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ABB DCS800 Drives

ABB DCS800 Drives

What this chapter contains

This chapter contains the safety instructions which you must follow when installing,

operating and servicing the drive. If ignored, physical injury or death may follow, or

damage may occur to the drive, the motor or driven equipment. Read the safety

instructions before you work on the unit.

To which products this chapter applies

The information is valid for the whole range of the product DCS800, the converter

modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the Rebuild

Kit DCS800-R00-9xxx.

Use of warnings and notes

There are two types of safety instructions throughout this manual: warnings and

notes. Warnings caution you about conditions which can result in serious injury or

death and/or damage to the equipment. They also tell you how to avoid the danger.

Notes draw attention to a particular condition or fact, or give information on a

subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause

physical injury and/or damage to the equipment.

General danger warning warns about conditions, other than those

caused by electricity, which can result in physical injury or death and/or

damage to the equipment.

Electrostatic sensitive discharge warning warns of electrostatic

discharge which can damage the equipment.

These warnings are intended for all who work on the drive, motor cable or motor.

Ignoring the instructions can cause physical injury or death and/or damage to the

equipment..

WARNING!

• Only qualified electricians are allowed to install and maintain the drive!

• Never work on the drive, motor cable or motor when main power is applied.

Always ensure by measuring with a multimeter (impedance at least 1 Mohm)

that:

1. Voltage between drive input phases U1, V1 and W1 and the frame is

close to 0 V.

2. Voltage between terminals C+ and D- and the frame is close to 0 V.

• Do not work on the control cables when power is applied to the drive or to the

external control circuits. Externally supplied control circuits may cause

dangerous voltages inside the drive even when the main power on the drive is

switched off.

• Do not make any insulation resistance or voltage withstand tests on the drive or

drive modules.

• Isolate the motor cables from the drive when testing the insulation resistance or

voltage withstand of the cables or the motor.

• When reconnecting the motor cable, always check that the C+ and D- cables

are connected with the proper terminal.

Note:

• The motor cable terminals on the drive are at a dangerously high voltage when

the main power is on, regardless of whether the motor is running or not.

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

may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and

RDIO).

• DCS800 with enclosure extension: Before working on the drive, isolate the

whole drive from the supply

These instructions are intended for all who are responsible for the grounding of the

drive. Incorrect grounding can cause physical injury, death and/or equipment

malfunction and increase electromagnetic interference.

WARNING!

• Ground the drive, motor and adjoining equipment to ensure personnel safety in

all circumstances, and to reduce electromagnetic emission and pick-up.

• Make sure that grounding conductors are adequately sized and marked as

required by safety regulations.

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

earth (PE ).

• Minimize EMC emission and make a 360° high frequency grounding (e.g.

conductive sleeves) of screened cable entries at the cabinet lead-through

plate.

• Do not install a drive equipped with an EMC filter to an ungrounded power

system or a high resistance-grounded (over 30 ohms) power system.

Note:

• Power cable shields are suitable as equipment grounding conductors only

when adequately sized to meet safety regulations.

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

DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is

required.

These instructions are intended for all who handle the circuit boards and fiber optic

cables. Ignoring the following instructions can cause damage to the equipment.

WARNING! The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not touch the

boards unnecessarily.

Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging optic cables,

always grab the connector, not the cable itself. Do not touch the ends of the fibers

with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed

bend radius is 35 mm (1.4 in.).

Mechanical installation

These notes are intended for all who install the drive. Handle the unit carefully to

avoid damage and injury.

WARNING!

• DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do not lift the

unit by the front cover. Place units D4, D4+ and D5 only on their back.

DCS800 sizes D5 ... D7: The drive is heavy. Lift the drive by the lifting lugs

only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

• Make sure that dust from drilling does not enter the drive when installing.

Electrically conductive dust inside the unit may cause damage or lead to

malfunction.

• Ensure sufficient cooling.

• Do not fasten the drive by riveting or welding

These warnings are intended for all who plan the operation of the drive or operate

the drive. Ignoring the instructions can cause physical injury or death and/or damage

to the equipment.

WARNING!

• Before adjusting the drive and putting it into service, make sure that the motor

and all driven equipment are suitable for operation throughout the speed range

provided by the drive. The drive can be adjusted to operate the motor at

speeds above and below the base speed.

• Do not control the motor with the disconnecting device (disconnecting mains);

instead, use the control panel keys and , or commands via the I/O

board of the drive.

• Mains connection

You can use a disconnect switch (with fuses) to disconnect the electrical

components of the drive from the mains for installation and maintenance work.

The type of disconnect switch used must be as per EN 60947-3, Class B, so as

to comply with EU regulations, or a circuit-breaker type which switches off the

load circuit by means of an auxiliary contact causing the breaker's main

contacts to open. The mains disconnect must be locked in its "OPEN" position

during any installation and maintenance work.

