUTPUT MENU AUTO OFF HAND REM…
• Page 133
  Operating Instructions Commissioning step Comments Field Autotuning? Field current controller opti- mization OUTPUT MENU AUTO OFF HAND REM <RUN> CAUTION CAUTION Field voltage of the motor will be Observe safety energized. instructions Start Drive Press key on panel to apply Press (I) field voltage to the motor.
• Page 134
  Operating Instructions Commissioning step Comments Armature Autotuning? Armature current controller optimization OUTPUT MENU AUTO OFF HAND REM <RUN> CAUTION CAUTION Motor will be energized. Observe safety instructions Press key on panel to apply Start Drive Press (I) field voltage armature voltage to the motor.
• Page 135
  Operating Instructions Commissioning step Do not use this path, if speed Speed Meas Adjust? controller adjustment is already done! OUTPUT MENU AUTO OFF HAND REM <RUN> Speed measurement mode 5.02 Speed Meas Mode Select and confirm. Depending on the selection made, EMF or Tacho or Encoder commission- Analogue Tacho OUTPUT…
• Page 136
  Operating Instructions Commissioning step Comments Speed Autotuning? Speed controller optimization Select and confirm. OUTPUT MENU AUTO OFF HAND REM <RUN> CAUTION CAUTION Observe safety Motor will accelerate twice up to instructions 80% of Base Speed! Press key on panel to switch Start Drive Press (I) on and enable the drive.
• Page 137
  Operating Instructions Commissioning step Comments Flux Adaptation? Flux optimization only available in Field weaken- OUTPUT MENU AUTO OFF HAND REM <RUN> ing Mode. CAUTION CAUTION Observe safety Motor will accelerate up to 50% instructions of Base Speed! Press key on panel to switch Start Drive Press (I) on and enable the drive.
• Page 138
  Operating Instructions Commissioning step Comments Stall Protection? Stall protection OUTPUT MENU AUTO OFF HAND REM <RUN> 3.17 Stall Torque Stall torque 100% OUTPUT MENU AUTO OFF HAND REM <RUN> 3.18 Stall Time 0.0s Stall time OUTPUT MENU AUTO OFF HAND REM <RUN>…
• Page 139
  Arm Autotun Switch the drive ON and increase speed reference slowly up to the value of Base Speed (1.05) by using a reference potentiometer or by using the DCS 400 operating panel in LOCal mode. Read parameter Speed Ref (5.04); same as Base Speed! Tacho Speed Act (5.06);…
• Page 140
  Operating Instructions with EMF feedback Set parameters Arm Cur Nom (1.01): see motor name plate Arm Volt Nom (1.02): see motor name plate Field Cur Nom (1.03): see motor name plate Field Volt Nom (1.04): see motor name plate Base Speed (1.05): see motor name plate Max Speed (1.06): same as Base Speed…
• Page 141
  Operating Instructions with Encoder feedback Set parameters Arm Cur Nom (1.01): see motor name plate Arm Volt Nom (1.02): see motor name plate Field Cur Nom (1.03): see motor name plate Field Volt Nom (1.04): see motor name plate Base Speed (1.05): see motor name plate Armature control range Field weakening range…
• Page 142
  Useful hints for commissioning Operating Instructions F12 — Field Undercurrent Field Autotuning failed F09 — Mains Undervoltage Check parameter Diagnosis (7.03) and read chapter 6.4.7 Diagnostic Messages A02 — Mains Voltage Low Drive doesn’t start Armature Autotuning failed DCS400 is suitable for main supply of 230…500V Check parameter Diagnosis (7.03) and read chapter without any parameter settings.
• Page 143
  Operating Instructions Hints for speed controller autotuning Drive accelerates to overspeed Only successfully commissioned selftuning will change With default parameter values (defaults: KP=0.200 / parameters of the speed controller Speed Reg KP TI=5000.0 ms) and slow ramps it may happen, that (5.07) and Speed Reg TI (5.08), other-wise parame- the drive accelerates to overspeed limit bypassing ters remain unchanged.
• Page 144
  Eliminate speed offset via Tacho Offset (5.34) fieldweakening • switch drive OFF If a DCS 400 is intended to be used in regenrative • read Speed Actual from panel mode including field-weakening we recommend the • set Tacho Offset (5.34) to this value incl. polarity following sequence to switch the drive on: •…
• Page 145
