Download DCS800-E Panel Solution

DCS800-E
DC Drive Panel Solution
20...450 A DC
PRE-MOUNTED
PRE-ENGINEERD
FAST INSTALLATION
DIN EN ISO 9001
DIN EN ISO 14001
Standard Features
• All necessary components installed
• Easy installation: 'Ready for use'
• Very short installation time
• Reduces power-down-time in rebuilding projects to a minimum
The DCS800-E Panel Solution
The DCS800-E is a compact user-friendly Panel-Solution. It offers all needed components pre-mounted,
fully wired and factory-tested. While mounting it into
an empty cabinet the mechanical installation will be
completed. This ready-to-use concept allows to squeeze
the power-down-time in rebuilding projects to a minimum.
The DCS800-E aims for revamping projects to replace
old DC-Drives up to 450 A, where the most economic
solution is to replace the whole drive including thyristor stack and field exciter.
When re-using the power part in bigger-sized DCDrives please take our special Rebuild Kits in consideration, that are tailor made for special ancient converters
(e.g. TYRAK8 Rebuild Kit for old ASEA TYRAK
Series) and offer modern digital control and auxiliary
electronics, while the thyristor stack and other powerparts can be re-used.
Features
DCS800-E mounted in old cabinet
Main contactor
DC fuses *
Aux. transformer
• Output currents from 25 to 450 A DC.
• AC input voltage from 400, 525 to 600 V AC.
• AC-Connection from top. Bottom-Connection can
also be realized.
• DC-connection from bottom of DCS-Module or
from DC-fuses if ordered.
• Pre-wired DC-Terminals at very bottom of DCSPanel as option for re-using existing motor cables.
• DCS is fully tested with DC-motor acc. DCS800-E
Enclosed Converters Test Specification.
• Special solutions for Pulp&Paper (incl. Safety relay)
available.
• The DCS800-E is available in different types:
- DCS800-E Standard - for standard applications
with DCS800 converter modules.
- DCS800-E Pulp and Paper - with safety relay for
P&P-Applications.
For every type a wide range of options is offered.
DC output terminals *
* as option
DCS800-E bottom view
User Benefits
• Cost-Saving by reusing long-life components, like
cabinet, power cables or busbars, incoming disconnector and line fuses and other power parts.
• Digital technology with up-to-date communication
interfaces and control performance offers increased
process availability, quality and productivity.
• Pre-engineered standard solution requires only a
minimum of engineering time.
• Pre-mounted components on a ready-to-connect
panel offer reduced installation time.
• System shut down time can be squeezed to a minimum.
• Additional tools for simple assembly on site.
DCS800-E top view
DCS800-E side view
Layout
5 20
51 3
DCS800-E consists of 3 separate units:
• Power unit
- Includes all power devices.
• Aux unit
- Includes all auxiliary devices
- Can be mounted either on the left or on the right
side of the power unit.
• I/O unit
- For IOB-2/3 and terminals.
5
19
1600
• All three units are fixed together to be mounted as
one single unit.
• They may also be mounted separately in different
places for space saving and small cabinets.
Mounting
A mounting kit is available for Standard TYRAK 8/L cabinets (Types
YxMK, YxML, YxMp). It consists of an upper and lower mounting
support, that are screwed to the cabinet for easy fixing of the panel, and
two sliding rails for easily sliding the whole DCS800-E-Panel into the
cabinet. The Sliding Rails may be removed and re-used after the
installation. Mounting kits for other types of cabinets on request.
51
5
DCS800-E draw_3d.dsf
DCS800-E mounting supports
With total dimensions of
WxDxH=515x515x1600 mm
the DCS800-E Panel can be used for most
cabinets with a footprint of 600x600 mm.
