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DCS800

Selection, Installation and Start-Up Manual for Rebuild Kits DCS800 Drives

DCS800 Single Drive Manuals All the documents available for the drive system DCS800 are listed below:

Language Public. number E D I ES F CN

DCS800 Quick Guide 3ADW000191 x p p p p DCS800 Tools & Documentation CD 3ADW000211 x DCS800 Converter module

Flyer DCS800 3ADW000190 x x p x p p Technical Catalogue DCS800 3ADW000192 x x x x p x Hardware Manual DCS800 3ADW000194 x x p p p p Firmware Manual DCS800 3ADW000193 x p p p p p Installation according to EMC 3ADW000032 x Technical Guide 3ADW000163 x Service Manual DCS800 3ADW000195 x p Planning and Start-up for12-Pulse converters 3ADW000196 p CMA-2 Board 3ADW000136 p Flyer Hard - Parallel 3ADW000153 p

Drive Tools

DriveWindow 2.x - User's Manual 3BFE64560981 x DriveOPC 2.x - User's Manual 3BFE00073846 x Optical DDCS Communication Link 3AFE63988235 x DDCS Branching Units - User´s Manual 3BFE64285513 x

DCS800 Applications

PLC Programming with CoDeSys CoDeSys_V23 x x x 61131 DCS800 target +tool description - Application Program 3ADW000199 x Winding with the DCS 800XXXXX 3ADW000058 Winder application description Flyer magnetic application Magnetic application description

DCS800-E Panel Solution

Flyer DCS800-E Panel solution 3ADW000210 x Hardware Manual DCS800-E 3ADW000224 x

DCS800-A Enclosed Converters

Flyer DCS800-A 3ADW000213 x System description DCS800-A 3ADW000198 p p Installation of DCS800-A 3ADW000091 p p

DCS800-R Rebuild System

Flyer DCS800-R 3ADW000007 p p DCS800-R Manual 3ADW000197 p DCS500/DCS600 upgrade manual

Extension Modules

RAIO-01 Analogue IO Extension 3AFE64484567 x RDIO-01 Digital IO Extension 3AFE64485733 x AIMA R-slot extension 3AFE64661442 x

Serial Communication

Drive specific serial communication NETA Remote diagnostic interface 3AFE64605062 x Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) 3AFE64504215 x Fieldbus Adapter with DC Drives RCAN-02 (CANopen) Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3AFE64506005 x Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x Fieldbus Adapter with DC Drives RMBA (MODBUS) 3AFE64498851 x Fieldbus Adapter with DC Drives RETA (Ethernet) 3AFE64539736 x

x -> existing p -> planned Status 01.2007 DCS800 Drive Manuals-List_c.doc

DCS800 Drives

DCS800-R0x

Selection, Installation and Start-Up Manual for Rebuild Kits

Code: 3ADW000195R0101 Rev A

DCS800 Service Manual e a.DOC

EFFECTIVE: June 19th, 2006 SUPERSEDES:

3ADW000195R0101 DCS800 Service Manual e a3ADW000197R0101 DCS800-R Sel e a

3

Table of contents

3ADW000xxxR0101 DCS800-R Sel e a

Table of contents

Introduction How to use this manual .................................................................................................. 0 H5 Contents of this manual.................................................................................................. 1 H5 Associated publications.................................................................................................. 2 H5

Basic Selection Technical preconditions and limits ................................................................................. 3 H7 Selecting the suitable Rebuild kit ................................................................................... 4 H7

Hardware conditions .................................................................................................... 5 H8 Drive´s design conditions ............................................................................................. 6 H9 Conditions caused by the application........................................................................... 7 H9 Type coding and accessories..................................................................................... 8 H10

Hardware Basic components of the DCS800-R kit ....................................................................... 9 H13 Housing for main electronics ........................................................................................ 1 0 H13 Pre-assembled part ...................................................................................................... 1 1 H14 Loose parts................................................................................................................... 1 2 H14 Optional parts ............................................................................................................... 1 3 H15 Dimensions main electronic housing............................................................................ 1 4 H16 Environmental conditions ............................................................................................. 1 5 H17 Pulse transformer board SDCS-PIN-48........................................................................ 1 6 H19

Wiring ......................................................................................................................... 1 7 H19 Measurement board SDCS-PIN-51 .............................................................................. 1 8 H20

Wiring ......................................................................................................................... 1 9 H22 Fastening ................................................................................................................... 2 0 H22 PTC temperature sensor............................................................................................ 2 1 H22 HW type coding.......................................................................................................... 2 2 H22 Voltage coding ........................................................................................................... 2 3 H23 Nominal current coding .............................................................................................. 2 4 H23 Additional settings ...................................................................................................... 2 5 H25

Interface board SDCS-REB-1....................................................................................... 2 6 H26 Power supply.............................................................................................................. 2 7 H27 Functionality ............................................................................................................... 2 8 H28 Fastening ................................................................................................................... 2 9 H28 Diagram...................................................................................................................... 3 0 H29

Interface board SDCS-REB-3....................................................................................... 3 1 H30 Firing pulses............................................................................................................... 3 2 H30 Signal flow and Thyristor designation ........................................................................ 3 3 H30 Design hints ............................................................................................................... 3 4 H32 Signal handling........................................................................................................... 3 5 H32 Plug connectors X1113: and X2113:.......................................................................... 3 6 H33

Interfacing the Electronics and Thyristors Connection for 2-quadrant application – No parallel Thyristors ................................. 3 7 H35 Connection for 4-quadrant application – No parallel Thyristors ................................. 3 8 H36

4

Table of contents

3ADW000195R0101 DCS800 Service Manual e a

Connection for 4-quadrant application - parallel thyristors......................................... 3 9 H37 Connection for 2-quadrant application - parallel thyristors......................................... 4 0 H38

Installation Background for the figures of this chapter ................................................................. 4 1 H39 Hints for Cabling......................................................................................................... 4 2 H51

Safety Instructions What this chapter contains ........................................................................................... 4 3 H53 To which products this chapter applies ........................................................................ 4 4 H53 Use of warnings and notes ........................................................................................... 4 5 H53 Installation and maintenance work ............................................................................... 4 6 H54

Grounding................................................................................................................... 4 7 H55 Mechanical installation ................................................................................................. 4 8 H56 Operation...................................................................................................................... 4 9 H56

Start-up What this chapter contains ........................................................................................... 5 0 H59

Safety Instructions...................................................................................................... 5 1 H59 Points to be observed because of the situation ......................................................... 5 2 H59 Maintenance work ...................................................................................................... 5 3 H60 Tools .......................................................................................................................... 5 4 H60 Measurements with the “old” equipment still working................................................. 5 5 H60 Mounting the Kit ......................................................................................................... 5 6 H61 Wiring the Kit .............................................................................................................. 5 7 H61 Commissioning the Kit................................................................................................ 5 8 H62

5

Introduction

3ADW000xxxR0101 DCS800-R Sel e a

Introduction

How to use this manual

The purpose of this manual is to provide you with the information necessary to select the right rebuild kit with all the necessary or available options, to install it, do the start-up and operate it as a DC drive system. Depending on the kit's configuration, different func-tionality and different options concerning the user interface are available. As long as the hardware needs to be named or cross-referenced to in a very general way, the term Rebuild kit will be used.

Contents of this manual Introduction describes how to use this manual and the boundary

conditions applying. Basic Selection provides the information about the types of the

Rebuild kits, their type designations and options.

Hardware description provides the information about the boards and components

Interfacing the Electronics and Thyristors provides the informa-tion about the configurations and functions of drives and examples of the whole circuit diagram.

Installation provides the information about required ambient condi-tions, space requirements, cabling and wiring and how to install a rebuild system.

Start-up gives some general guidelines and cross references how to commission and start up a DC drive system using a Rebuild kit.

Associated publications Associated publications see inner page of the jacket of that manual.

6

Introduction

3ADW000197R0101 DCS800-R Sel e a

7

Basic Selection


Basic Selection

Technical preconditions and limits If an electrical drive is in operation for several years, most often discussions will be

started about items like: - better factory automation based on latest technology - decrease of standstill time of production - availability of spare parts - increase of productivity; perhaps an enlargement of the whole installation using

both types of drives, DC and AC drives - and other arguments These wishes can be turned into real life by: - upgrading the drive itself completely - upgrading only the converter, which had controlled the DC motor - upgrading the converter´s electronics only - upgrading a part of the converter´s electronics. For a final solution, all the benefits described by:

• higher production • more accurate control • design of state of the art • others

will be compared with the disadvantages of revamping described by: • standstill time of production • hardware cost • training etc.

If this comparison is based on an upgrade of the converter´s electronics the Re-build kit, which is described within this document, may be a solution. Before the fi-nal decision is made to use a Rebuild kit, the configuration of the existing drive needs to be checked more in detail to make sure the kit fulfills all demands.

Selecting the suitable Rebuild kit The basic structure of a converter to control a DC motor looks like this:

The electronics of the existing converter indicated by the left box above is splitted into 2 boxes in the kit. The Rebuild kit can be used for armature bridges in non-regenerative or regenera-

Rebuild kit

electronics: interface to

PLC

electronics: interface to

thyristor bridge

thyristor bridge

Existing

Converter control electronics with interface to: - thyristor bridge - PLC

thyristor bridge

8

Basic Selection


tive mode with maximum 4 thyristors in parallel. In case there are more than 4 thy-ristors in parallel per current direction there is no standard kit prepared; please con-tact your local ABB organization.

To selecting the Rebuild kit, first the HARDWARE CONDITIONS must be checked to become aware of critical limitations. If this is not a problem the DRIVE´S DESIGN CONDITIONS will give some guidelines for the overall design. After that a decision must be made for the functionality of the interface between the kit and the Programmable Logic Controller. Depending on that, the Rebuild kit´s type code can be fixed by using the type designations listed on the next pages. Afterwards please check if all conditions are fulfilled as listed in CONDITIONS CAUSED BY THE APPLICATION.

Hardware conditions If a Rebuild kit is taken into consideration, the items listed afterwards will give

some help to decide whether a Rebuild kit or a converter module / enclosed con-verter is the better solution. - Before an existing DC power part is upgraded by the Rebuild kit, it should be

checked if a brand new module may be easier to install or may be a more reli-able solution (tested power stack).

- The existing power bridge should be build up by max. 4 thyristors in parallel per current direction (solution for more thyristors in parallel on request). It doesn't matter whether the bridges have the same number of thyristors in parallel.

- The supply voltage used for the existing thyristor bridge has to be lower than 990 V because of the devices used to interface the electronics to the thyristors (higher mains voltages on request).

- The thyristors actually used should be of a disk type. One single thyristor bridge should be capable of running around 1000 A or more, if the converter is built up by more than one bridge in parallel. If a single bridge cannot give this current a brand new converter is probably the more economical solution.

- The ratio between reverse / forward blocking voltage of the thyristors and the nominal line voltage should be factor 3 or higher the blocking voltage has to be measured on a thyristor test stand if the actual blocking voltage gives a lower ratio the thyristor(s) need to be replaced. In such a case, please check if a complete new converter may be more economical.

9

Basic Selection


Drive´s design conditions It is intended to install the kit into the existing drive cabinet. The following drive equip-

ment will be reused and should therefore be in good condition: - Check all parts in the AC supply like main disconnecting switch with fuses or main

contactor or similar for good condition. - Check the thyristor bridge itself (fixing devices, press clamps for thyristor mounting,

etc.) with cooling equipment for good condition. - If a Rebuild kit is used for the armature supply the existing field supply can be re-

used or upgraded too. - If the field supply will be upgraded one of these can be used:

SDCS-FEX-425-internal (built in; 1 or 3 phase) DCF803-0035 (external; 1 or 3 phase) DCF803-0050 / ...4-0050 (external; 1 phase) DCS800-S0x-xxxx-05 (external; 3 phase)

- If the old field supply will be reused check the overall strategy concerning monitoring, fault tracing and overall control and performance of the drive. Ei-ther a binary or an analogue signal should be available indicating “field supply equipment o.k.”. In case this signal is not available galvanic isolated then it should be made potentially free for safety reasons. If the drive should also be used in the field weakening range, an analogue signal, representing the actual field current, is highly recommended. It will be used for monitoring and fault in-dications generated within the Rebuild kit´s software.

- Depending on the old control structure an analogue tacho generator can be re-used. A pulse generator can only be (re)used if it generates a pulse train as an output signal (see Hardware Manual).

- The Rebuild kit expects an armature current feedback signal for the current control loop. This signal normally is taken from two current transformers on the a.c. side of the thyristor bridge. The current transformers shall give 0.5 - 0.85 A, which corre-sponds to the nominal current of the thyristor bridge (other solutions on request).

- A 115V or 230 V AC supply for the Rebuild kit´s electronics is needed.