  A compromise is provided by two series- Then DCS 400 is using automatic field weakening connected fuses, as used in the power supply. to achieve full speed but will lose torque in field weakening range.
• Page 146
  Reserved for External FPROM checksum error In addition to the seven segment display, the LCD of the control panel DCS 400 PAN will be able to show COMM LOSS Internal error in even address of the fault and alarm signals as well as the diagnostic messages as clear text.
• Page 147
  After Reset, switch ON and RUN off and on again. DCS 400 Initialisation phase initialisation phase After the electronics supply has been switched on, both LEDs light up briefly during the initialisation phase of the DCS 400. Flashes Flashes DCS 400 Hardware problem with the power supply…
• Page 148
  SDCS-CON-3A as codes F . . as well as on the LCD Fault no. of the control panel DCS 400 PAN as plain text. Auxiliary Voltage Fault All fault signals — with the exception of F1 to F6 — can be reset by Aux Voltage Fault 7.09…
• Page 149
  Operating Instructions Definition / Definition / Possible source Possible source Fault message Fault message Fault no. Fault no. Converter Over Temperature Mains Synchronization Fault Converter Overtemp 7.09 F 11 Mains Sync Fault 7.09 Temperature of the converter too The synchronization to the mains bit 6 bit 10 high.
• Page 150
  Operating Instructions Definition / Definition / Possible source Possible source Fault message Fault message Fault no. Fault no. Field Overcurrent Tacho Polarity Fault F 13 Field Overcurrent 7.09 F 17 Tacho Polarity Fault 7.10 Field current has reached a limit Polarity of feed back signal from bit 12 bit 0…
• Page 151
  Operating Instructions Definition / Possible source Fault message Fault no. Local Control Lost F 21 Local Control Lost 7.10 During operation in Local control bit 4 mode no message has been received for a time longer than the value that has been set in Parameter Comm Fault Time (2.08).
• Page 152
  Possible source Alarm message control board SDCS-CON-3 as codes A . . as well as on the LCD of Alarm no. the control panel DCS 400 PAN as clear text. Alarm signals will only Parameters Added Alarm Parameters Added 7.12 be displayed, if there is no fault signal active.
• Page 153
  Wizard. Then Mains Drop Out Alarm Main Voltage Drop Out 7.12 read out parameter Diag- DCS 400 is equipped with an bit 7 nosis (7.03) manually and „Auto Reclosing“ that allows for also the Fault Logger for a continous operation after more information.
• Page 154
  Operating Instructions Definition / Definition / Possible source Possible source Alarm message Alarm message Alarm no. Alarm no. A 14 Up/Download Failed Alarm Upload Download Fai- 7.12 A 18 Parameter Restored Parameter Restored 7.13 bit 13 To enable data loss in the bit 1 The checksum verification failed FlashProm to be detected, the…
• Page 155
  None Actually no problems Internal software causes. Reference list of Diagnostic messages Please contact your ABB local — sorted by alphabetical order service center. Tune Aborted Procedure aborted by FAULT or switching off the RUN command.
• Page 156
  Field R Meas Not enough measurement for the de- Upload or Download start timeout. tection of field resistance. The value of Please contact your ABB local “Field R” is used for calculation the service center. Parameter 4.04 (Field Cur TI).
• Page 157
  Operating Instructions Definition / Definition / Possible source Possible source 7.03 Diagnosis 7.03 Diagnosis Diagn. message Diagn. message AI2 vs PTC AI2 is set as PTC evaluation and Ref- 3bbbb 3bbbb 3bbbb faulty thyristor diagnosis erence value source. (b=bridge) If PTC is allocated to AI2 this input will 3bbbb 1…6 = thyr.
• Page 158
  Operating Instructions II K 6-36…
• Page 159
  Drive configuration with serial communication The drive can be operated (ON / RUN / Reset / Emergency Stop) The DCS 400 is equipped with the following serial interfaces: according to parameter Cmd Location (2.02) via terminal X4: or • Panel-Port (standard, built-in) one out of three serial interfaces (Panel-Bus or RS232-Bus or •…
• Page 160