Sliding rails in cabinet
bottom
Load cycles
DCS800-E Panel Solution unit types
Unit type
DC I ➀
[A]
400 V / 525 V
DCS800-E01-0020-04/05-960t
DCS800-E02-0025-04/05-960t
DCS800-E01-0045-04/05-960t
DCS800-E02-0050-04/05-960t
DCS800-E01-0065-04/05-960t
DCS800-E02-0075-04/05-960t
DCS800-E01-0090-04/05-960t
DCS800-E02-0100-04/05-960t
DCS800-E01-0125-04/05-960t
DCS800-E02-0140-04/05-960t
DCS800-E01-0180-04/05-960t
DCS800-E02-0200-04/05-960t
DCS800-E01-0230-04/05-960t
DCS800-E02-0260-04/05-960t
DCS800-E01-0315-04/05-960t
DCS800-E02-0350-04/05-960t
DCS800-E01-0405-04/05-960t
DCS800-E02-0450-04/05-960t
DCS800-E01-0470-04/05-960t
DCS800-E02-0520-04/05-960t
600 V
DCS800-E01-0290-06-960t
DCS800-E02-0320-06-960t
DC II current
100 %
150 %
15 min
60 sec.
[A]
[A]
DC III current
100 %
150 %
15 min
120 sec.
[A]
[A]
DC IV current
100 %
200 %
15 min
10 sec.
[A]
[A]
Field
current
Power loss
[A]
[kW]
➁
DC I ➀
IDC I continuous
IDCI
100%
18
22
41
45
61
67
81
90
115
125
160
180
210
225
285
300
365
405
400
450
17
21
36
40
47
53
55
64
87
95
119
134
150
159
219
228
285
316
308
345
27
32
55
59
73
80
70
96
130
142
180
201
225
239
329
342
428
475
462
517
16
20
33
37
44
50
41
62
83
91
118
131
141
150
211
222
275
306
290
330
26
31
51
56
68
75
66
93
123
136
178
197
212
225
316
333
413
459
435
495
14
18
32
36
44
50
41
61
83
91
99
111
124
132
192
200
254
283
275
308
30
35
68
72
93
100
91
122
166
186
198
223
248
264
384
400
509
567
550
616
6
6
6
6
6
6
6
6
6
6
15
15
15
15
20
20
20
20
20
20
<0.58
<0.58
<0.65
<0.65
<0.72
<0.72
<1.00
<1.00
<1.00
<1.00
<1.51
<1.51
<1.51
<1.51
<1.89
<1.89
<2.47
<2.47
<2.57
<2.57
260
285
214
235
300
330
192
211
268
294
192
210
344
377
DCF503
DCF503
<1.85
<1.85
t
DC II
15 min
Voltage class: (example: DCS800-E02-0025-04-960t)
4 ⇒ 400V
5 ⇒ 525V
6 ⇒ 600V
➀ = Given Ratings are typical values for mounting
in IP 21 cabinets; actual values may differ and are
strongly depending on the cabinet and its cooling,
especially with higher protection classes
➁ = Values are valid for Standard Scope of
delivery without options
100%
150%
DC III
IDC III for 15 min
15 min
150%
DC IV
Table 1: DCS800-E types
t=1 ⇒ Standard type
t=2 ⇒ P&P type
IDC II for 15 min and
100%
IDC IV for 15 min
IDCIV
15 min
200%
100%
t
DCS
8
Aux. Transformer T2 incl. F2 and MCB F5 on secondary side
Fusing of Auxiliary Circuits with MCBs
Single Wires are tinned
Complete set of drawings in a binder
Control panel DCS800-PAN
Field Exciter Circuit 6/15/20 A
X
X
X
X
X
X
X
X
X
X
•
X
X
X
•
X
X
X
X
X
X
X
X
X
X
X
X
X
X
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Remarks
Standard Scope of Delivery
DCS800 module
Main Contactor K1
Standard Fuseholder incl. Semiconductor Fuses F1
Power unit has Protection Class IPauc
AC-connection at top of F1,
DC-connection at DCS-Module bottom (if DC-Fuses are selected,
DC-connection is at botton of DC-fuses)
Auxiliary Devices
Digital I/O-board IOB-2x
Converter Fan contactor K8
EStop Time Relay K15
Safety Relais A04 acc. to P&P Standard
DCS
8
00-E
0
00-E
0
x (S t
d)
x (P &
P)
Scope of delivery and options
DCS800-S01/S02-0025...0520 (Design current 22-450A DC)
Fuseholder incl. Disconnecting device as option
as standard
for 1.5m long pre-mounted AC- and DC-cables check options
not possible, when 2nd Fex is installed (shared Motion)
T2 primary side not connected to incoming AC-Supply,
but to terminals. Connection to be done by user.