Conditions caused by the application It has to be checked if the selected Rebuild kit type can handle the application of the

existing drive. As long as the existing one was used in a 6 pulse bridge configuration, there is no limitation. - If the existing bridge has been used in a configuration different to 6-pulse , addi-

tional engineering is needed. It should be checked at first, if a standard converter DCS800-S0x can be used for such a configuration. Most likely the DCS800-R0x can be designed similar as with a standard converter.

- There are drives used in the past in a configuration sometimes named MASTER - FOLLOWER or MASTER - SLAVE or similar. In all these applications, one drive had generated references or commands for the second, third etc. The Rebuild kit is basically prepared for those configurations; the final wiring may be different. For more details, please refer to the documentation.

- If the existing converter has been used in a non motor application most often a pre-pared solution is not available, but most often an engineered solution can be found. Please contact your local ABB engineering organization.

10

Basic Selection


Type coding and accessories There is only one mechanical construction for all the different versions of the kit. It

basically serves as a cover for that part named DCS800-R0x on the next figure. Ordering of the kit is done with the ordering code shown on the right page. The op-tions available for the Rebuild kit are identical as for a DCS800-S0x converter. Some options (e.g. +K454 adapter module for PROFIBUS DP communication) will be build in if ordered, some will come within the kits box and others need to be specified seperate and will come in a separate box. All applications, which can be done with a DCS800 converter, can be done with this DCR kit too, as long as the components, necessary for that application can be used for both systems. Engineering help is given within the DCS800 converter module´s documentation (see inner page of the jacket of this manual). This manual just focuses on items related to the engineering of the Rebuild kit.

T2

F2

≤500V

POW 1POW-4

DCS800-R00-0000-00

FEX-425 Internal

a or b

115/230 V

SD

CS

-CC

B4

8 38 4

83 73

PanelCDP 312

-NDPA-02-NDPC-12-NISA-03 (ISA)

NDBU95

(PCMCIA)

Master/Follower

AIM

A

Slot1

Slot2

Slot3

NDBU95

IOB-2x IOB-3

CON-4

RDIORAIO

X2

X1

X3 X4 X5 X6 X7

DSLX5124V-

DCS800 CP

X34

PC +CoDeSys

DWL

DSL

Mem

ory Card

RS232

RJ45

X52 X53

Ch3Ch2Ch1Ch0

X19

COM-8

1

optical fibreoptical fibre

twisted pair

PC +DriveWindow

Overridingcontrol

Door mounting

kit

Door mounting

kit

Slot 1

Slot 2Slot 3

Slot 4

Advantcontroller

DCSLink

Fieldbus adapter Rxxxor RDIO/RAIO

Figure 1: Overview of DCS800-R System

11

Basic Selection


Ordering code:

DCS800 0000 01 +-DC DrivesProduct family DCS800 converterRebuild kit Bridge type 1 = single (2Q) 2 = anti (4Q)Number of parallel / antiparallel thyristors 01 = 1 bridge 02 = 2 bridges in parallel 03 = 3 bridges in parallel 04 = 4 bridges in parallel Options +xxxx codes according list for add-on options

selectable option

R0- 1 - 0000

DCS8-R_sys_ovw.dsf

PIN-48

REB-3

PIN-48

PIN 1xPIN-51

REB-2

REB-1

a b

existing field exciter

a or b b a QUINT-PS~-

~-

T

T

≤990V

Existing partsResidual current detection

M

M

DC

F 803-0035

to motor field

DC

S800-S0x as field exciter

DC

F 803-0050 / 804-0050

Overview of DCS800-R System

12

Basic Selection


13

Hardware


Hardware

This chapter gives information about all the components and boards being exclu-

sively used at the DCS800-R0x kit. Components which are used at DCS800-S0x converter modules are just mentioned within that chapter, but not described in de-tail. In case those components need special handling it will be listed here. This for example is valid for measuring actual signals at the existing power stack or doing the galvanic isolation for the firing pulse transmission. In addition to that environmental conditions, dimensions and some hints are listed for better and straighter forward engineering. All other components which may come or may had been ordered together with the kit are described in detail either within the DCS800 Hardware Manual or within their dedicated documentation.

Basic components of the DCS800-R kit The kit is ordered according to the type designation at chapter Basic Selection.

The delivery can be subdivided into several parts, mostly two: - rebuild kit´s main electronics already pre-assembled - electronic boards and cables to measure signals at the power part and control

the existing thyristors; this will come as loose parts The interface towards the PLC can be done via inputs / outputs. In this case op-tional parts may be added.

Housing for main electronics

DCS800-R0x kit´s main electronics, named DCS800-R00-0000-00

14

Hardware


Pre-assembled part This part is pre-assembled and consists of:

- Housing for electronics (as shown on figure before) - Control board SDCS-CON-4 built-in - Electronic power supply SDCS-POW-4 built in (including flat cable to SDCS-

CON-4). This board needs to be feed by a 2-phase AC line voltage, either 115 V or 230 V

- Drive-to-drive interfacevia SDCS-DSL-4 board - Control panel DCS800 CP - Flat cable interconnection board SDCS-CCB4 Hint: The older version of the electronic power supply SDCS-POW-1 can be used

as a spare part for the actual one, SDCS-POW-4.

As shown at the end of chapter Basic Selection some options can be ordered us-ing a so called plus code. Such options most often can only be used together with the controller board; sometimes they need to be plugged on the controller board to get their function. Those options will be put at their correct place during production and therefore will come within the housing. Plug-in modules (e.g. Prfibus, I/O extensions) and the field supply FEX-425 Inter-nal are parts handled by plus codes.

Loose parts The kit is available as a 2-Q or 4-Q version. Both of them are available for power

parts with one up to four thyristors in parallel. Because of the different versions some components will be part of the delivery in every case like the SDCS-PIN-51 and SDCS-REB-1 board, others depend on the configuration:

DCS800-R01 -0000-01 (1 bridge)

-0000-02 (2 bridges)

-0000-03 (3 bridges)

-0000-04 (4 bridges)

(2-Q) 1x PIN-48 - - - - - - - -

2x PIN-48 2x QUINT-PS 1x REB-2



DCS800-R02 -0000-01 (1 bridge)

-0000-02 (2 bridges)

-0000-03 (3 bridges)

-0000-04 (4 bridges)

(4-Q) 2x PIN-48 - - - - - - - -




15

Hardware


The boards serve for different purposes: - SDCS-PIN-48: Pulse transformer board is mounted on a card holder. For the interconnections

6 firing leads (twisted pair; system plug on one end) and a shielded flat cable (round; 20-pole) will come with the kit. For cable length, please refer to chapter Installation.

- SDCS-PIN-51: Measuring board is mounted on a card holder. For the interconnections 5 leads

for the AC and DC voltage measurement (single core; 6,3 mm faston on one end), 2 leads for the current measurement (twisted pair; system plug on one end), 2 shielded flat cable (round; 16 pole) and a pluggable resistor for X22 will come with the kit. For cable length, please refer to chapter Installation.

- SDCS-REB-1: (Interface board) - QUINT-PS: (Power supply) - SDCS-REB-2:

Pulse amplification board for more than one bridge in parallel is mounted on a card holder. For the interconnections 2 flat cables (20-pole) will come with the kit. For cable length, please refer to chapter Installation.

Optional parts The options available differ in their usage. Some of them are related to the rebuild

kit, some to the drive itself or to the application the drive is used for: - Subassembly SDCS-REB-3: This board is used together with the SDCS-REB-2 and SDCS-PIN-48. With the

help of this board the firing pulse assignment can be changed and adapted to the needs given by the existing power part construction. The board will come mounted on a card holder. For the interconnections 4 flat cables (20-pole) will come with the kit. For cable length, please refer to chapter Installation.

- Plus code +S164 (FEX-425 Internal): This field supply can be build into the electronic housing. When ordered using

the plus code it will be mounted inside the housing during production. The board can be connected to any 2- or 3-phase power supply with up to 500V.

Power rating: with 2-phase supply: 16A max ! with 3-phase supply: 25A max ! When doing the engineering please make sure all conditions for the power sup-

ply configuration are taken into consideration. - Subassembly SDCS-IOB-2x/IOB-3: This subassembly is a part of the accessories of the DCS800-S0x converter

module. In case the inputs or outputs available at the controller board directly do not fulfill the criteria concerning the input or output voltage range or the crite-ria of the input / output to ground this option may be a solution.

The subassembly needs to be placed close to the electronic housing. Depending on the overall configuration and the needs caused by the application itself it may be necessary to add other options. These options should be selected based on the overview of the DCS800-R system shown at the end of chapter Basic Selection.

16

Hardware


Dimensions main electronic housing The electronics housing is just equipped with these components mentioned before.

There is no cooling fan. Nevertheless based on the components build in natural convection is necessary to keep the temperature of the used components within the limits. Because of that it is important to mount the housing as shown on the figure before and to make sure the convection is not blocked.

Wei

ght:

7 kg

90

100

∅ 4

.2

DCS8-R dim draw.dsf

4080

104

46.2

198

264

145.3114

34.8

38.8165

270

250

225

f. M

6

43.5

370.5

350

307

10.5

M6

20

Dimensional drawing of the DCS800-R

17

Hardware


Environmental conditions The next tables describe the technical specifications of the product, e.g. the

ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Remark:

This chapter with exactly the same lay-out is used for all subsets of the system DCS800. Because of this only headlines without (*) are applicable to the product DCS800-R !

System connection Environmental limit values Voltage, 3-phase: 230 to ≤ 1000 V acc. to IEC 60038 Permissible cooling air temperat. Voltage deviation: ±10% continuous; ±15% short-time * - at converter module air inlet: 0 to +55°C Rated frequency: 50 Hz or 60 Hz with rated DC current: (*) 0 to +40°C Static frequency deviation: 50 Hz ±2 %; 60 Hz ±2 % w. different DC curr. acc. Fig.

below: (*) +30 to +55°C

Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz - Options: 0 to +40°C df/dt: 17 % / s Relative humidity (at 5...+40°C): 5 to 95%, no condensation

* = 0.5 to 30 cycles. Relative humidity (at 0...+5°C): 5 to 50%, no condensation Please note: Special consideration must be taken for voltage devia-tion in regenerative mode.

Change of the ambient temp.: < 0.5°C / minute

Degree of protection Storage temperature: -40 to +55°C Transport temperature: -40 to +70°C Converter Module and op-

tions (line chokes, fuse holder,

Pollution degree (IEC 60664-1, IEC 60439-1):

2

field supply unit, etc.): IP 00 / NEMA TYPE OPEN Vibration class 3M3 - D1...D4 Enclosed converters: (*) IP 20/21/31/41 3M1 - D5...D7 Paint finish (*) Site elevation Converter module: light grey RAL 9002 <1000 m above M.S.L.: 100%, without current re-

duction Enclosed converter: light grey RAL 7035 >1000 m above M.S.L.: with curr. reduct., see Fig.

below

Size Sound pressure level LP (1 m dis-tance) (*)

Vibration Shock Transport in original pack-age (*)

Short circuit withstand rating (*) The DCS800 is suitable for use in a circuit capable of delivering not more than:

as module enclosed conv. as module D1 55 dBA 54 dBA D2 55 dBA 55 dBA

1.2 m

D3 60 dBA 73 dBA D4 66...70 dBA,

depending on fan 77 dBA

1.5 mm, 2...9 Hz 0.5 g, 9...200 Hz

7 g / 22 ms

1.0 m

65 kA rms symmetrical amps at maximum 600 VAC

D5 73 dBA 78 dBA D6 75 dBA 73 dBA D7 82 dBA 80 dBA

0.3 mm, 2...9 Hz 0.1 g, 9...200 Hz

4 g / 22 ms

0.25 m Shock monitor

100 kA rms symmetrical amps at maximum 600 VAC

Effect of the site elevation above sea level on the con-verter’s load capacity (*)

Effect of the ambient temperature on the converter module load capacity (*)

50

60

70

80

90

100

1000 2000 3000 4000 5000 m

Current reduction to (%)

70

80

90

100

110

30 35 40 45 50 55°C Current reduction to (%) for converter modules

18

Hardware


Regulatory Compliance (*) The converter module and enclosed converter components are designed for use in industrial envi-ronments. In EEA countries, the components fulfil the requirements of the EU directives, see table below. European Union Directive Manufacturer's Assur-

ance Harmonized Standards

Converter module Enclosed converter Machinery Directive 98/37/EEC 93/68/EEC

Declaration of Incorpora-tion

EN 60204-1 [IEC 60204-1]

EN 60204-1 [IEC 60204-1]

Low Voltage Directive 73/23/EEC 93/68/EEC

Declaration of Conformity EN 61800-1 [IEC 61800-1] EN 60204-1 [IEC 60204-1]

EN 60204-1 [IEC 60204-1] EN 60204-1 [IEC 60204-1]

EMC Directive EN 61800-3 ➀ [IEC 61800-3]

EN 61800-3 ➀ [IEC 61800-3]

89/336/EEC 93/68/EEC

Declaration of Conformity

(Provided that all installa-tion instructions concern-ing cable selection, ca-bling and EMC filters or dedicated transformer are followed.)

