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DCS 500 thyristor power converter for DC drive systems 25 to 5150 A 6 to 4900 kW System Description

DCS 500B

9ROXPH ,, ' System Description DCS 500B


3ADW000066

How the DCS 500 Dokumentation System works


This is to give you an overview how the system of information for DCS 500 converters is built up. The shaded part indicates the volume within the

9ROXPH ,,, Technical Data


3ADW000054

total system you are just now working with. In addition you see all other available documents for the same system. Remarks:

9ROXPH ,9 ' Operating Instruct. DCS500


3ADW000055

Volume

II, III and IV you will receive together

with every delivered converter unit. Volume V can only be ordered separately.

9ROXPH 9 ' SW Description DCS 500B


3ADW000078

9ROXPH 9 ' Application Blocks DCS 500B


3ADW000048

List of contents

II D
2.1 2.2 2.3 2.4 2.5

SYSTEM DESCRIPTION

1 DCS 500 - a new generation of converters II D 1-1 2 Overview of DCS 500 components ............ II D 2-1
Environmental conditions ............................................ II D 2-2 DCS 500 power converter modules ............................ II D 2-3 DCS 500 overload withstand capability ...................... II D 2-5 Field Supplies .............................................................. II D 2-7 Options for power converter modules ......................... II D 2-8 Inputs/Outputs ............................................................ II D 2-8 Panel (control and display panel) ............................ II D 2-11 Serial interface for operation ............................................................. II D 2-12 for drive control ........................................................ II D 2-12 2.6 Options for the drive .................................................. II D 2-14 Line reactors for armature-circuit supply ................. II D 2-14 Aspects of fusing for armature-cuircuit and field supplies of DC drives ............................................ ...II D 2-16 Fuses and fuse holders for armature supply ........... II D 2-18 Additional components for field supply .................... II D 2-18 Electronic system / fan supply ................................. II D 2-19 Earth fault monitor ................................................... II D 2-19 EMC filter ................................................................. II D 2-19

3 Overview of Software (Vers. 21.22x) ......... II D 3-1


3.1 Introduction to the structure and handling .................. II D 3-1 3.2 GAD Engineering Program ....................................... II D 3-18

4 Connection examples ................................. II D 4-1 Unfolder: Explanations to GAD drawings


II D i

DCS 500 - a new generation of power converters

y state-of-the-art technology y flexible design y user-friendliness


ABBs long years of experience with variablespeed DC drives, plus use of the latest state-ofthe-art technologies, have combined to create this new product. The DCS 500 constitutes a complete program for ratings between 25 A and 5150 A as a power converter module (for 12pulse parallel connection, approx. 10,000 A), suitable for all commonly used three-phase systems. Our products of course have CE DIN EN

Basic hardware complements p Thyristor bridge(s) (from 900 A with leg fuses
installed)

p p p p

Temperature monitor for the thyristor bridge(s) Fan Power supply for the electronics Microprocessor board

approvals, and

Additional components for integration in the module p Field power converter


uncontrolled full wave diode bridge, 6A or half-controlled diode/thyristor bridge, 16A

also comply with the stipulations laid down in the

ISO 9001

quality management system.

p p
R

Communication board Control panel

DCS 500 Drives are approved according to CSA (Canadian

Standards Association)

and NRTL/C.

NRTL /C
DCS 500 converter units are suitable for both, standard drive applications as well as demanding applications. Appropriate PC programs ensure that the drives are human-engineered for user-friendly operator control.

Moreover, the accessories listed below can be used to individually customize the drive package in accordance with the application intended p External field supply units p Additional I/O boards p Interface modules for various communication
protocol

p p p

EMC filter(s) Application software packages PC programs

Unit range
The range comprises of 4 sizes, C1, C2, C3 and C4. We can deliver both modules and standard cubicles.