as standard
as standard
as standard
mounted on converter module
for 400 V and 525 V types
Options (price see pricelist)
Mounting Kit
For light Industrial Environment
depending on line and field voltage
replaces Standard Fuseholder
incl. K6, F6, F60
not possible, when 2nd Fex is installed (shared Motion)
also necessary for Residual Current Detection
inside converter module
inside converter module
incl. K11+K12
inside converter module
inside converter module
loose delivery, free of use
can be used for encoder, IOB-2x, IOB-3 for RDIO RAIO
suitable for TYRAK8 types
3 pc. AC-cables connected to the AC-fuseholder
plus 2 pc DC output terminals at the very bottom of the power
unit
2 Mounting Supports to be screwed into the old cabinet
plus 2 rails for sliding the Kit easily into the cabinet,
to be removed after mounting.
Details see mounting instruction.
•
•
•
3ADW 000 210 R0101 REV A
02_2006
Power Devices
Line Chokes L1 Type NDxx uk=1%
Field Transformer T3
Fuseholder incl. Disconnecting Function (F1)
Motor Fan Supply
for Motor Currents/A (please specify when ordering):
0.4-0.63; 0.63-1; 1-1.5; 1.5-1.7; 1.7-2.3; 2.3-3; 3-3.8;
3.8-4.8; 4.8-6.3; 6.3-8
DC-Fuse-Holder and DC-Fuses for Armature Circuit
I/O Options
Analogue I/O-Board IOB-3
RDIO Digital extension board
RAIO Analogue extension board
24V Supply 2A
Local I/O Control with latching function
Electrical Disconnect K16
Aux Control Voltage 115V (IOB-22)
Fieldbusadapter
DDCS Communication board
Other Options
Coated Boards
Cable Marking A2 plus
Prepared for UL certification (Cabling and Aux-Fuses)
Door Mounting Kit for Panel DCS800-PAN
2 pc cable W0205 + W0206, each 7x1mm², 4m
Spare cable 4*2*0.5, 4m long
Isolation switch replacement kit
AC and DC Connection cables
ABB Automation Products
68526 Ladenburg • GERMANY
Phone +49(0) 62 03 71-0
Fax +49(0) 62 03 71-76 09
www.abb.com/motors&drives
e-mail: [email protected]
*210R0101A6080000*
*210R0101A6080000*
K11
K12
X7:18
1
X3:
2
AITAC
_ +
AI2
_ +
AI3
_ +
4
5
6
7
8
if there are intermediate
terminals
3
9
AI4
_
A10 SDCS-IOB-3
AI1
_ +
Slot 3
Slot 2
K15
K16
X7:14
ELECTR.