➀ in accordance with 3ADW 000 032

➀ in accordance with 3ADW 000 032/3ADW 000 091

North American Standards (*) In North America the system components fulfil the requirements of the table below. Rated supply voltage Standards Converter module Enclosed converter to 600 V • see UL Listingwww.ul.com / certifi-

cate no. E196914 Approval: cULus The spacings in the modules were evaluated to table 36.1 of UL 508 C. Spacings also comply with table 6 and table 40 of C22.2 No. 14-05. • or on request

UL types: on request

>600 V to 990 V EN / IEC xxxxx see table above. Available for converter modules in-cluding field exciter units.

EN / IEC types: on request (for details see table above)

19

Hardware


Pulse transformer board SDCS-PIN-48 This board is always required with the rebuild kit.

Normally one SDCS-PIN-48 board per 6 thyristors, if the board can be placed close (gate wires <1 m) to all 6 thyristors of one bridge.

GC

GC

GC

GC

GC Gate

Cathode

X113

X1

X213

X2

SDCS-PIN-48

A B C D E F

270

100

GC

Pin48.dsf

line potential !

conductive supports

8 301

317

8010

260

85 85 857.5

∅5

∅4.8

5

8010

Card holder for SDCS-PIN-48

10~

60

SDCS-PIN-48 board and card holder

Wiring The gate-cathode wires, which are a part of the rebuild kit's delivery, have to be

handled in this way: - One end is equipped with a coded plug, which fits the C and G pins on the

SDCS-PIN-48 - The cable length in the delivery condition is 2 m. The cable routing should be

done, to end up with a cable length as short as possible; the max. cable length is 1 m. The cables have to be shortened and have to be equipped with the plug connector, demanded by the thyristor type in use.

20

Hardware


Measurement board SDCS-PIN-51 This board is always required with the rebuild kit.

One SDCS-PIN-51 board per kit.

The SDCS-PIN-51 board contains following functions: - Connection to pulse transformer board / boards - Interface for heat sink temperature measurement with a PTC resistor - Measurement and scaling of AC and DC voltage via high ohmic resistors - Measurement of the armature current and scaling with burden resistors to 1.5 V

for rated current; burden resistors for zero current detection

X5

13

X1

3

X23 X24 X25

R1 . . . . . . . R21

X12S

X13S

X413S

X313S

X22 X122

X1

2

U1

V1

W1

D1

C1

W5 W4 W3 W2 W1

W16 W15 W14 W13 W12

W26 W25 W24 W23 W22

W11 W9 W8 W7 W6

W21 W20 W19 W18 W17

W5

R123

R22

R26

1 2 2 21 1

SDCS-PIN-51

S3

W10 W70

W80

W71

W81

W72

W82W83

X1

13

X2

13

X4

13

S1S2

X3

13

305

100

213 4

PTC Conductivesupports

Isolatingsupports

One PTCTwo PTC

line potential !see diagrampower part

~ 6

0

8 331

347

8010

∅5

168.5 121.5

182.55

100.7

∅4.8

8010

Card holder for SDCS-PIN-51

10

SDCS-PIN-51 board and card holder

21

Hardware


A Bba

A Bba

X2

2:

X2

2:

X1

22:

X1

22:

**

Fus

e da

ta 1

A, s

uita

ble

volta

ge

EX

IST

ING

PA

RT

S1

S2

X12 S

X13 S

X313 S

X413 S

4.7

nF

cond

uctiv

e m

ount

ing

hole

s

V21

V23

V25

V2

4

V2

6

V2

2th

yris

tor

desi

gnat

ion

of r

ever

se B

ridge

DCS8_reb_diagr_wir_p48_p51.dsf

X12

:X

12:

X13

:X

13:

X12

:X

12:

X13

:X

13:

SD

CS

-PIN

-48

SD

CS

-PIN

-51

* * * *

Typical rebuild connection with controller board, SDCS-PIN-48 and SDCS-PIN-51 boards

22

Hardware


Wiring If the distance between the SDCS-PIN-51 terminals C1, D1, U1, V1, W1 and the

power terminals of the existing power part exceeds 1 m, an additional fuse has to be used per wire (see fig. before). Make sure a jumper is installed connecting fas-ton point S1 with S2 ! This connection is essential for proper grounding of the flat cables x12: and X13:.

Fastening The boards SDCS-PIN-48 and SDCS-PIN-51 will come with a card holder, which

has got six M4 mounting holes. Using this card holder care must be taken to have a good connection to ground! When mounting these boards without card holder (the figures for the corresponding boards shown before) show which of the holes have to be grounded and which have to be isolated. 15 to 20 mm long metal stand-offs and insulation stand-offs have to be used. The insulation clearance must be rated for 990 V AC working voltage.

PTC temperature sensor Normally there is no temperature sensor in existing converters; in this case, a

separate resistor (2.21 kohm; 0.5 W; 1%; delivered with the kit) must be connected between terminals X22:1 and X22:3 on SDCS-PIN-51; jumper S3 on the same board must be in position 1-2. Because of this, the temperature measurement reads a fixed value and is out of operation. Some kind of power part monitoring can be designed by using optional devices. For more information see chapter Special Accessories.

HW type coding - All jumpers W70 to W72 and W80 to W83 and W10 should be kept untouched

(default condition). - In case a board should be used, which had been in operation or which had

been coded why ever reason with the above listed jumpers no additional ac-tions need to be done. It can be used without further modification; just leave the jumpers as they are. They will not be read by the converter´s software and therefore not taken into calculation.

23

Hardware


Voltage coding Use the settings given by the next table. Depending on the line voltage applied to

the existing power stack the jumpers need to be removed accordingly (lower line voltage scaling on request). Note: At existing power parts with high supply voltage the option galvanic isolation should be taken into consideration because of personal and functional safety rea-sons.

appr.200...500 V

500 600 690 800 1000

W1, 6, 12, 17, 22W2, 7, 13, 18, 23W3, 8, 14, 19, 24W4, 9, 15, 20, 25W5, 11, 16, 21, 26

to the power stackVoltage applied

Value forS ConvScaleVolt (97.03)

indicates a removed jumper

501...600 V 601...700 V 701...800 V 801...990 V

Nominal current coding At first make sure, that the current transformers are mounted and wired according

to the figure before. In addition to that two other definitions are important:

• the nominal current IdN is equivalent to 1.5 V across the nominal current burden resistors

• the current measurement is designed to handle peak currents up to two-times of IdN

Most often the current IdN is the thermal current of the existing power part (thyristor stack); the peak current may be the highest current running through the motor.

• If the peak current is higher than two-times IdN the nominal current needs to be redefined.

The value peakdNDCR II *5.0= has to be used instead of

IdN at all the next equations!

• The scaling for nominal current will be done by the resistors R1 to R21, which are connected in parallel.

24

Hardware


If the ratio of the current transformer is either 2500:1 or 4000:1 The next table lists some burden resistor settings based on two types of current

transformers (2500:1 and 4000:1) and some values for the nominal current IdN.

As long as the nominal current of the power stack is close to these cur-rents and the current transformers are identical as listed below this op-tion for coding the current should be used!

In such a case remove the jumpers on the SDCS-PIN-51 board according to the current selected and set parameter S ConvScaleCur (97.02) to exactly that se-lected rated current.

2500:1 4000:1900 1200 1500 2000 2500 3000 2600 3300 4000

R1-R4 18 ΩR5 18 ΩR6 18 ΩR7 18 ΩR8 18 ΩR9 18 ΩR10 18 ΩR11 18 ΩR12 18 ΩR13 18 ΩR14 18 ΩR15 18 ΩR16 18 ΩR17 33 ΩR18 68 ΩR19 120 ΩR20 270 ΩR21 560 ΩR22 47 ΩR23 47 ΩR24 47 ΩR25 47 ΩR26 100 Ω

4800 5200

DCS800-R volt & curr coding.dsf

Current transf. ratioNominal current IdN [A]

Rat

ed c

urre

nt s

calin

gZe

ro c

urre

ntde

tect

ion

indicates a removed jumper

Hint:

In case a DCS800-R0x will be used to replace a DCR500B or DCR600 keep the coding of the SDCS-PIN-51 board as done in the past and set parameter 97.02 exactly to that value the SDCS-PIN-51 board was coded. The zero current detection is done on the controller board SDCS-CON-4. Because of that the resistors available for that function need not to be coded!

25

Hardware


If the ratio of the current transformer is different to 2500:1 or 4000:1 Calculate the total burden resistance Rbr:

roctI

VRdN

br *5,1=

Calculate the resistors to be cut off within R1 to R21 according to the next formula.

The resulting resistance Rr should be as close as possible to the burden resis-tance Rbr. If the resulting resistance Rr is smaller than Rbr, the nominal current IdN(Rr) will be higher than the current the calculation was based on (keep the coding and use the recalculated current at parameter S ConvScaleCur (97.02)):

RnRRRRRbr

1.....4

13

12

11

11 +++++=

Additional settings The following settings will be done by software parameters:

Converter Parameter Parameter no.

Settings Remarks

type code TypeCode (97.01) NONE nominal current S ConvScaleCur (97.02) xxxxx (A) as coded nominal voltage S ConvScaleVolt (97.03) xxx (V) as coded power stack temperature monitoring

S MaxBrdgTemp (97.04) 60 (°C)

2-Q or 4-Q mode S BlockBridge2 (97.07) 1 2

at 2-Q power part at 4-Q power part

with: IdN = nominal current of power part

roct = ratio of current transformer

26

Hardware


Interface board SDCS-REB-1 Using SDCS-REB-1 plugged to SDCS-PIN-51 the firing commands are arranged in

such a manner, that one SDCS-PIN-48 gives firing pulses to the six forward bridge thyristors and another one to the six reverse bridge thyristors.

If the REB-1 is plugged on SDCS-PIN-51 board connectors X513, X113 and X213, the board routes the firing pulse so that the pulse transformer board for the forward bridge is connected to X613 and the pulse transformer board for the reverse bridge is connected to X713.

Thyristors in old bridges are often differently positioned on the heat sink than in modern converter modules. At the bigger standard DCS800 modules firing com-mands are arranged on the pulse transformer board SDCS-PIN-48. In this way three channels are used for forward bridge and three channels for re-verse bridge. This solution keeps the gate leads as short as possible (see chapter Interfacing the Electronics and Thyristors).

SDCS-REB-1

X213

X713

X113

X613

X513

70

50

front side of the board

Layout of the SDCS-REB-1 board

27

Hardware


Power supply The power supply can be made with two +24 V power supplies, wired up in series.

For this connection suitable power supply is QUINT-PS; rated +24 V / 2.5 A.

2

4

X1:1 +48V

3

conductive support

X2:1 Power o.k.2 66V

+24V

+0V100µF

200µF

2x QUINT-PS

7

9

X6:1

8

SDCS-CON-4(DCS800-R0x)

+24V

DI 7

DI 8

100 V ... 240 V AC

PE

L1

NSDCS-REB-2

or

+24V = ++

--

LN DC ok

1314

+24V =

DC ok

++

--

LN

1314

55

130

122

Quint_conn.dsf

QUINT-PS connection and dimensions

Mounting and wiring of the external power supply: - the device is cooled by convection; because of that mounting direction is impor-

tant - the device needs to be connected to ground (e.g. because of the metal housing,

etc.) - care must be taken for correct wiring and protection of the feeding lines - for more details see description which comes with the device

Monitoring of the external power supply by the SDCS-REB-2: - +48 V and +24 V are monitored - if +48 V is below +41 V and +24 V below +19.5 V then firing pulses are sup-

pressed, the green led V58 is not lit and the transistor switch connected to X2 is open. Normally V58 should be lit and the transistor switch is closed.

- the transistor output rating is 60 V DC/ max. 50 mA; the output is isolated; see figure above

28

Hardware


Hint: The above mentioned monitoring signal should be read by the PLC (programmable logic controller) or connected to an input (one of the 2 inputs, which have a fast update time) of the DCS800-R0x electronics (as indicated above) to handle the COASTING function of the converter. If the supply voltage is o.k. the converter can be released by the PLC. If the supply voltage drops below the threshold, the signal level changes at X2:1 /2. The COASTING function should be activated, which will block the controllers of the converter and force the current to zero as fast as possi-ble for safety reasons. To avoid a blocking and unblocking condition the “power ok” signal should be latched off. The PLC should release the system depending on other starting conditions.