C1 - Module

Switchgear cubicle

II D 1-1

Basic functions
All units are provided with the same digital control board and software. The software can be modified in an infinite number of ways by means of appropriate PC based "tools" to meet the requirements of the application. The standard software includes 300 function blocks for programming specialized solutions for various applications.

Design and commissioning tool CMT (Commissioning


and

Maintenance Tool)

Commissioning and maintenance program PC program under Windows 3.1 or 3.11 platform for: Parameter setting Error detection Trending - capability of all signals Programming of software structures Data logger Fault logger

The basic software includes the following options:


Processing the speed reference value with speed ramp generator (S-ramp capability, 2sets of accel/decel) Processing the speed feedback Speed controller Torque / current reference processing External torque limitation Current regulator Selectable field weakening for constant kWapplications Automatic/manual field reversal Automatic adjustment for armature-circuit controller Speed monitor Drive control logic Remote/local operation Emergency stop Electronic circuits are not sensitive to line phase sequence Electrical and mechanical brake control Motor overload sensing Dual field supply software Internal motor potentiometer for speed reference Programmable analogue outputs

GAD

(Graphical Application Designer)

PC program under Windows 3.1 or 3.11 platform for: Drawing, altering and creating software functions by means of function blocks, plus documenting circuit diagrams

CDP 312

removable control and display panel

with plaintext display for: Parameter setting Error detection Altering software structures Software uploading and downloading Local operation

Monitoring functions
Self-test Non-volatile fault memory Motor protection
In the event of: speed feedback error overtemperature overload overspeed zero speed armature-circuit overcurrent armature-circuit ripples armature-circuit overvoltage minimum field current field overcurrent

Controlling and operating


via

I/O terminals

analogue and digital inputs and outputs via

communication data bus

e.g.: Profibus, Modbus, CS31 bus, etc. via

Power converter protection MMI


(man-machine interface) overtemperature software errors (watchdog function) Outputting: Alarms Errors Status information Parameter setting Controlling the drive Altering the software structure

Incorrect supply protection


mains interruption auxiliary supply undervoltage incorrect mains phase sequence (only inform.)

II D 1-2

DCS 500 Components Overview


DCS 500 power converter modules. This chapter provides a brief description of the DCS 500 components available for matching the drive to the conditions on site.

The DCS 500 power converter range is a system of components and complete standard switchgear cubicles for controlling DC power motors as single-motor or multi-motor drives. It comprises a system of individual components, based on the

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DCS 500 Components overview

This overview has been designed to help you to familiarize yourself with the system; its main components are shown in the diagram above.

The systems heart is the DCS 500 power converter module.

7 3

8 4

II D 2-1

T
" $ T Q

2.1 Environmental Conditions

System connection Voltage, 3-phase: Voltage deviation: Rated frequency: Static frequency deviation: Dynamic: frequency range: df/dt:

230 to 1000 V to IEC 38 10% continuous; 15% short-time * 50 Hz or 60 Hz 50 Hz 2 %; 60 Hz 2 % 50 Hz: 5 Hz; 60 Hz: 5 Hz 17 % / s

* = 0.5 to 30 cycles. Please note: Special consideration must be taken for voltage deviation in regenerative mode.

Environmental limit values Permissible ambient temp. with rated I DC: +5 to +40C Ambient temp. converter module: +40C to 55C; s. Fig. 2.1/2 Change of the ambient temp.: < 0.5C / minute Storage temperature: -40 to +55C Transport temperature: -40 to +70C Relative humidity: 5 to 95%, no condensation Pollution degree: Grade 2 Site elevation: <1000 m above M.S.L.: >1000 m above M.S.L.: 100%, without current reduction with current reduct., see Fig. 2.1/1

Degree of protection Converter Module: Enclosed converters: Paint finish Converter module: Enclosed converter:

IP 00 IP 20/21/31/41 NCS 170 4 Y015R light grey RAL 7035

Vibration converter module: 0.5 g, 5 Hz to 55 Hz Noises: (1 m distance) Size C1 C2 C3 C4


110 100 90

as module 59 dBA 71 dBA 71 dBA 83 dBA

in the ABB standard cabinet 57 dBA 64 dBA 70 dBA 76 dBA

Current reduction to (%)


100 90 80 70 60 50 1000

Current reduction to (%)

80 70 2000 3000 4000 5000 m 30 35 40 45 50 55 C

Fig. 2.1/1: Effect of the site elevation above sea level on the converters load capacity.