  Serial Interfaces T‡h‡rÂs 6p‡ˆhy 6p‡ˆhy 9…v‰r ‰hyˆr ‰hyˆr DataSet 2.1 DataSet 2.2 DataSet 2.3 HhvÃT‡h‡ÃX‚…q 6p‡ˆhyÃWhyˆrà 6p‡ˆhyÃWhyˆrÃ! SHF DG D(N) D(P) R XD Nxxx-01 TX D x xx xx x xx ADA PTER XM I T BU S TE R M I N A TI O N R EC ER R O R +2 4 V…
• Page 161
  Serial Interfaces DataSet 3.1 DataSet 3.2 DataSet 3.3 DataSet 4.1 DataSet 4.2 DataSet 4.3 9vtv‡hyÃSrs 6hy‚tÃSrs 6hy‚tÃSrs AyqÃ8ˆ…Ã6p‡ Q‚r…Ã6 p‡ U‚…„ˆrÃ6 p‡ SHF DG D(N) D(P) R XD Nx xx -01 TX D x xx xx x xx ADA PTER XM I T BU S TE R M I N A TI O N…
• Page 162
  Serial Interfaces Communcation Parameters Necessary parameter-settings for fieldbus communication Parameter Parameter name possible settings recommended The following communication paramters are relevant 2.02 Cmd Location 0=Macro depend in case of external drives control. 1=Terminals 2=Bus 2=Bus Cmd Location (2.02) 3=Key Purpose: Determines whether Drive is externally con- 2.07 Comm Fault Mode 0=Ramp…
• Page 163
  Irrespective of the bus protocol, these ports main control word (2.05) and main status word communicate with the DCS400 software via specified (2.06) of the DCS 400 converter. The allocation is as data sets. Four data sets are available with three 16- follows: bit words each.
• Page 164
  Serial Interfaces Status word allocation Panel-Port 4 bits of the status word (data set 2.1) can be param- The Panel Port is normally used for connection of the eterized. The signals are selected in the parameters control panel. The default settings of this interface are MSW bit 11 Ass (6.22), MSW bit 12 Ass (6.23), MSW as follows: bit 13 Ass (6.24) and MSW bit 14 Ass (6.25).
• Page 165
  Serial Interfaces RS232-Port The RS232 interface is normally used for setting parameter in the drive via the PC Tool Drive Window Light. The default settings of this interface are as follows: Signal level: RS232 (+12V / -12V) Description Data format: UART not connected Message format:…
• Page 166
  Several fieldbus protocol specific adapters are avail- Fieldbus cable able as options for the DCS 400. The following de- scription is an overview. Detailed information is avail- able from the specific adapter descriptions. DG D( N ) D( P )
• Page 167
  Data Set Offset 0…255 0 = no Offset 8.07 Cut Off Timeout 0…255 (20ms grid) between NPBA-02 and 30 = 600ms Master 8.08 Comm Profile 0 = ABB DRIVES 0 = ABB DRIVES 1 = CSA 2.8/3.0 II K 7-9…
• Page 168
  Serial Interfaces Modbus (including parameter transfer) Parameter Meaning Alternative settings Typical settings 8.01 Module Type 0 = Disable 1 = Fieldbus Fieldbus 2 = RS232-Port 3 = Panel-Port 4 = Res Feldbus 8.02 Modbus Mode 0 = RTU wdg:flt 0 = RTU wdg:flt 1 = RTU wdg:rst 8.03 Station Number…
• Page 169
  0 = Disable 1 = Fieldbus Fieldbus 2 = RS232-Port 3 = Panel-Port 4 = Res Feldbus 8.02 Protocol 1 = ABB CS31 8.03 Modul ID 0 = Word 0 = Word 1 = Binary 8.04 Station Number 0… 5 (Word Mode) 0…57 (Binary Mode)
• Page 170
  Parameter settings for the most commonly used fieldbus adapters For detailed information please refer to the related fieldbus adapter description. In the case you need a fieldbus other than shown, please contact your local ABB sales office. ABB is continuously developing on new solutions. II K 7-12…
• Page 171
  Serial Interfaces DCS 400 Fieldbus parameter PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 1 — Motor Settings 40101 3065 Arm Cur Nom 40102 3066 Arm Volt Nom 40103 3067 Field Cur Nom 40104 3068 Field Volt Nom…
• Page 172
  Serial Interfaces PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 4 — Field 40401 3191 Field Cur Ref 40402 3192 Field Cur Act 40403 3193 Field Cur KP 40404 3194 Field Cur TI 40405 3195 Fld Ov Cur Trip 40406 3196 Field Low Trip…
• Page 173
  Serial Interfaces PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 6 — Input/Output 40601 3259 AI1 Scale 100% 40602 325A AI1 Scale 0% 40603 325B AI2 Scale 100% 40604 325C AI2 Scale 0% 40605 325D AO1 Assign 40606 325E AO1 Mode…
• Page 174
  Serial Interfaces PROFIBUS Modbus, CAN-BUS DCS400 DCS-400 Par.Name Remark Par. No Modbus+ Par.No. 8 — Fieldbus 40801 3321 Fieldbus Par 1 40802 3322 Fieldbus Par 2 40803 3323 Fieldbus Par 3 40804 3324 Fieldbus Par 4 40805 3325 Fieldbus Par 5 40806 3326 Fieldbus Par 6…