Functionality Electrical characteristics of the SDCS-REB-2

- Current requirement for +24 V is 100 mA - Current requirement for +48 V is 0.4 A for each parallel connected thyristor; if

there are 4 parallel thyristors the requirement is about 1.6 A - The power supply should contain sufficient amount of capacitance so that

+10% secondary voltage tolerance is not exceeded due to voltage ripple; 0 V terminal of the electronics on SDCS-REB-2 is connected to the six mounting holes on the board. Therefore it is grounded.

At the input plug connectors X613 and X713, firing pulse signals 1 to 6 are re-ceived, and the current-direction signals SR1 and SR2 as well. The board ampli-fies these signals and distributes them to 8 plug connectors named X11 to X42. The current direction signal SR1 is assigned to plug connectors Xx1, and current direction signal SR2 to plug connectors Xx2.

Fastening The SDCS-REB-2 board has six M4 mounting holes. All of them must be grounded

using metal stand-offs (see figure Layout of the SDCS-REB-2 board below).

29

Hardware


Diagram

0V

X11 X12

0V

X21 X22

0V

X31 X32

0V

X41 X42

&

12k

22nF

X613

12k

22nFX613

X713

470pF

X613

X613+48V

0V

19V

40V&

X1:2

X1:4

X1:1

X1:3

+24V

ZD66V

POWER OK

+48VX2:1

X2:2

POWER SUPPLY +48V

66

6 6 6 6

0V

0V

0V

0Vseparated potential range

6x 0k5BZP1BZP2BZP3BZP4BZP5BZP6

FWD

REV

0V 0V

+48V

6x

Diagram of the SDCS-REB-2 board

SDCS-REB-2

X713

X11

X21

X22

X12

X31

X32

X42

X1

X4112

0

4

77

116218.5

233

105

67.5

X2 2 1 1

diam

eter

of a

ll su

ppor

ts: 4

.6 m

mhe

ight

: <

55 m

m w

ithou

t cle

aran

ce

s

uppo

rts a

re c

ondu

ctiv

e

V58

X613

200

Card holder for SDCS-REB-2

∅4.5

150

15

20

285

45

~ 65

30


30

Hardware


Interface board SDCS-REB-3 This board is not included in the standard kit. In case the function described later

on gives some advantage it needs to be ordered separately! In a single thyristor bridge the distance between the 6 thyristors and the pulse transformer board is often quite short. The length of these cables, which is limited to 1 meter, is sufficiently long. In big thyristor stages with parallel thyristors the dis-tance can be longer than 1 meter. In addition to that, there is another reason, which becomes more critical at big thy-ristor stages. The wiring of the SDCS-PIN-51, SDCS-REB1 and SDCS-REB-2 is designed, that firing pulses for one complete thyristor bridge will be available at SDCS-PIN-48. To get flexible routing of the firing pulses, the SDCS-REB-3 board comes into use. This board enables the firing pulses to be assigned to the pulse transformers and therefore to the thyristors as well. If the SDCS-REB-3 board is used, it must be installed between the SDCS-REB-2 and the pulse transformer board SDCS-PIN-48. This board represents a matrix which is used for assigning the current direction signals and the firing pulses re-ceived at plugs X11: to X:42 to the output plugs X113: to X813:. If possible try to avoid connecting thyristors of different bridges to the same SDCS-PIN-48. Com-missioning and testing will become easier.

At a power part with parallel thyristors each thyristor gets a three digit number. Every digit has the meaning (see chapter Interfacing the Electronics and Thyristors figure Arrangement of thyristors in an anti parallel bridge): - thyristors named 1xx, 2xx, 3xx or 4xx belong to the first, second, third or fourth

bridge - thyristors named x1x belong to the forward bridge, which is activated by the

current direction signals SR_1ACE and SR_1BDF - thyristors named x2x belong to the reverse bridge, which is activated by the

current direction signals SR_2ACE and SR_2BDF - thyristors named xx1, xx2, up to xx6 indicate the normal firing sequence by

their number

Firing pulses The pulse transformer board SDCS-PIN-48 contains 6 channels numbered A to F.

These are in turn subdivided into 2 groups, one with the channels A, C, E and one with the channels B, D, F. These are controlled by two current direction signals. The next figure shows the routing of the firing pulses and the activation of the two groups for three different configurations, used with the bigger standard DCS800-S0x modules.

Signal flow and Thyristor designation Signal flow of firing pulses and doubling of current direction signals are shown

based on the relevant figures in chapter Interfacing the Electronics and Thyristors. That results in the thristor designation.

31

Hardware


1

2

3

SR_1

4

5

6

SR_2

SDCS-CON-4 SDCS-PIN-51

X1

13

C

E

&

&

&

&

&

&

B

D

F

V 4

V 6

V 2

V 1

V 3

V 5

to thyristor

SDCS-PIN-48

SR_xBDF

SDCS-REB-1

A

SR_xACE

X1

13

C

E

&

&

&

&

&

&

B

D

F

V 4

V 6

V 2

V 1

V 3

V 5

to thyristor

SDCS-PIN-48

SR_xBDF

A

SR_xACE

signal routing

SR_1ACE

SR_1BDF

SR_2ACE

SR_2BDF

signal routing

X1

3

X1

3

X6

13X

713

X5

13X

113

X2

13X

413

X3

13

(reverse)

(forward)

1

2

3

SR_1

4

5

6

SR_2


C

E

&

&

&

&

&

&

B

D

F

V 4

V 6

V 2

V 1

V 3

V 5

to thyristor

SDCS-PIN-48

SR_1BDF

A

SR_1ACE

signal routing

SR_1ACE

SR_1BDF

SR_2ACE

SR_2BDF

X1

3

X1

3

X1

13X

213

X4

13X

313

(forward)

X1

13

X5

13

1

2

3

SR_1

4

5

6

SR_2


C

E

&

&

&

&

&

&

B

D

F

V23

V22

V25

V13

V12

V15

to thyristor

SDCS-PIN-48

SR_1BDF

A

SR_2ACE

X1

13

C

E

&

&

&

&

&

&

B

D

F

V24

V21

V26

V14

V11

V16

to thyristor

SDCS-PIN-48

SR_1BDF

A

SR_2ACE

signal routing

SR_1ACE

SR_1BDF

SR_2ACE

SR_2BDF

X1

3

X1

3

X5

13X

113

X2

13X

313

(forward & reverse)

X1

13

X4

13

(forward & reverse)

X5

13X

113

DCS8-R RB_sign.dsf

Signal flow of firing pulses and thyristor designation

32

Hardware


The following results from this configuration: - A thyristor receives firing pulses when it has been addressed by one of the sig-

nals A to F and by one of the current direction signals SR_Xxxx. - All members of one group have always to be assigned to the same current di-

rection but not necessarily to the same bridge.

There are four horizontal groups of rows assigned to the input terminals, and eight vertical rows assigned to the output terminals. There is one column for the SR_1 and another one for the SR_2 signal, and eight pair of rows for the outgoing SR_ACE and SR_BDF signals. Penetrations are located in the intersections of these signals, vertical to horizontal. If a wire is inserted in these penetrations and soldered on both sides, an input-to-output connection has thus been established. The multilayer construction used for this board enables this method to be em-ployed.

Design hints • Name the AC terminals of the existing power part

• Name all thyristors according to the list above • Look for a place, where the SDCS-PIN-48 board can be mounted and make

sure, that the distance to the gates of the thyristors does not exceed one me-ter; the best noise immunity can be achieved with the shortest gate leads

• Assign the thyristors to a firing channel, bearing in mind the group assignments

Signal handling The handling of the signals, controlling a thyristor is presented by an example:

• Stipulation - Thyristor Vx26 is to be controlled via plug X32: to plug X813: and via chan-

nel D of SDCS-PIN-48 board • Evaluation

- Thyristor Vx26 has been assigned to signal 6 - Thyristor Vx26 belongs to current direction 2 (SR_2) - Channel D has been assigned to group SR_BDF - Channels B and F are then likewise assigned to current direction 2

33

Hardware


• Implementation - Solder in pin: row to X813: - intersection SR_2 - SR_BDF - Solder in pin: field 3/8 - intersection 6 – D (Pins have to be soldered in by inserting the pin, solder it on both sides of

the board and shorten the pin)

BD

FA

CE

4/7

-SR

2-

3/7

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

4/8

-SR

2-

3/8

SR ACESR BDF

X713X813

X42 X32

Signal handling of SDCS-REB-3

• Check the configuration

- A firing pulse amplifier of the SDCS-REB-2 via plug connectors X11, X21, X32 and X42 may operate only one firing pulse transformer per current di-rection

- There is only one connecting point allowed per column at a 2-Q system - There are only two connecting points allowed per column at a 4-Q system - There is only one connection allowed per row - Precisely one matrix field with six connections should be assigned per out-

going plug connector (X113...X813). - The SR_ACE or SR_BDF outputs of plug connectors X113 to X813 must

always be assigned to only one current direction signal, either to SR1 or to SR2

• Assign SDCS-PIN-48 to SDCS-REB-3 board connections

• Configure the SDCS-REB-3 board, complying with the information given by the example

• Inspect visually for clean solder points and remove undesired tin bridges • Check firing pulses

Plug connectors X1113: and X2113: These plug connectors are only used in simple applications aiming solely at a re-

distribution of the firing pulses as compared to and deviating from the standard dis-tribution in modular design. In this variant, REB-1 and REB-2 are dispensed with, with the result that only two anti-parallel thyristor bridges can be controlled.

34

Hardware


Fastening

The SDCS-REB-3 has nine fixing holes. All of them must be grounded.

BD

FA

CE

4/1

-SR

2-

3/1

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/1

-SR

1-

1/1

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/2

-SR

2-

3/2

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/2

-SR

1-

1/2

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/3

-SR

2-

3/3

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/3

-SR

1-

1/3

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDFB

DF

AC

E

4/4

-SR

2-

3/4

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/4

-SR

1-

1/4

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/5

-SR

2-

3/5

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/5

-SR

1-

1/5

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/6

-SR

2-

3/6

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/6

-SR

1-

1/6

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/7

-SR

2-

3/7

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

SR ACESR BDF

BD

FA

CE

2/7

-SR

1-

1/7

-1-

-3-

-5-

-4-

-6-

-2-

-1-

-3-

-5-

-4-

-6-

-2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/8

-SR

2-

3/8

SR ACESR BDF

BD

FA

CE

2/8

-SR

1-

1/8

BD

FA

CE

SR ACESR BDF

X1213 X1113

X113X213

X313X413

X513X613

X713X813

X42 X32 X21 X11

SR ACESR BDF

5

conuctive supports

17080

7532

0

580

8075

340

360

80 45221.5

Card holder for SDCS-REB-3

45

~ 45

∅4.5

30


35

Interfacing the Electronics and Thyristors


Interfacing the Electronics and Thyristors There are several ways to connect the firing commands from the measurement

board to the pulse transformer board(s). The assignment of power section, mains connection and wiring to the SDCS-PIN-51 board is mandatory, since the com-puter board uses this assignment as the basis for computing the pulse sequence. With existing systems, we recommend following our configuration when numbering the semiconductor valves so as to preclude any errors. The arrangement of the thyristors in an anti parallel bridge is presented in the figure below. Thyristors for forward bridge (current direction 1; SR1) are numbered V11, V12...V16 and thyris-tors for reverse bridge (current direction 2; SR2) are numbered V21, V22...V26. In two quadrant applications only the forward bridge is existing.