DISCONNECT
4x DDCS interface
X33
X34
K15
Slot 1
E-STOP
R-Fieldbus
adapter
K12
X7:12
X7:13
X7:10
X7:9
X7:11
+
DC800-E0x...9601 (Standard)
10
residual
current
detection
11
Field
X4: 3x Analogue Output
1.5/5mA current source
12 ±10V voltage source
Burden
resistor
100
Converter
fan
Motor
fan
K3
DO2
K10
DO3
(K10)
DO8
X96: 1
K1
Mains
contactor
(DO3)
F5
2
K8
X6: 1
A9
K6
2
K1
3
5
6
7
K16 X7:12 K11
4
SDCS-IOB-2x
K15
X7:9
K12
8
2
1
2
DO2
DO3
DO4
5
1
11
10
9
8
7
6
5
4
3
2
5
6
5
6
M
~
2
1
X2: 1
K8
690V
660V
600V
575V
525V
500V
450V
415V
400V
380V
3
4
1
3
2
4
1
2
V
M
3~ U
2
4
3
F2
DO5
DO6
DO7
DO8
K1
(K10)
Field Mains
contactor
K3
_
T
+
the polarities are shown for motoring
Fans
K6
K8
T
3
option
depending on the unit type
X2: 4
14
115V
13
T2
F6
K6
230V
12
F60
W
X4: 1 2 3 4 5 6 7 8 X5: 1 2 3 4 5 6 7 8
DO1
Power supply
(PIN-4)
X99: 1
Interface to
ext. UPS
K16 / K15
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 COM
Control board (CON-4)
K8
X2:4 Fan
X2:5 Klixon
K6
F60
DO1
Reset
DCS800-PAN
Panel
PC
K11
X7:15
START
ON
K1
X7:17
STOP
X7:16
X7:14
OFF
X7:13
Circuit diagram
wiring by
customer
X5:1...10
depending on converter size
X7:1/X7:2
Motor fan starter
L1
1
V1
4
3
5
W1 PE
6
Converter
module
DCS800
U1
2
L3
+
C1
M
D1
_
depending on converter type
the wiring and the components
F1, K1, L1 are different
K1
Fuse
switch
F1
L2
Main supply
L1
+
X1: 5
3
_
Field exciter
unit (PIN-4)
L3
K3
F3
3
4
6
5
L13
_
DCS800-E_ans a.dsf
+
DCF 503-0035
2
1
L11 L12
option for
600 V
included for
400 V and 525 V
DCS800-PAN
Panel
PC
Safety
circuit
Safety
A04
relay
Circuit diagram
Status
display
K11
1
X3:
2
AITAC
_ +
4
AI3
_ +
5
6
7
8
9
AI4
_
SDCS-IOB-3
AI2
_ +
Slot 2
E-STOP
MONITOR
K15
if there are intermediate
terminals
3
A10
AI1
_ +
Slot 3
X33
X34
Slot 1
K11
4x DDCS interface
R-Fieldbus
adapter
DI7
A04
DO4
+
10
residual
current
detection
11
Field
K3
DO2
K10
DO3
(K10)
DO8
X96: 1
K1
Mains
contactor
(DO3)
K15
2
K8
X6: 1
A9
K6
2
K1
3
4
5
6
SDCS-IOB-2x
7
8
2
1
2
DO2
DO3
DO4
5
1
11
10
9
8
7
6
5
4
3
2
1
5
6
5
6
M
~
2
1
X2: 1
K8
690V
660V
600V
575V
525V
500V
450V
415V
400V
380V
3
3
4
1
4
2
2
V
M
3~ U
2
4
3
F2
DO5
DO6
DO7
DO8
K1 K15
(K10) E-Stop
monitor
Field Mains
contactor
K3
Prev. of Start
E-STOP
_
T
+
the polarities are shown for motoring
Fans
K6
K8
T
3
option
depending on the unit type
X2: 4
14
115V
13
T2
F6
K6
230V
12
F60
W
X4: 1 2 3 4 5 6 7 8 X5: 1 2 3 4 5 6 7 8
DO1
Power supply
(PIN-4)
X99: 1
Interface to
ext. UPS
F5
DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 COM
Control board (CON-4)
Converter
fan
K8
X2:4 Fan
Klixon
X2:5
X4: 3x Analogue Output
1.5/5mA current source
12 ±10V voltage source
Burden
resistor
100
Motor
fan
K6
F60
DO1
DCS800-E0x...9602 (DCS800-E P&P)
depending on converter size
X5:1...10
Safety relay A04
X7:1/X7:2
Motor fan starter
L1
V1
4
3
W1 PE
6
5
Converter
module
DCS800
U1
2
1
L3
+
C1
M
D1
_
depending on converter type
the wiring and the components
F1, K1, L1 are different
K1
Fuse
switch
F1
L2
Main supply
L1
+
X1: 5
3
_
Field exciter
unit (PIN-4)
L3
K3
F3
4
3
L12
6
5
L13
_
DCS800-E_ans P&P a.dsf
+
DCF 503-0035
2
1
L11
option for
600 V
included for
400 V and 525 V