• Page 175
  Appendix A Appendix Appendix A — Accessories Line chokes L1 DCS type Type of Fig. 500V reactor 2-quadrant converter DCS401.0020 ND01 DCS401.0045 ND02 DCS401.0065 ND04 DCS401.0090 ND05 DCS401.0125 ND06 DCS401.0180 ND07 DCS401.0230 ND07 DCS401.0315 ND09 DCS401.0405 ND10 DCS401.0500 ND10 DCS401.0610 ND12 DCS401.0740 ND12…
• Page 176
  Appendix A Line chokes type ND Type Choke Weight Power loss peak [mH] [kg] ND 01 ND 02 ND 04 ND 05 ND 06 ND 07 12.6 ND 09 37.5 16.0 ND 10 25.0 22.2 ND 12 18.8 36.0 ND 13 18.2 1047 46.8…
• Page 177
  Appendix A Line chokes type ND 07…ND 12 H ±2 C ±1 ±0.3 3 AST 4 7 8 2 2 3 D5 3AFE 10014603 0 . 0 1 8 8 mH 4 9 0 A I ma x 7 3 4 A Max D F ±0.3 B ±1…
• Page 178
  Appendix A Fuses and fuse holders for armature- circuit supply The semiconductor fuses used are blade fuses. The relevant data are listed in the table below. The fuses’ construction requires special fuse holders. Fuse hold- er of the OFAX and OFAS type series are available for this purpose.
• Page 179
  Appendix A L1 L2 L3 Manufacturer/ Type Loss [W] Resistance [mW] Fuse F1 Size Fuse holder Caliper [mm] Bussman 170M 1564 50A 660V UR OFAX 00 S3L 78.5 Bussman 170M 1566 80A 660V UR OFAX 00 S3L 78.5 Bussman 170M 1568 125A 660V UR OFAX 00 S3L 78.5…
• Page 180
  Grids of this kind DCS401.0020 NF3-500-25 250x150x65 have an earthed neutral conductor. For DCS401.0045 NF3-500-50 250x150x65 these cases, ABB offers its three-phase DCS401.0065 NF3-500-64 250x150x65 DCS401.0090 NF3-500-80 450x170x90 mains filters for 500 V and 25 A … 1000 A.
• Page 181
  Appendix B — Declaration of conformity II K B-1…
• Page 182
  Appendix C — Quick Installation & Commissioning guide II K C-1…
• Page 183
  Appendix C II K C-2…
• Page 184
  Appendix D — Examples for basic parameter programming The experience has shown that certain parameters must be adapted in most applications. These parameters show the following tables. Table 1: Operation for armature control mode Table 2: Operation for field control mode Table 3: Operation for field control mode with speed-dependent current limitation Table 4:…
• Page 185
  Appendix D Operation for field control mode Armature control range Field control range norm Base Speed Max Speed Table 2 Parameter Parameter Significance Contents Entry number name Arm Cur Nom Nominal armature current Arm Volt Nom Nominal armature voltage Field Cur Nom Nominal field current Field Volt Nom Nominal field voltage…
• Page 186
  Appendix D Operation for field control mode with speed-dependent current limiting Armature Field control range norm control range Speed-dependent current limiting Base Speed Cur Lim Speed Max Speed Table 3 Parameter Parameter Significance Contents Entry number name Arm Cur Nom Nominal armature current Arm Volt Nom Nominal armature voltage…
• Page 187
  Appendix D Common parameters for the three operating modes Table 4 Parameter Parameter Significance Contents Entry number name Arm Cur Max Maximum current limit Overload Time Overload time Recovery Time Recovery time Torque Lim Pos Positive torque limit Torque Lim Neg Negative torque limit Stall Torque Stall torque…
• Page 188
  Index Symbole 7-Segment display 2-5, 3-7, 6-24, 6-26, 6-30 Factory Setting 6-5 Fan data 3-6 Fault Signals (F) 6-26 Alarm Signals (A) 6-30 Faultlogger 6-4 Alternative parameters for speed controller Field current controller 3-10, 4-37, 4-54 4-2, 4-36 Field Exciter Board SDCS-FIS-3A 3-10 Analogue Tacho feedback 6-17 Field heating 4-25 Application Macros 4-2…
• Page 189
  Index Operating Instructions 6-1 Overload 2-4 Overtemperature Protection 4-31 Overview of software 4-1 Paint finish 2-2 Panel DCS400PAN 1-4, 2-5, 6-1, 6-7, 6-24, 6-25, 7-6 Panel LEDs 6-25 Panel Lock 6-5 Panel mode 6-2 Drive control 6-6 Function selection 6-3 Menu selection 6-2 Parameter programming 6-3 Panel-Port 7-6…
• Page 190
  Notices…
• Page 191
  Notices…
• Page 192
  ABB Automation Products GmbH Postfach 1180 D-68619 Lampertheim Telefon +49(0) 62 06 5 03-0 Telefax +49(0) 62 06 5 03-6 09 www.abb.com/motors&drives…