A B

ba

A B

ba

I actual

(L1) U1

(L2) V1

(L3) W1

V14 V21 V16 V23 V12 V25

D1(-)

V11 V24 V13 V26 V15 V22

C1(+)

DCS800 u i meas val.dsf

U AC actual U DC actual

to SDCS-PIN-51

Arrangement of thyristors in an anti parallel bridge Connection for 2-quadrant application – No parallel Thyristors

V14

SDCS-PIN-48

U1

SDCS-PIN-51

SD

CS

-CO

N-4

V1

W1

C1

D1

X22 X122 X23 X24 X25

X1

2 S

X1

3 S

X4

13 S

X3

13 S

X1

3

X5

13

X1

13

X2

13

X4

13

X3

13

S2

S1

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

V11 V16 V13 V12 V15

X2

13

A

X1

3X

12

X1

2

2q_c34_c.dsf

2-quadrant application, no parallel connected thyristors

36



Connection for 4-quadrant application – No parallel Thyristors There are three ways shown on the next three figures, how to connect the thyris-

tors, the pulse transformer board(s) and the measuring board to each other. At figure below the flat cables are connected between SDCS-PIN-51 X113 to SDCS-PIN-48 X113 and SDCS-PIN-51 X213 to SDCS-PIN-48 X213, which gives the result, that - one SDCS-PIN-48 board transfers all the firing pulses for the thyristors, con-

nected to D1 (see figure Arrangement of thyristors in an anti parallel bridge) - the other SDCS-PIN-48 board transfers all the firing pulses for the thyristors,

connected to C1 (see figure Arrangement of thyristors in an anti parallel bridge)

X113

SDCS-PIN-48

G

C

G

C

G

C

G

C

G

C

G

C

T4 T1 T6 T3 T2

V24

SDCS-PIN-48

U1

SDCS-PIN-51

SD

CS

-CO

N-4

V1

W1

C1

D1

X22 X122 X23 X24 X25

X1

2 S

X1

3 S

X4

13 S

X3

13 S

X1

3

X5

13

X1

13

X2

13

X4

13

X3

13

S2

S1

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

V11 V26 V13 V22 V15

X2

13

A

X1

3X

12

X1

2

V25 V12 V23 V16 V21 V14

F

X2

13

4q_c3a_c.dsf

Firing pulse assignment

At figure below the flat cables are connected between SDCS-PIN-51 X413 to SDCS-PIN-48 X113 and SDCS-PIN-51 X313 to SDCS-PIN-48 X113, which gives the result, that - one SDCS-PIN-48 board transfers all the firing pulses for the thyristors, con-

nected to phase L1 and half of the thyristors, connected to phase L2 (see fig-ure Arrangement of thyristors in an anti parallel bridge)

- the other SDCS-PIN-48 board transfers all the firing pulses for the rest of the thyristors, connected to phase L2 and for the thyristors, connected to phase L3 (see figure Arrangement of thyristors in an anti parallel bridge)

X213

SDCS-PIN-48

G

C

G

C

G

C

G

C

G

C

T1 T6 T3 T2 T5

V23

SDCS-PIN-48

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

V13 V22 V12 V25 V15

X2

13

A

U1

SDCS-PIN-51

SD

CS

-CO

N-4

V1

W1

C1

D1

X22 X122 X23 X24 X25

X1

2 S

X1

3 S

X4

13 S

X3

13 S

X1

3

X5

13

X1

13

X2

13

X4

13

X3

13

S2

S1

X1

3X

12

X1

2

A

C

G

V24 V14 V21 V11 V26 V16

X1

13

4q_c4a_b.dsf

Firing pulse assignment

37



The connection shown below is used normally when the anti parallel bridge is built by connecting two mechanically separate bridges in an anti parallel configuration. Then gate wiring is most simple and short when all six thyristors of a bridge are connected to one pulse transformer board.

X213

SDCS-PIN-48

G

C

G

C

G

C

G

C

G

C

T1 T6 T3 T2 T5

V14

SDCS-PIN-48

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

V11 V16 V13 V12 V15

X2

13

A

U1

SDCS-PIN-51

SD

CS

-CO

N-4

V1

W1

C1

D1

X22 X122 X23 X24 X25

X1

2 S

X1

3 S

X4

13 S

X3

13 S

X1

3

X5

13

X1

13

X2

13

X4

13

X3

13

S2

S1

X1

3X

12

X1

2

A

C

G

V24 V21 V26 V23 V22 V25

X1

13

20

X513

X113

X213

X413

X313

SDCS-REB-1

X713

X713

X613

X513

X113

X213

4q_nopa_a.dsf

4-quadrant application, no parallel thyristors Connection for 4-quadrant application - parallel thyristors With parallel connected thyristors, both additional boards

SDCS-REB-1 and SDCS-REB-2 are needed. Because of the REB-2 board exter-nal +24V and +48V are needed. The power supply SDCS-POW-4 is not able to give enough power for parallel connected thyristors. The figure below shows the configuration for a 4-quadrant bridge with 4 parallel connected thyristors.

V4

24

SDCS-PIN-41

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V4

21

V4

26

V4

23

V4

22

V4

25

V3

24

SDCS-PIN-41

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V3

21

V3

26

V3

23

V3

22

V3

25

V2

24

SDCS-PIN-41

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V2

21

V2

26

V2

23

V2

22

V2

25

V1

24

SDCS-PIN-48

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V1

21

V1

26

V1

23

V1

22

V1

25

V4

14

SDCS-PIN-41

B C D E F

X11

3

C

G

C

G

C

G

C

G

C

G

C

G

X21

3

A

V4

11

V4

16

V4

13

V4

12

V4

15

V3

14

SDCS-PIN-41

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V3

11

V3

16

V3

13

V3

12

V3

15

V2

14

SDCS-PIN-41

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V2

11

V2

16

V2

13

V2

12

V2

15

V1

14

SDCS-PIN-48

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V1

11

V1

16

V1

13

V1

12

V1

15

U1

SDCS-PIN-51

V1

W1

C1

D1

X22 X122 X23 X24 X25

X1

2 S

X1

3 S

X4

13 S

X3

13 S

X1

3

X5

13

X1

13

X2

13

X4

13

X3

13

S2

S1

X1

2

20

X513

X113

X213

X413

X313

SDCS-REB-1

X713

X713

X613

X513

X113

X213

Reverse bridge pulse transformer boards

Forward bridge pulse transformer boards

+24VEXT+48VEXT

0VEXT

X2

SDCS-REB-2

X713

X613

X42

X41

X32

X31

X22

X21

X12

X11X1

0VEXT

RB_4q_4p_a.dsf

4-quadrant application, parallel thyristors.

38



Connection for 2-quadrant application - parallel thyristors With parallel connected thyristors, the additional board SDCS-REB-2 is needed.

Because of the REB-2 board external +24V and +48V are needed. The power supply SDCS-POW-4 is not able to give enough power for parallel connected thy-ristors. The additional board SDCS-REB-1 can be used, but must not be used. Depending on the final decision the flat cable from X613 (SDCS-REB-2) has to be connected to either X613 (SDCS-REB-1) or X513 (SDCS-PIN-51 with SDCS-REB-1 re-moved). The figure below shows the configuration for a 2-quadrant bridge with 4 parallel connected thyristors.

V4

14

SDCS-PIN-41

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V4

11

V4

16

V4

13

V4

12

V4

15

V3

14

SDCS-PIN-41

B C D E F

X11

3

C

G

C

G

C

G

C

G

C

G

C

G

X21

3

A

V3

11

V3

16

V3

13

V3

12

V3

15

V2

14

SDCS-PIN-41

B C D E F

X11

3

C

G

C

G

C

G

C

G

C

G

C

G

X21

3

A

V2

11

V2

16

V2

13

V2

12

V2

15

V1

14

SDCS-PIN-48

B C D E F

X1

13

C

G

C

G

C

G

C

G

C

G

C

G

X2

13

A

V1

11

V1

16

V1

13

V1

12

V1

15

U1

SDCS-PIN-51

V1

W1

C1

D1

X22 X122 X23 X24 X25

X1

2 S

X1

3 S

X4

13 S

X3

13 S

X13

X51

3

X11

3

X21

3

X41

3

X31

3

S2

S1

X12

20

X513

X113

X213

X413

X313

SDCS-REB-1

X713

X713

X613

X513

X113

X213

Forward bridge pulse transformer boards

+24VEXT+48VEXT

0VEXT

X2

SDCS-REB-2

X713

X613

X42

X41

X32

X31

X22

X21

X12

X11X1

0VEXT

RB_2q_4p_a.dsf

2-quadrant application, parallel thyristors.

39

Installation


Installation The information given within this chapter shall help the installation personnel to se-

lect a place for the different components of the rebuild kit, to mount them and do the interconnections between the boards and the existing hardware.

Background for the figures of this chapter The figures within this chapter show the different electrical configurations of the kit

and give some suggestions for mechanical mounting. On the electrical figures a 4-Q version is drawn: in case a 2-Q version is in use, the SDCS-PIN-48 boards plus cables for

the reverse bridge will not be delivered with the kit (please ignore that part of the figures)

The drawings 5 9 HFigure 4 to 6 0 HFigure 6 differ from the ones afterwards. With the first ones the SDCS-REB-3 board is not shown to indicate, that this board does not need to be used in every case as long as the mechanics allow gate cable length lower than 1m! Parts which are common for the different configurations are always drawn at the same position. So the parts not needed or not used in the one or the other situa-tion can easily be recognised.

The installation of the kit can be subdivided into 3 parts. 6 1 HFigure 3 is taken as an example and will have these 3 parts marked (read the other pictures in a similar way):

• Part 1 consists of the SDCS-PIN-48 boards, which have to be mounted as close as possible to the thyristors.

• Part 2 covers the SDCS-PIN-51 and the SDCS-REB-2 boards with their acces-sories. The components within this part may be different depending on the final configuration needed for the existing power part. The cable connections within these boards are quite short; so the boards have to be mounted close to each other, but can be mounted quite far away from the boards used for part 1 or 3. Figure 6 gives a suggestion how the components can be mounted on a metal plate. In case the configuration according to 6 2 HFigure 8 or 6 3 HFigure 9 is used 6 4 HFigure 10 and the following ones will show the mechanical possibilities.

• Part 3 shows the main DCS800-R0x electronics with the electronic power sup-ply SDCS-POW-4 and the microprocessor system SDCS-CON-4. All other op-tions which can be connected to the controller boards are left out for easier reading. They are indicated on the diagrams at chapter Basic Selection show-ing the overall configuration. The detailed description of these options is to be found within the Hardware Manual. All components belonging to the third part should be mounted close to each other in the existing drive cabinet (see di-mension drawing).

40

Installation


SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

Rev

erse

brid

ge p

ulse

tran

sfor

mer

boa

rd(s

)(C

able

s an

d bo

ards

are

mis

sing

in 2

-Q k

its!)

For

war

d br

idge

pul

se tr

ansf

orm

er b

oard

(s)

X12

L3

X22

X12

2X

23

Vol

tage

s fr

om p

ower

par

t(c

able

leng

th a

ppr.

1 m

) fr

om C

urre

nt tr

ansf

orm

ers

(cab

le le

ngth

app

r. 2

m)

SD

CS

-PO

W-4

+L2

L1

115/

230

V A

C

1616

2020

~ 3

m<

1 m

Cab

le le

ng

thC

able

len

gth

~ 5 m

Cable length2.

21k Ω

-

Mou

ntin

g pl

ate

(car

d ho

lder

)

Gro

und

conn

ectio

n

Sin

gle/

mul

ti st

rand

cab

le; n

ot s

hiel

ded;

incl

uded

in th

e ki

t

Sin

gle/

mul

ti st

rand

cab

le n

ot s

hiel

ded;

no

t in

clud

ed in

the

kit

Rib

bon

cabl

e (r

ound

) sh

ield

ed; i

nclu

ded

in th

e ki

t

Rib

bon

cabl

e (f

lat)

no

t shi

elde

d; in

clud

ed in

the

kit

Leg

end

Put

on

cabl

e lu

g w

ith ∅

5m

m

to F

asto

n co

nnec

tor

X12

S/X

13S

at S

DC

S-P

IN-5

1

conn

ect t

o co

nnec

tor

X1

at S

DC

S-P

IN-4

8P

ut o

n fa

ston

con

nect

or 6

.3 m

m

conn

ect t

o co

nduc

tive

supp

ort

at S

DC

S-P

IN-5

1

DCS8_reb_card_layout electr_st1.dsf

cabl

e sh

ield

ing

-ca

ble

shie

ldin

g-

- co

nnec

t S1

and

S2

via

jum

per

(fas

ton

type

6.3

mm

)

X12 S

X13 S

S2

S1co

nnec

t S1

and

S2

via

jum

per

(fas

ton

type

6.3

mm

)

Figure 2: Electrical drawing: 1 thyristor stage

41

Installation


X12 S

X13 S

S2

S1

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V214

V211

V216

V213

V212

V215

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V224

V221

V226

V223

V222

V225

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

Rev

erse

brid

ge p

ulse

tran

sfor

mer

boa

rd(s

)(C

able

s an

d bo

ards

are

mis

sing

in 2

-Q k

its!)

For

war

d br

idge

pul

se tr

ansf

orm

er b

oard

(s)

X12

L3

X22

X12

2X

23

SD

CS

-RE

B-2

X613

X713

X11X21

X12X22

X31X41

X32X42

X2

X1

24V

DC

QU

INT

-PS

24V

DC

+48V

+24V

0V

Vol

tage

s fr

om p

ower

par

t(c

able

leng

th a

ppr.

1 m

) fr

om C

urre

nt tr

ansf

orm

ers

(cab

le le

ngth

app

r. 2

m)

2 1 2 1

SD

CS

-PO

W-4

+L2

L1

115/

230

V A

C

2020

1616

20 2020 20

115/

230

V A

C

~ 0.