Fig. 2.1/2: Effect of the ambient temperature on the converter module load capacity.

Regulatory Compliance The converter module and enclosed converter components are designed for use in industrial environments. In EEA countries, the components fulfil the requirements of the EU directives, see table below.
Harmonized Standards
European Union Directive Manufacturers Assurance

North American Standards In North America the system components fulfil the requirements of the table below.

Converter module

Enclosed converter EN 60204-1 [IEC 204-1] EN 60204-1 [IEC 204-1] EN 60439-1 [IEC 439-1] EN 61800-3 [IEC 1800-3]

Machinery Directive 89/392/EEC 93/68/EEC Low Voltage Directive 73/23/EEC 93/68/EEC

Safety for Power conversion Equipment 600 V Industrial control Equipment: industrial products 600 V

Standard for module UL 508 C

Declaration of Incorporation

EN 60204-1 [IEC 204-1] EN 60146-1-1 [IEC 146-1-1] EN 50178 [IEC --] see additional IEC 664 EN 61800-3 [IEC 1800-3]

CSA C 22.2. No.1495

Declaration of Conformity

Note: Only for Converter Modules

EMC Directive 89/336/EEC 93/68/EEC

Declaration of Conformity Provided that all installation instructions concerning cable selection, cabling and EMC filters or dedicated transformer are followed.

were limits are under consideration EN 50081-2 / EN 50082-2 has been supplied in accordance with in accordance with 3ADW 000 032/ 3ADW 000 032 3ADW 000 091 The Technical Construction File to which this declaration relates has been assessed by Report and Certificate from ABB EMC Certification AB being the competent Body according to EMC Directive.

II D 2-2

2.2 DCS 500 Power Converter Modules


The power converter modules are modular in construction. They are based on the casing, which houses the power section with the RC snubber circuit. There are 4 different sizes, graduated in terms of current and voltage ranges. All units are fan-cooled. The power section is controlled by the units electronic system, which is identical for the entire range. Parts of the units electronic system can be installed in the unit, depending on the particular application involved, e.g. a field supply for the motor, or an interface board. A control/display panel is available for the operator. It can be snapped into place on the power converter module or installed in the switchgear cubicle door by means of a mounting kit. Accessories such as external fuses, line reactors and the like are also available, for putting together a complete drive system.

Reference variables
The voltage characteristics are shown in Table 2.2/1. The DC voltage characteristics have been calculated using the following assumptions:

System conDC voltage nection voltage (max. Motor voltage) Uv Ud 2Q 4Q 230 380 400 415 440 460 480 500 525 575 600 660 690 790 1000 265 440 465 480 510 530 555 580 610 670 700 765 800 915 1160 240 395 415 430 455 480 500 520 545 600 625 685 720 820 1040

Ideal DC voltage without load Udi0 310 510 540 560 590 620 640 670 700 770 810 890 930 1060 1350

Recommended DCS 500 Voltage class y= 4 4 4 4 5 5 5 5 6 6 6 7 7 8 9

Voltage tolerance 10 %

UVN = rated input terminal voltage, 3-phase


If a deviation or a voltage drop has to be taken into consideration in compliance with IEC and VDE standards, the output voltage or the output current must be reduced by the actual factor according to the table on the right.