DCS400- компактный цифровой привод постоянного тока, предназначенный для  использования в самых различных применениях с двигателями постоянного тока мощностью до 522 кВт.

Данная модель имеет два исполнения – для 2-х и 4-х квадрантного управления двигателем.

Настройка DCS400 осуществляется посредством цифровой панели управления или с помощью программного обеспечения, данная модель привода постоянного тока отличается простотой настройки и ввода в эксплуатацию.

Основные особенности DCS400:

• Функция управление моментом двигателя

• Простота подключения

• Глубокая система диагностики

• Работа с различными датчиками обратной связи (энкодеры, тахогенераторы)

• Управление током обмотки возбуждения (встроенный контроллер поля до 20А)

• 2-х и 4-х квадрантное исполнение

• Рекуперация энергии в сеть

• Функция автоматического ослабления поля

Номинальный ток, напряжение питания, степень защиты DCS400:

• 3 х 230-500 В

Номинальный ток двигателя 20-1000А

Степень защиты – IP00

IP21(шкафное исполнение)

Охлаждение DCS400:

• Вентиляторы охлаждения

• Радиатор

Входывыходы управления DCS400:

• Количество программируемых дискретных входов – 8

• Количество программируемых дискретных выходов – 4

• Количество программируемых аналоговых входов – 2

• Количество программируемых аналоговых выходов – 2

• Количество программируемых встроенных реле -1

• Порт для подключения энкодера -1

Температура окружающей среды для DCS400:

• Работа +5/+55 °С

• Хранение -40/+55 °С

Доступные опции  для DCS400:

Модули связи:

• Profibus-DP

• DeviceNet

• CANopen

• Modbus

• Сетевые дроссели

• Предохранители

• ЭМС фильтры

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Я согласен на обработку моих персональных данных

DCS400

Сообщение

komldo » 26 окт 2013, 06:29

Добрый день, помогите пожалуйста!!!! есть привод DC ABB и инвертор DCS401.0065 reva1 при нормальной работе отключился и выдал ошибку A7 и B12 недостаточный ток возбуждения. Как проверить? те какое напряжение подать на управление х14 (1 и 3) ножку

Re: DCS400

Сообщение

komldo » 27 окт 2013, 11:56