5 m

~ 5

m<

1 m

Cab

le le

ng

thC

able

len

gth

Cab

le le

ng

th

~ 5 m

Cable length

2.21

k Ω

Brid

ge

Brid

ge

-

DCS8_reb_card_layout electr_st2to4.dsf

QU

INT

-PS

Mou

ntin

g pl

ate

(car

d ho

lder

)

Gro

und

conn

ectio

n

Sin

gle/

mul

ti st

rand

cab

le; n

ot s

hiel

ded;

incl

uded

in th

e ki

t

Sin

gle/

mul

ti st

rand

cab

le n

ot s

hiel

ded;

no

t in

clud

ed in

the

kit

Rib

bon

cabl

e (r

ound

) sh

ield

ed; i

nclu

ded

in th

e ki

t

Rib

bon

cabl

e (f

lat)

no

t shi

elde

d; in

clud

ed in

the

kit

Leg

end

to F

asto

n co

nnec

tor

X12

S/X

13S

at S

DC

S-P

IN-5

1

cabl

e sh

ield

ing

-ca

ble

shie

ldin

g-

conn

ect S

1 an

d S

2 vi

a ju

mpe

r (f

asto

n ty

pe 6

.3 m

m)

Mou

ntin

g pl

ate

(car

d ho

lder

)

to F

asto

n co

nnec

tor

X1

at S

DC

S-P

IN-4

8

Par

t 1

Par

t 2

Par

t 3

Figure 3: Electrical drawing: 2 Thyristor stages in parallel

42

Installation


SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V314

V311

V316

V313

V312

V315

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V324

V321

V326

V323

V322

V325

3 3

2020

X12 S

X13 S

S2

S1

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V214

V211

V216

V213

V212

V215

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V224

V221

V226

V223

V222

V225

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

Rev

erse

brid

ge p

ulse

tran

sfor

mer

boa

rd(s

)(C

able

s an

d bo

ards

are

mis

sing

in 2

-Q k

its!)

For

war

d br

idge

pul

se tr

ansf

orm

er b

oard

(s)

X12

L3

X22

X12

2X

23

SD

CS

-RE

B-2

X613

X713

X11X21

X12X22

X31X41

X32X42

X2

X1

24V

DC

QU

INT

-PS

24V

DC

+48V

+24V

0V

Vol

tage

s fr

om p

ower

par

t(c

able

leng

th a

ppr.

1 m

) fr

om C

urre

nt tr

ansf

orm

ers

(cab

le le

ngth

app

r. 2

m)

2 1 2 1

SD

CS

-PO

W-4

+L2

L1

115/

230

V A

C

2020

1616

20 2020 20

115/

230

V A

C

~ 0.

5 m

~ 5

m<

1 m

Cab

le le

ng

thC

able

len

gth

Cab

le le

ng

th

~ 5 m

Cable length2.

21k Ω

Brid

ge

Brid

ge

-


QU

INT

-PS

Mou

ntin

g pl

ate

(car

d ho

lder

)

Gro

und

conn

ectio

n

Sin

gle/

mul

ti st

rand

cab

le; n

ot s

hiel

ded;

incl

uded

in th

e ki

t

Sin

gle/

mul

ti st

rand

cab

le n

ot s

hiel

ded;

no

t in

clud

ed in

the

kit

Rib

bon

cabl

e (r

ound

) sh

ield

ed; i

nclu

ded

in th

e ki

t

Rib

bon

cabl

e (f

lat)

no

t shi

elde

d; in

clud

ed in

the

kit

Leg

end

to F

asto

n co

nnec

tor

X12

S/X

13S

at S

DC

S-P

IN-5

1

cabl

e sh

ield

ing

-ca

ble

shie

ldin

g-

conn

ect S

1 an

d S

2 vi

a ju

mpe

r (f

asto

n ty

pe 6

.3 m

m)

Mou

ntin

g pl

ate

(car

d ho

lder

)

to F

asto

n co

nnec

tor

X1

at S

DC

S-P

IN-4

8

Par

t 1

Par

t 2

Par

t 3


43

Installation


SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V414

V411

V416

V413

V412

V415

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V424

V421

V426

V423

V422

V425

2020

4 4

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V314

V311

V316

V313

V312

V315

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V324

V321

V326

V323

V322

V325

3 3

2020

X12 S

X13 S

S2

S1

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V214

V211

V216

V213

V212

V215

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V224

V221

V226

V223

V222

V225

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

Rev

erse

brid

ge p

ulse

tran

sfor

mer

boa

rd(s

)(C

able

s an

d bo

ards

are

mis

sing

in 2

-Q k

its!)

For

war

d br

idge

pul

se tr

ansf

orm

er b

oard

(s)

X12

L3

X22

X12

2X

23

SD

CS

-RE

B-2

X613

X713

X11X21

X12X22

X31X41

X32X42

X2

X1

24V

DC

QU

INT

-PS

24V

DC

+48V

+24V

0V

Vol

tage

s fr

om p

ower

par

t(c

able

leng

th a

ppr.

1 m

) fr

om C

urre

nt tr

ansf

orm

ers

(cab

le le

ngth

app

r. 2

m)

2 1 2 1

SD

CS

-PO

W-4

+L2

L1

115/

230

V A

C

2020

1616

20 2020 20

115/

230

V A

C

~ 0.

5 m

~ 5

m<

1 m

Cab

le le

ng

thC

able

len

gth

Cab

le le

ng

th

~ 5 m

Cable length

2.21

k Ω

Brid

ge

Brid

ge

-


QU

INT

-PS

Mou

ntin

g pl

ate

(car

d ho

lder

)

Gro

und

conn

ectio

n

Sin

gle/

mul

ti st

rand

cab

le; n

ot s

hiel

ded;

incl

uded

in th

e ki

t

Sin

gle/

mul

ti st

rand

cab

le n

ot s

hiel

ded;

no

t in

clud

ed in

the

kit

Rib

bon

cabl

e (r

ound

) sh

ield

ed; i

nclu

ded

in th

e ki

t

Rib

bon

cabl

e (f

lat)

no

t shi

elde

d; in

clud

ed in

the

kit

Leg

end

to F

asto

n co

nnec

tor

X12

S/X

13S

at S

DC

S-P

IN-5

1

cabl

e sh

ield

ing

-ca

ble

shie

ldin

g-

conn

ect S

1 an

d S

2 vi

a ju

mpe

r (f

asto

n ty

pe 6

.3 m

m)

Mou

ntin

g pl

ate

(car

d ho

lder

)

to F

asto

n co

nnec

tor

X1

at S

DC

S-P

IN-4

8

Par

t 1

Par

t 2

Par

t 3


44

Installation


X5

13

X13

X23X24X25

R21 . . . . . . . R1

X12S

X13S

X413S

X313S

X22X122

X1

2

U1

V1

W1

D1

C1

W5W4W3W2W1

W16W15W14W13W12

W26W25W24W23W22

W11W9W8W7W6

W21W20W19W18W17

R26

R22

1222 11

SDCS-PIN-51

S3

W10W70

W80

W71

W81

W72

W82W83

X1

13

X2

13

X4

13

S1 S2

X3

13

2 134

One PTCTwo PTC

SDCS-REB-1

X2

13

X5

13

X6

13

X7

13

X1

13

SD

CS

-RE

B-2

X713

X11 X21

X22X12

X31

X32 X42

X1

X41

4

X2

2 1

1V

58

X613

to SDCS-CON-4

to SDCS-PIN-48

50 mm

DCS8_reb_card_Layout_mechan_reb2.dsf

+ + - -

L N

+ + - -

L N

mounting direction for pow

er supply units

3

Figure 6: Mechanical suggestion Part 2 without SDCS-REB-3

45

Installation


X12 S

X13 S

S2

S1

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V314

V311

V316

V313

V312

V315

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V214

V211

V216

V213

V212

V215

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V324

V321

V326

V323

V322

V325

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V224

V221

V226

V223

V222

V225

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

Rev

erse

brid

ge p

ulse

tran

sfor

mer

boa

rd(s

)(C

able

s an

d bo

ards

are

mis

sing

in 2

-Q k

its!)

For

war

d br

idge

pul

se tr

ansf

orm

er b

oard

(s)

X12

L3

X22

X12

2X

23

SD

CS

-RE

B-2

X613

X713

X11X21

X12X22

X31X41

X32X42

X2

X1

+48V

+24V

0V

SD

CS

-RE

B-3

X11X21X32X42

X1

113

X1

213

X113...X813

Vol

tage

s fr

om p

ower

par

t(c

able

leng

th a

ppr.

1 m

) fr

om C

urre

nt tr

ansf

orm

ers

(cab

le le

ngth

app

r. 2

m)

3 2 1 3 2 1

SD

CS

-PO

W-4

+-

L2L1

115/

230

V A

C

2020

1616

20 202020

20 202020 2020

~ 0.

5 m

~ 0.

5 m

~ 5

m<

1 m

Cab

le le

ng

thC

able

len

gth

Cab

le le

ng

thC

able

len

gth

~ 5 m

Cable length

2.21

kΩ

Brid

ge

Brid

ge

24V

DC

QU

INT

-PS

24V

DC

115/

230

V A

C

QU

INT

-PS

DCS8_reb_card_layout electr_st4_reb3.dsf

Mou

ntin

g pl

ate

(car

d ho

lder

)

Gro

und

conn

ectio

n

Sin

gle/

mul

ti st

rand

cab

le; n

ot s

hiel

ded;

incl

uded

in th

e ki

t

Sin

gle/

mul

ti st

rand

cab

le n

ot s

hiel

ded;

no

t in

clud

ed in

the

kit

Rib

bon

cabl

e (r

ound

) sh

ield

ed; i

nclu

ded

in th

e ki

t

Rib

bon

cabl

e (f

lat)

no

t shi

elde

d; in

clud

ed in

the

kit

Leg

end

to F

asto

n co

nnec

tor

X12

S/X

13S

at S

DC

S-P

IN-5

1

cabl

e sh

ield

ing

-ca

ble

shie

ldin

g-

- co

nnec

t S1

and

S2

via

jum

per

(fas

ton

type

6.3

mm

)

Mou

ntin

g pl

ate

(car

d ho

lder

)

to F

asto

n co

nnec

tor

X1

at S

DC

S-P

IN-4

8

conn

ect S

1 an

d S

2 vi

a ju

mpe

r (f

asto

n ty

pe 6

.3 m

m)

Figure 7: Electr. drawing: 3 Thyr. stages in parallel w. REB-3

46

Installation


SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V414

V411

V416

V413

V412

V415

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V424

V421

V426

V423

V422

V425

4 4

2020

X12 S

X13 S

S2

S1S

DC

S-P

IN-4

1

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V314

V311

V316

V313

V312

V315

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V214

V211

V216

V213

V212

V215

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V324

V321

V326

V323

V322

V325

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V224

V221

V226

V223

V222

V225

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

Rev

erse

brid

ge p

ulse

tran

sfor

mer

boa

rd(s

)(C

able

s an

d bo

ards

are

mis

sing

in 2

-Q k

its!)

For

war

d br

idge

pul

se tr

ansf

orm

er b

oard

(s)

X12

L3

X22

X12

2X

23

SD

CS

-RE

B-2

X613

X713

X11X21

X12X22

X31X41

X32X42

X2

X1

+48V

+24V

0V

SD

CS

-RE

B-3

X11X21X32X42

X11

13X

121

3

X113...X813

Vol

tage

s fr

om p

ower

par

t(c

able

leng

th a

ppr.

1 m

) fr

om C

urre

nt tr

ansf

orm

ers

(cab

le le

ngth

app

r. 2

m)

3 2 1 3 2 1

SD

CS

-PO

W-4

+-

L2L1

115/

230

V A

C

2020

1616

20 202020

20 202020 2020

~ 0.

5 m

~ 0.

5 m

~ 5

m<

1 m

Cab

le le

ng

thC

able

len

gth

Cab

le le

ng

thC

able

len

gth

~ 5 m

Cable length2.