• EMERGENCY STOP buttons must be installed at each control desk and at all

other control panels requiring an emergency stop function. Pressing the STOP

button on the control panel of the drive will neither cause an emergency stop of

the motor, nor will the drive be disconnected from any dangerous potential.

To avoid unintentional operating states, or to shut the unit down in case of any

imminent danger according to the standards in the safety instructions it is not

sufficient to merely shut down the drive via signals "RUN", "drive OFF" or

"Emergency Stop" respectively "control panel" or "PC tool".

• Intended use

The operating instructions cannot take into consideration every possible case

of configuration, operation or maintenance. Thus, they mainly give such advice

only, which is required by qualified personnel for normal operation of the

machines and devices in industrial installations.

If in special cases the electrical machines and devices are in-tended for use in

non-industrial installations - which may require stricter safety regulations (e.g.

protection against contact by children or similar) - these additional safety

measures for the installation must be provided by the customer during

assembly.

Note:

• When the control location is not set to Local (L not shown in the status row of

the display), the stop key on the control panel will not stop the drive. To stop

the drive using the control panel, press the LOC/REM key and then the stopkey

The type code contains information on the specification and configuration of the drive. The first digits

from left show the basic configuration (e.g. DCS800-S01-2000). The optional selections are given

thereafter on the name plate by plus code. The main selections are described below. Not all

selections are available for all types.

The technical data and specifications are valid as of going to press. ABB reserves the right to make

subsequent alterations.

The drive's basic type code: DCS800-AAX-YYYY-ZZ-B + plus code

Product family DCS800

Type: AA = S0

= R0

= E0

= A0

Standard converter module

Rebuild kit

Panel solution

Enclosed converter

Bridge type: X = 1

= 2

Single bridge (2-Q)

2 anti-parallel bridges (4-Q)

Module type: YYYY = Rated DC current

Rated AC voltage: ZZ = 04

= 05

= 06

= 07

= 08

= 10

= 12

230 VAC - 400 VAC

230 VAC - 525 VAC

270 VAC - 600 VAC

315 VAC - 690 VAC

360 VAC - 800 VAC

450 VAC - 990 VAC

540 VAC - 1200 VAC

Power connection: - =

= L

= R

Standard D1 - D6

Left side D7

Right side D7

Revision code: B =

= a

= b

Standard

Second thyristor type D5, D6

ErP compliant cooling fan D5, D6, D7 and second thyristor type

Field exciter

configuration:

+0S163

+S164

D1 - D4 without OnBoard field exciter

D4+ and D5 with internal field exciter, supply external

(D4+ and D5: 25 A, Rebuild kit: 16 A / 25 A)

Fan voltage:

Standard

+S171

Size D4

Fan voltage: 230 V / 1-ph

Fan voltage: 115 V / 1-ph

Current measurement: +S175 SDCS-CMA-2 (D5 - D7)

Voltage measurement: +S186

+S185

+S180

+S181

+S182

+S183

+S189

+P905

+P906

120 V SDCS-SUB-4 (D1 - D4+)

SDCS-PIN-51 configured to 120 V (D5 - D7)

SDCS-PIN-51 configured to 600 V (D5 - D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to 690 V (D5 - D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to 800 V (D6, D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to 990 V (D6, D7), 12-pulse serial / serial sequential

SDCS-PIN-51 configured to galvanic isolation (D6, D7)

Electronic boards are located in the D7 module

Electronic boards are in an external control unit (outside the D7 module)

SDCS-DSL-4: +S199

+0S199

With SDCS-DSL-4

Without SDCS-DSL-4

DCS Control Panel: +0J404

+J409

Without DCS Control Panel

Door mounting kit, including 3 m cable

Fieldbus: +K454

+K451

+K457

+K466

+K458

Profibus RPBA-01

DeviceNet RDNA-01

CANopen RCAN-01

Ethernet/IP, Modbus/TCP RETA-01

Modbus (RTU) RMBA-01

I/O and DDCS: +L500

+L501

+L508

+L509

Analog Extension RAIO-01

Digital Extension RDIO-01

DDCS communication board (10 Mbaud CH0) SDCS-COM-81

DDCS communication board (5 Mbaud CH0) SDCS-COM-82

Chapter overview

This chapter describes the mechanical installation of the DCS800.

Unpacking the unit

• Open the box,

• take out shock dampers,

• separate manual and accessories.

Attention:

Do not lift the drive by the cover!

Delivery check

Check that there are no signs of damage. Before attempting installation and

operation, check the information on the nameplate of the converter module to verify

that the unit is of the correct type. The label includes an IEC rating, cULus, C-tick

(N713) and CE markings, a type code and a serial number, which allow individual

identification of each unit. The remaining digits complete the serial number so that

there are no two units with the same serial number.

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