Internal voltage drop approx. 1%

in case of a 2-Q converter, which is used in regenerative mode, please use 4-Q voltage values Table 2.2/1: DCS 500 max. DC voltages achievable with a specified input voltage. Converter type x=1 2-Q x=2 4-Q DCS50xB0025-y1 DCS50xB0050-y1 DCS50xB0050-61 DCS50xB0075-y1 DCS50xB0100-y1 DCS50xB0110-61 DCS50xB0140-y1 DCS50xB0200-y1 DCS50xB0250-y1 DCS50xB0270-61 DCS50xB0350-y1 DCS50xB0450-y1 DCS50xB0520-y1 DCS50xB0700-y1 DCS50xB0900-y1 DCS50xB1200-y1 DCS50xB1500-y1 DCS50xB2000-y1 DCS50xB2050-y1 DCS50xB2500-y1 DCS50xB2650-y1 DCS50xB3200-y1 DCS50xB3300-y1 DCS50xB4000-y1 DCS50xB4750-y1 DCS50xB5150-y1 IDC [A] 4Q 25 50 50 75 100 110 140 200 250 270 350 450 520 700 900 1200 1500 2000 2050 2500 2650 3200 3300 4000 4750 5150 2Q 25 50 50 75 100 100 125 180 225 245 315 405 470 700 900 1200 1500 2000 2050 2500 2650 3200 3300 4000 4750 5150 y IAC [A] 4Q 20 41 41 61 82 90 114 163 204 220 286 367 424 571 734 979 1224 1632 1673 2040 2162 2611 2693 3264 3876 4202 2Q 20 41 41 61 82 82 102 147 184 200 257 330 384 571 734 979 1224 1632 1673 2040 2162 2611 2693 3264 3876 4202 y=4 (400 V) P [kW] 4Q 10 21 31 42 58 83 104 145 187 216 291 374 498 623 830 2Q 12 23 35 47 58 84 105 146 188 219 326 419 558 698 930 y=5 (500 V) P [kW] 4Q 13 26 39 52 73 104 130 182 234 270 364 468 624 780 1040 2Q 15 29 31 44 58 69 73 104 131 169 183 235 273 406 522 696 870 1160 281 172 284 70 35 y=6 (600 V) P [kW] 4Q 2Q y=7 (690 V) P [kW] 4Q 2Q y=8 (790 V) P [kW] 4Q 2Q y=9 (1000V) P [kW] 4Q 2Q

563 938

630 1050

648 1080

720 1200

1038

1163

1300

1450

1281 1563

1435 1750

1476 1800

1640 2000

1681

1876

2132 2756 3328 4160

2378 3074 3712 4640

2624 1370 1660 2137 1535 1860 2395 1716 2080 2678 1914 2320 2987 2063 2500 2969 2310 2800 3325 2376 2880 3420 2640 3200 3800 3280 3895

2928 3660 4346

Table 2.2/2: Table of DCS 500 unit types


II D 2-3

Construction type C1

Construction type C2

Construction type C3

Construction type C4 Left busbar connection Power loss at 500V PV [kW] < 0.2 < 0.2 < 0.3 < 0.5 < 0.6 < 0.8 < 1.0 < 1.3 < 1.5 < 1.8 < 2.5 < 4.8 < 6.2 < 6.3 < 8.2 < 12 < 15 < 16 < 20 Fan connection 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 230 V/1 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph 400/690 V/3 ph

Converter type

Dimensions HxWxD [mm] 420x273x195 420x273x195 420x273x195 420x273x195 469x273x228 469x273x228 469x273x228 505x273x361 505x273x361 505x273x361 505x273x361 505x273x361 505x273x361 652x273x384 1493x548x447 1493x548x447 1493x548x447 1493x548x447 2330x820x624 2330x820x624 2330x820x624 2330x820x624 2330x820x624 2330x820x624 2330x820x624 2330x820x624

Weight [kg] 7.1 7.2 7.6 7.6 11.5 11.5 11.5 22.3 22.3 22.8 22.8 28.9 28.9 57 150 150 150 150 350 350 350 350 350 350 350 350