21kΩ

Brid

ge

Brid

ge

24V

DC

QU

INT

-PS

24V

DC

115/

230

V A

C

QU

INT

-PS

DCS8_reb_card_layout electr_st4_reb3.dsf

Mou

ntin

g pl

ate

(car

d ho

lder

)

Gro

und

conn

ectio

n

Sin

gle/

mul

ti st

rand

cab

le; n

ot s

hiel

ded;

incl

uded

in th

e ki

t

Sin

gle/

mul

ti st

rand

cab

le n

ot s

hiel

ded;

no

t in

clud

ed in

the

kit

Rib

bon

cabl

e (r

ound

) sh

ield

ed; i

nclu

ded

in th

e ki

t

Rib

bon

cabl

e (f

lat)

no

t shi

elde

d; in

clud

ed in

the

kit

Leg

end

to F

asto

n co

nnec

tor

X12

S/X

13S

at S

DC

S-P

IN-5

1

cabl

e sh

ield

ing

-ca

ble

shie

ldin

g-

- co

nnec

t S1

and

S2

via

jum

per

(fas

ton

type

6.3

mm

)

Mou

ntin

g pl

ate

(car

d ho

lder

)

to F

asto

n co

nnec

tor

X1

at S

DC

S-P

IN-4

8

conn

ect S

1 an

d S

2 vi

a ju

mpe

r (f

asto

n ty

pe 6

.3 m

m)

Figure 8: Electr. drawing: 4 Thyr. stages in parallel w. REB-3

47

Installation


X513

X13

X23

X24

X25

R1 . . . . . . . R

21

X12SX

13S X413SX

313S

X22

X122

X12

U1

V1

W1

D1

C1

W5

W4

W3

W2

W1

W16

W15

W14

W13

W12

W26

W25

W24

W23

W22

W11

W9

W8

W7

W6

W21

W20

W19

W18

W17

R22

R26

12

22

11

SD

CS

-PIN

-51

S3

W10

W70

W80

W71

W81

W72

W82

W83X113

X213

X413

S1

S2

X313

21 3

4

One P

TCTw

o PTC

SD

CS

-RE

B-1

X213

X513

X613

X713

X113

SDCS-REB-2

X71

3

X11

X21

X22

X12 X31

X32

X42

X1

X41

4

X2 2 1 1

V58

X61

3

B D F A C E

4 / 1- S R 2 -

3 / 1

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 1- S R 1 -

1 / 1

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 2- S R 2 -

3 / 2

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 2- S R 1 -

1 / 2

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 3- S R 2 -

3 / 3

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 3- S R 1 -

1 / 3

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 4- S R 2 -

3 / 4

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 4- S R 1 -

1 / 4

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 5- S R 2 -

3 / 5

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 5- S R 1 -

1 / 5

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 6- S R 2 -

3 / 6

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 6- S R 1 -

1 / 6

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 7- S R 2 -

3 / 7

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 7- S R 1 -

1 / 7

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 8- S R 2 -

3 / 8

SR

AC

ES

R B

DF

B D F A C E

2 / 8- S R 1 -

1 / 8B D F A C E

SR

AC

ES

R B

DF

X12

13X

1113

X113 X213 X313 X413 X513 X613 X713 X813

X42

X32

X21

X11

SR

AC

ES

R B

DF

to SD

CS

-CO

N-4

to SDCS-PIN-48

50 mm

DCS8_reb_card_Layout_mechan_reb3_1.dsf

+ + - -

L N

+ + - -

L N


er supply units 3

Figure 9: Mechanical suggestion 1 for Part 2 with REB-3

48

Installation


X513

X13

X23

X24

X25

R1 . . . . . . . R

21

X12SX

13S X413SX

313S

X22

X122

X12

U1

V1

W1

D1

C1

W5

W4

W3

W2

W1

W16

W15

W14

W13

W12

W26

W25

W24

W23

W22

W11

W9

W8

W7

W6

W21

W20

W19

W18

W17

R22

R26

12

22

11

SD

CS

-PIN

-51

S3

W10

W70

W80

W71

W81

W72

W82

W83X113

X213

X413

S1

S2

X313

21 3

4

One P

TC

Two P

TC

SD

CS

-RE

B-1

X213

X513

X613

X713

X113

SDCS-REB-2

X71

3

X11

X21

X22

X12 X31

X32

X42

X1

X41

4

X2 2 1 1

V58

X61

3

B D F A C E

4 / 1- S R 2 -

3 / 1

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 1- S R 1 -

1 / 1

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 2- S R 2 -

3 / 2

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 2- S R 1 -

1 / 2

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 3- S R 2 -

3 / 3

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 3- S R 1 -

1 / 3

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 4- S R 2 -

3 / 4

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 4- S R 1 -

1 / 4

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 5- S R 2 -

3 / 5

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 5- S R 1 -

1 / 5

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 6- S R 2 -

3 / 6

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 6- S R 1 -

1 / 6

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 7- S R 2 -

3 / 7

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 7- S R 1 -

1 / 7

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 8- S R 2 -

3 / 8

SR

AC

ES

R B

DF

B D F A C E

2 / 8- S R 1 -

1 / 8B D F A C E

SR

AC

ES

R B

DF

X12

13X

1113

X113 X213 X313 X413 X513 X613 X713 X813

X42

X32

X21

X11

SR

AC

ES

R B

DF

to SDCS-PIN-48

to SD

CS

-CO

N-4

50 mm


+ + - -

L N

+ + - -

L N


er supply units

3


49

Installation


X5

13

X1

3

X23X24X25

R21 . . . . . . . R1

X12S

X13S

X413S

X313S

X22X122

X1

2

U1

V1

W1

D1

C1

W5W4W3W2W1

W16W15W14W13W12

W26W25W24W23W22

W11W9W8W7W6

W21W20W19W18W17

R26

R22

1222 11

SDCS-PIN-51

S3

W10W70

W80

W71

W81

W72

W82W83

X1

13

X2

13

X4

13

S1 S2

X3

13

2 134

One PTCTwo PTC

SDCS-REB-1

X213

X513

X6

13

X7

13

X113

SD

CS

-RE

B-2

X713

X11 X21

X22X12

X31

X32 X42

X1

X41

4

X2

2 1

1V

58

X613

B D F A C E

4 / 1- S R 2 -

3 / 1

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 1- S R 1 -

1 / 1

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 2- S R 2 -

3 / 2

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 2- S R 1 -

1 / 2

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 3- S R 2 -

3 / 3

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 3- S R 1 -

1 / 3

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 4- S R 2 -

3 / 4

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 4- S R 1 -

1 / 4

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 5- S R 2 -

3 / 5

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 5- S R 1 -

1 / 5

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 6- S R 2 -

3 / 6

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 6- S R 1 -

1 / 6

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 7- S R 2 -

3 / 7

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

SR

AC

ES

R B

DF

B D F A C E

2 / 7- S R 1 -

1 / 7

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

- 1 -- 3 -- 5 -- 4 -- 6 -- 2 -

B D F A C E

SR

AC

ES

R B

DF

B D F A C E

4 / 8- S R 2 -

3 / 8

SR

AC

ES

R B

DF

B D F A C E

2 / 8- S R 1 -

1 / 8B D F A C E

SR

AC

ES

R B

DF

X12

13X

1113

X113 X213 X313 X413 X513 X613 X713 X813

X42

X32

X21

X11

SR

AC

ES

R B

DF

to SDCS-CON-4

to SDCS-PIN-48

50 mm


+ + - -

L N

+ + - -

L N


er supply units

3


50

Installation


X513

X13

X23

X24

X25

R1 . . . . . . . R

21

X12SX

13S X413SX313S

X22

X122

X12

U1

V1

W1

D1

C1

W5

W4

W3

W2

W1

W16

W15

W14

W13

W12

W26

W25

W24

W23

W22

W11

W9

W8

W7

W6

W21

W20

W19

W18

W17

R22

R26

12

22

11

SD

CS

-PIN

-51

S3

W10

W70

W80

W71

W81

W72

W82

W83X113

X213

X413

S1

S2

X313

21 3

4

One P

TC

Two P

TC

SD

CS

-RE

B-1

X213

X513

X613

X713

X113

SDCS-REB-2

X71

3

X11

X21

X22

X12 X31

X32

X42

X1

X41

4

X2 2 1 1

V58

X61

3

BD

FA

CE

4/

1-

SR

2-

3/

1

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

1-

SR

1-

1/

1

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

2-

SR

2-

3/

2

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

2-

SR

1-

1/

2

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

3-

SR

2-

3/

3

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

3-

SR

1-

1/

3

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

4-

SR

2-

3/

4

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

4-

SR

1-

1/

4

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

5-

SR

2-

3/

5

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

5-

SR

1-

1/

5

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

6-

SR

2-

3/

6

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

6-

SR

1-

1/

6

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

7-

SR

2-

3/

7

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

SR ACESR BDF

BD

FA

CE

2/

7-

SR

1-

1/

7

-1

--

3-

-5

--

4-

-6

--

2-

-1

--

3-

-5

--

4-

-6

--

2-

BD

FA

CE

SR ACESR BDF

BD

FA

CE

4/

8-

SR

2-

3/

8

SR ACESR BDF

BD

FA

CE

2/

8-

SR

1-

1/

8B

DF

AC

E

SR ACESR BDF

X1213X1113

X11

3X

213

X31

3X

413

X51

3X

613

X71

3X

813

X42X32X21X11

SR ACESR BDF

to SD

CS

-PIN

-48

to SD

CS

-CO

N-4

50 mm


+ + - -

L N

+ + - -

L N


er supply units

3


51

Installation


Hints for Cabling Each kit will be delivered already with most of the cables needed to do the com-

plete wiring. The next table lists the flat cables. Together with 6 5 HFigure 13 they can be identified to use the right cable for any of the connections. In case there is more than one connection between two or more boards (e.g. connection made by cable B2) all the cables will have the same marking.

Marking at 6 6 HFigure 13

Order number Remark

A 3ADT 693567R1 2 cables per kit; 5 m long B1 3ADT 693230R1 1...2 cables per bridge; 3 m long B2 3ADT 693217R1 2...8 cables per kit; 5 m long C GNT 6093268R6 2 cables per kit; 0.5 m long D DCA 0020531P1 1x Resistor 2.21 kΩ E cable type: AWG20, UL10203,T F DCA 0021154R0001 Adapters for different gate connections

52

Installation


SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V414

V411

V416

V413

V412

V415

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V424

V421

V426

V423

V422

V425

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V314

V311

V316

V313

V312

V315

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V324

V321

V326

V323

V322

V325

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V214

V211

V216

V213

V212

V215

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-41

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V224

V221

V226

V223

V222

V225

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X11X21

X12X22

X31X41

X32X42

20 20 20 20 20 20 20 20

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V114

V111

V116

V113

V112

V115

SD

CS

-PIN

-48

BC

DE

F

X113

C

G

C

G

C

G

C

G

C

G

C

G

X213

A

X1

X2

V124

V121

V126

V123

V122

V125

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

X12

L3

X22

X12

2X

23

SD

CS

-PO

W-4

+L2

L1

1616

2020

2.21

kΩ-

X513

X113

X213

X413

X313

U1

X24

X25

X12 S

X13 S

X413 S

X313 S

S2

S1SDCS-PIN-51

X13

SD

CS

-RE

B-1

X713 X713

X613

X513

X113

X213

SD

CS

-CO

N-4

X13

X12

D1C1W1V1

X12

L3

X22

X12

2X

23

SD

CS

-RE

B-2

X613

X713

X2

X1

+48V

+24V

0V

SD

CS

-PO

W-4

+-

L2L1

2020

1616

2.21

kΩ24

VD

C

QU

INT

-PS

24V

DC

115/

230

V A

C

QU

INT-

PS

D

EF

E

D

FE

CAA

E

B1

B2

DCS8_reb_card_layout electr_cabling.dsf

Figure 13: Principles of cabling

53

Safety Instructions


Safety Instructions

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

operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

To which products this chapter applies This chapter applies to the whole range of the product DCS800, the converter

modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the re-build kit DCS800-R0x.

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 dan-ger. 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 volt-age which can cause physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by electricity, which can result in physical injury and/or damage to the equip-ment.

Electrostatic discharge warning warns of electro-static discharge which can damage the equip-ment.

54

Safety Instructions


Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death.

Only qualified electricians are allowed to install and maintain the drive.

• Never work on the drive, motor cable or motor when main power is applied. Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:

1. Voltage between drive input phases U1, V1 and W1 and the frame is close to 0 V.

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

• Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off.

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

• When reconnecting the motor cable, always check that the C+ and D- cables are connected with the proper terminal.

Note: • The motor cable terminals on the drive are at a dangerously high

voltage when the input power is on, regardless of whether the mo-tor is running or not.

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs SDCS-IOB-2 and RDIO.

• DCS800 with enclosure extension: Before working on the drive, isolate the whole drive from the supply.

55

Safety Instructions


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

Grounding These instructions are intended for all who are responsible for the

grounding of the drive. Incorrect grounding can cause physical injury, death or equipment malfunction and increase electromagnetic interfer-ence

• Ground the drive, motor and adjoining equipment to ensure per-sonnel safety in all circumstances, and to reduce electromagnetic emission and pick-up.

• Make sure that grounding conductors are adequately sized as re-quired 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 ground-ing of screened cable entries at the cabinet lead-through.

• Do not install a drive with EMC filter on an ungrounded power sys-tem or a high resistance-grounded (over 30 ohms) power system.

Note: • Power cable shields are suitable for equipment grounding conduc-

tors 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.

56

Safety Instructions


Fiber optic cables

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.

• DCS800 sizes D4...D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back. DCS800 sizes D5...D7: The drive is heavy. Lift the drive by the lift-ing 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 in-stalling. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

• Ensure sufficient cooling. • Do not fasten the drive by riveting or welding.

Operation

These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death or damage the equipment.

• Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed.

• Do not activate automatic fault reset functions of the Standard Ap-plication Program if dangerous situations can occur. When acti-vated, these functions will reset the drive and resume operation af-ter a fault.

• Do not control the motor with the disconnecting device (discon-

necting mains); instead, use the control panel keys and , or commands via the I/O board of the drive.

57

Safety Instructions


• Mains connection You can use a disconnect switch (with fuses) in the power supply of the thyristor power converter to disconnect the electrical com-ponents of the unit from the power supply for installation and main-tenance work. The type of disconnect used must be a disconnect switch as per EN 60947-3, Class B, so as to comply with EU regu-lations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main con-tacts 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 thy-ristor power converter will neither cause an emergency motor stop, nor will the drive be disconnected from any dangerous potential. To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals "RUN", "drive OFF" or "Emergency Stop" respectively "control panel" or "PC tool".

• Intended use The operating instructions cannot take into consideration every possible case of configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in in-dustrial 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 chil-dren or similar) -, these additional safety measures for the installa-tion must be provided by the customer during assembly.

Note: • When the control location is not set to Local (L not shown in the

status row of the display), the stop key on the control panel will not stop the drive. To stop the drive using the control panel, press the

LOC/REM key and then the stop key .

58

Safety Instructions


59

Start-up


Start-up

What this chapter contains This chapter describes the commissioning procedure for a DCR kit. This is done

based on the procedure used for DCS800-S0x converters. Only the actions and steps, which are different, are listed here.

Safety Instructions The rebuilt kit together with the power part and other components being reused will

form a converter and a drive system very similar as a new converter module or a new cubicle with a converter module built-in. Based on that the mechanical and electrical danger installation and commissioning personal is exposed to during the work is similar, sometimes even higher. There is some work, which will only be-come necessary together with a rebuild kit like thyristor assignment, activation of feedback signals and some tests and measurements not necessary to ready made converters.

Because of that the Safety Instructions which have been given within the chapter before need to be observed with extreme care! When listing the different steps of the start-up procedure additional warnings will be given. Based on the possible variations caused by the individual projects not all conditions can be covered. Please take that procedure as a general guideline and be prepared for individual decisions concerning safety and security.

Points to be observed because of the situation All relevant safety regulations must be observed in the installation, commissioning

and maintenance work.

Because the rebuild kit enclosure class is IP00, it´s main and auxiliary connections and other electrical parts can be reached without any protection.

After the supply voltage is disconnected by the main switch, always ensure by measuring that no part of the system has voltage or the system is protected with sufficient touching cover before any work is started.

There might be live terminals inside the drive cabinet even after the supply voltage has been disconnected by the any main switch, e.g. incoming busbars of the main switch itself or external auxiliary power supplies.

Avoid unnecessary voltage withstand tests on any part of the unit.

60

Start-up


Maintenance work All maintenance must be carried out by a competent electrician, who shall also

have custody of keys to the doors, unless the system is located in switch gear.

All points within this chapter must be observed before any work is begun.

Tools In addition to the tools needed to maintain electrical parts some special tools are

recommended: - Oscilloscope either with galvanically isolating transformer or isolating amplifier

for safe measurements - Clamp on current probe; an AC type is sufficient for gate firing pulse measure-

ments; in case the scaling of the DC load current needs to be checked, a DC type is needed

- Voltmeter Make sure, all equipment in use is suitable for that voltage level applied to the power part!

General hint In addition to the work specific for the installation of the pure rebuild kit hardware

attention should be paid to features related to drives in general. There is the engi-neering and the interface to other components in general, the selection of control cables and their routing, earthing and grounding, screening and other points which need further considerations. The manual Technical Guide gives some help within the chapter EMC Compliant Installation and Configuration for a Power Drive Sys-tem. This chapter gives information specific to fulfill the needs necessary for the CE marking. Most often CE marking is not the most important target for a system upgraded by a rebuild kit. Nevertheless using some of the ideas will make the complete system safer.

Measurements with the “old” equipment still working

Some measurements should be carried out before the existing installation is switched off and dismantled. They serve to document the existing performance and get the definition of some signals or terminals of the existing hardware: - record the actual signals of

- the speed - the armature and the field current - line, armature and field voltage - other application related signals - record line and armature voltage to determine the name of the single line

phase and the position of the + and – terminal; this will be an alternative to disassemble the thyristor stack to check the orientation of the thyristors

- at power parts with more than one thyristor in parallel, record the firing pulse and the thyristor current of each thyristor to be sure, all of them are conducting

61

Start-up


Mounting the Kit

When starting the installation work make sure the equipment is disconnected from the power supply and checked for safe condition! The figures within chapter Instal-lation show all the components needed for the different configurations possible. Use this drawing as a basic guideline which fits the best to the actual power part depending on the number of parallel thyristors and the configuration (with / without SDCS-REB-3). Mounting the boards can be subdivided into 3 steps:

- Select a place for the SDCS-PIN-48 board(s) as close as possible beside the

thyristors. When fixing the board at the selected place make sure it´s conduc-tive supports / card holder have good metal contact to the cubicle´s frame. This frame by itself has to be grounded.

- Select a place for the SDCS-PIN-51 (and all the other components shown within “part 2“). Take care for the cable length towards the SDCS-PIN-48 board(s) and towards the SDCS-CON-4 board. All components of this part 2 have to be mounted on a metal plate to ensure good contact between conduc-tive supports / card holder and the cubicle´s frame. This frame by itself has to be grounded. Make sure the shields of the shielded cables follow the guide-lines given in chapter Installation (grounding on large areas by means of clamps).

- Select a place for the electronics housing and mount it. Take care for the cable length towards the SDCS-PIN-51. Take the same grounding guidelines as be-fore.

Wiring the Kit

The system still has to be in a safe condition! The drawing used for the mechanical work should now be used for the electrical wiring too. For single thyristor bridges take the hints given in chapter Interfacing the Electronics and Thyristors into con-sideration. Before the wiring work is started do the following preparations: - Check, if there are labels / indications on the existing power part naming the

thyristors and / or phases according to figure Arrangement of thyristors in an anti parallel bridge. In case labels are existing, check, if they are correct and fit to each other.

- If there are no labels existing or they are incorrect, start in this way: - look for the phase U1 (L1) and mark it; do the same with V1 (L2) and W1

(L3) - look for thyristor V11 and mark it; the next statements may be of help in

case problems may arise • use the measurements done before • if not, follow the busbar U1; the thyristor connected to that busbar is ei-

ther V11 or V24 • the cathode of V11 (or the heatsink) has electrical contact to the C1 / +

power part terminal • at disk type thyristors the orientation can easily be recognised by the

smaller distance between cathode and gate compared to the bigger dis-tance between gate and anode

• if the place of V11/V24 is found, but the orientation is not clear and the thyristor is not visible take one pair of pulse firing leads (one of them is

62

Start-up


the auxiliary cathode) and check them for electrical contact to C1 / + power part terminal by means of an Ω-meter

- look for the other thyristors and mark them - if there are parallel connected thyristor bridges do the same marking as for

the first - do the electrical connections according to the drawing for:

- all the flat cable connections within and between the 3 parts - the 3 AC and the 2 DC voltage measurements - the 2 current transformers - for the power part monitoring (klixon, fan monitoring, others) - the auxiliary voltage - make sure a 2.2 kohm resistor or something similar is plugged on terminal

X22: at SDCS-PIN-51 board - make sure the jumper is placed on S1 and S2 on the SDCS-PIN-51 board - make sure all cable shields are correctly connected - don´t connect any of the gate leads!

Commissioning the Kit

The complete commissioning of a DC drive consisting of the motor and the thyris-torized power part equipped with a rebuild kit is based on the manuals used for the converter type DCS800-S0x. Only a few additional steps are recommended and will be listed afterwards. Start with the commissioning steps used for complete converter modules:

- Safety Instructions, local safety regulations, etc. - Check the engineering, e.g. make sure the selected voltage levels are

correct and selector switches (if existing) are in the correct position. - Make sure safety equipment is working properly. - Set basic parameters, e.g. the ones which are presetted by the WIZARD

within the PC-based tool DriveWindow Light during steps 1 and 2. - Set the parameters in group 97 described in chapter Hardware section

Measurement board SDCS-PIN-51 For setting the values of parameters 97.01 to 97.03 the following procedure needs to be used:

• Select 99.06 and set to SetTypeCode (equivalent value 10) • Select 97.01 and make sure it's set to None (equivalent value 0) • Select 97.02 and set the value demanded by the hardware • Select 97.03 and set the value demanded by the hardware • Select 97.04 and 97.07 and set as recommended/necessity • Switch OFF the control voltage of the rebuild kit and ON again to apply

the settings!

In contrast with the normal commissioning procedure additional precautions should be made to avoid damage to components of the drive system in case of wrong wir-ing or unknown data. • Connect the gate leads to thyristor V11, V13 and V15. • Set the parameter for the bridge changeover to a remarkable value. • Before the drive is released the first time, the parameter for the minimum firing

63

Start-up


angle should be set to values higher than 95 degrees. Allow the system some moments to adapt to the new value. This limits the output voltage of the drive and gives a safe operation, even with a fault in the current feedback circuit. Precautions should be made do avoid to get EMF at the DC circuit (disable field current or block the motor), if the drive will be released and will generate current.

• Switch on the drive using the ON/OFF command. The RUN command has to remain in logic “0” level. This action causes the pulse firing logic to work and to generate single firing pulses at inverter limit position. No current should flow. Record the thyristor voltage (connection U1 – C1) and the firing pulse (e.g. by means of a current probe) and check the firing pulse position being at 150°el.

• Switch off the drive. • Connect the gate leads to thyristor V14, 16 and 12. • Switch on the drive using the ON/OFF command. • No current should flow! Record the thyristor voltage and the firing pulse as be-

fore. • Switch off the drive. • Switch on the drive using the ON/OFF command. Set the RUN command to

logic “1” level. Generate small current references within zero and limit discon-tinuous / continuous current. Everything is o.k., if the current can be varied and does not hit the limit set by the parameter above or inverter limit position. De-pending on the value of the minimum firing angle (perhaps higher than 120°el, perhaps close to 150°el) it may happen, that there is either no current at all or a very small one. In this case change the settings step by step until a value around 100°el reached.

• Switch off the drive. • In case of trouble check the wiring for open loop or wrong connections. Do the

check once again. • In case the current can be varied by the reference and the power part consists

of a reverse bridge go on with the same procedure used for the forward bridge. Keep the value of the parameter for minimum firing angle position. Check for correct connections.

If current is flowing in forward and reverse direction in a controlled manner set the parameter for the minimum firing angle back to default. Check for the correct value for the parameter of the bridge changeover time.

In case the power part consists of parallel bridges do the gate interconnections bridge per bridge and check for correct assignment. Do the commissioning of the other parallel bridges once again with the minimum firing angle set to high values because of safety reasons.

When the gate connections are done and current is flowing in a controlled manner set the minimum firing angle position to default, the bridge changeover time to val-ues necessary and go on with the other steps necessary to get the drive into op-eration.

ABB Automation Products GmbH Wallstadter Straße 59 68526 Ladenburg • GERMANY Tel: +49 (0) 6203-71 0 Fax: +49 (0) 6203-71 7609 www.abb.com/motors&drives *197R0101A7110000*

*197R0101A7110000*

Iden

t. N

o.: 3

AD

W00

0197

R01

01 R

ev A

03

_200

7

DCS800 family

CompactHighest power abilitySimple operationComfortable assistants, e.g. for commissioning or fault tracingScalable to all applicationsFree programmable by means of integrated IEC61131-PLC

Individually adaptable to customer requirementsUser-defined accessories like external PLC or auto-mation systems can be includedHigh power solutions in 6- and 12-pulse up to 20,000 A, 1,500 VIn accordance to usual standardsIndividually factory load testedDetailed documentation

DCS800 module with all necessary accessories mounted and fully cabled on a panelVery fast installation and commissioningSqueezes shut-down-times in revamp projects to a minimumFits into Rittal cabinetsCompact version up to 450 A and Vario version up to 2,000 A

Proven long life components are re-used, such as power stacks, (main) contactors, cabinets and cabling / busbars, cooling systemsUse of up-to-date communication facilitiesIncrease of production and qualityVery cost-effective solutionOpen Rebuild Kits for nearly all existing DC drivestailor-made solutions for… BBC PxD BBC SZxD ASEA TYRAK other manufacturers

DCS800-S modulesThe versatile drive for any application

20 … 5,200 ADC

0 … 1,160 VDC

230 … 1,000 VAC

IP00

DCS800-A enclosed convertersComplete drive solutions

20 … 20,000 ADC

0 … 1,500 VDC

230 … 1,200 VAC

IP21 – IP54

DCS800-E seriesPre-assembled drive-kits

20 … 2,000 ADC

0 … 700 VDC

230 … 600 VAC

IP00

DCS800-R Rebuild KitDigital control-kit for existing powerstacks

20 … 20,000 ADC

0 … 1,160 VDC

230 … 1,200 VAC

IP00

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