Clearances top/bottom/side [mm] 150x100x5 150x100x5 150x100x5 150x100x5 250x150x5 250x150x5 250x150x5 250x150x5 250x150x5 250x150x5 250x150x5 250x150x10 250x150x10 250x150x10 300x100x20 300x100x20 300x100x20 300x100x20

Construct. type C1 C1 C1 C1 C1 C1 C1 C2 C2 C2 C2 C2 C2 C2 C3 C3 C3 C3 C4 C4 C4 C4 C4 C4 C4 C4

Semiconductor Fuses extern extern extern extern extern extern extern extern extern extern extern extern extern extern intern intern intern intern intern intern intern intern intern intern intern intern

DCS50xB0025-y1 DCS50xB0050-y1 DCS50xB0050-61 DCS50xB0075-y1 DCS50xB0100-y1 DCS50xB0110-61 DCS50xB0140-y1 DCS50xB0200-y1 DCS50xB0250-y1 DCS50xB0270-61 DCS50xB0350-y1 DCS50xB0450-y1 DCS50xB0520-y1 DCS50xB0700-y1 DCS50xB0900-y1 DCS50xB1200-y1 DCS50xB1500-y1 DCS50xB2000-y1 DCS50xB2050-y1 DCS50xB2500-y1 DCS50xB2650-y1 DCS50xB3200-y1 DCS50xB3300-y1 DCS50xB4000-y1 DCS50xB4750-y1 DCS50xB5150-y1

to be installed in cubicle

The dimensions for modules with busbar connection on the right side are 2330x800x624 mm (Busbar connect. on the right side is optionally, Example for the type designat.: connection left DCS50xB2050-y1; connection right DCS50xB2050+y1) The depth of 1000 V units is 654 mm x=1 2-Q; x=2 4-Q; y=4...9 400...1000 V supply voltage On supply voltages up to 400 V in delta connection; from 415 V on in star connection Table 2.2/3: Table of DCS 500 unit types
II D 2-4

2.3 DCS 500 Overload Withstand Capability

To match a drive systems components as efficiently as possible to the driven machines load profile, the power converters can be dimensioned by means of the load cycle. Load cycles for driven machines have been defined in the IEC 146 or IEEE specifications, for example.
The currents for the DC I to DC IV types of load (see diagram on the following page) for the power converter modules are listed in the table below.

Unit type

IDC I continuous [A] 25 50 75 100 125 140 180 200 225 250 315 350 405 450 470 520 700 900 1200 1500 2000 2500 3300 4000 5150 50 100 110 245 270 405 450 900 1500 2050 2500 3300 4000 4750 2050 3200 4000 4750 2050 2650 3200 4000 100 % 15 min

IDC II 150 % 60 s [A] 24 44 60 71 94 106 133 149 158 177 240 267 317 352 359 398 556 684 888 1200 1479 1830 2416 2977 3800 44 79 87 193 213 316 352 684 1200 1502 1830 2416 3036 3734 1502 2655 3036 3734 1577 2000 2551 2975 36 66 90 107 141 159 200 224 237 266 360 401 476 528 539 597 834 1026 1332 1800 2219 2745 3624 4466 5700 66 119 130 290 320 474 528 1026 1800 2253 2745 3624 4554 5601 2253 3983 4554 5601 2366 3000 3827 4463 23 42 56 69 91 101 132 146 155 173 233 258 306 340 347 385 534 670 872 1156 1421 1740 2300 2855 3669 43 76 83 187 207 306 340 670 1104 1426 1740 2300 2900 3608 1426 2540 2889 3608 1500 1900 2428 2878 100 % 15 min

IDC III 150 % 120 s [A] 35 63 84 104 137 152 198 219 233 260 350 387 459 510 521 578 801 1005 1308 1734 2132 2610 3450 4283 5504 65 114 125 281 311 459 510 1005 1656 2139 2610 3450 4350 5412 2139 3810 4334 5412 2250 2850 3642 4317 24 40 56 68 90 101 110 124 130 147 210 233 283 315 321 356 524 594 764 1104 1361 1725 2277 2795 3733 40 75 82 169 187 282 313 594 1104 1484 1725 2277 2950 3700 1484 2485 2933 3673 1471 1922 2458 2918 100 % 15 min

IDC IV 200 % 10 s [A] 48 80 112 136 180 202 220 248 260 294 420 466 566 630 642 712 1048 1188 1528 2208 2722 3450 4554 5590 7466 80 150 165 338 374 564 626 1188 2208 2968 3450 4554 5900 7400 2968 4970 5866 7346 2942 3844 4916 5836

400 V / 500 V DCS 50xB0025-41 / 51 DCS 50xB0050-41 / 51 DCS 50xB0075-41 / 51 DCS 50xB0100-41 / 51 DCS 501B0140-41 / 51 DCS 502B0140-41 / 51 DCS 501B0200-41 / 51 DCS 502B0200-41 / 51 DCS 501B0250-41 / 51 DCS 502B0250-41 / 51 DCS 501B0350-41 / 51 DCS 502B0350-41 / 51 DCS 501B0450-41 / 51 DCS 502B0450-41 / 51 DCS 501B0520-41 / 51 DCS 502B0520-41 / 51 DCS 50xB0700-41 / 51 DCS 50xB0900-41 / 51 DCS 50xB1200-41 / 51 DCS 50xB1500-41 / 51 DCS 50xB2000-41 / 51 DCS 50xB2500-41 / 51 DCS 50xB3300-41 / 51 DCS 50xB4000-41 / 51 DCS 50xB5150-41 / 51 600 V / 690 V DCS 50xB0050-61 DCS 501B0110-61 DCS 502B0110-61 DCS 501B0270-61 DCS 502B0270-61 DCS 501B0450-61 DCS 502B0450-61 DCS 50xB0900-61 / 71 DCS 50xB1500-61 / 71 DCS 50xB2050-61 / 71 DCS 50xB2500-61 / 71 DCS 50xB3300-61 / 71 DCS 50xB4000-61 / 71 DCV 50xB4750-61 / 71 790 V DCS 50xB2050-81 DCS 50xB3200-81 DCS 50xB4000-81 DCS 50xB4750-81 1000 V DCS 50xB2050-91 DCS 50xB2650-91 DCS 50xB3200-91 DCS 50xB4000-91

x=1 2-Q; x=2 4-Q Table 2.3/1: The power converter modules currents with the corresponding load cycles. The characteristics are based on an ambient temperature of max. 40C and an elevation of max. 1000 meters.

II D 2-5

Types of load
Operating cycle Load for converter Typical applications Load cycle

DC I

IDC I continuous (IdN)

pumps, fans
100%

DC II

IDC II for 15 min and 1,5 * IDC II for 60 s

extruders, conveyor belts

15 min 150% 100%


DC III *

IDC III for 15 min and 1,5 * IDC III for 120 s

extruders, conveyor belts

15 min 150% 100%

DC IV *

IDC IV for 15 min and 2 * IDC IV for 10 s

15 min 200% 100%

* Load cycle is not identical to the menu item Duty cycle in the DCSize program ! Table 2.3/2: Definition of the load cycles

If the driven machines load cycle does not correspond to one of the examples listed, you can determine the necessary power converter using the

DCSize

software program.

This program can be run under Microsoft

Win-

dows, and enables you to dimension the motor and the power converter, taking types of load (load cycle), ambient temperature, site elevation, etc. into account. The design result will be presented in tables, charts, and can be printed out as well. To facilitate the start-up procedure as much as possible, every power converter has been provided with a current measuring feature, which can be adjusted to the high current required by means of software parameters.

Fig. 2.3/1: Entry mask on the computer screen for the dimensioning program.
Microsoft is a registered trademark. Windows is a designation of the Microsoft Corporation.

II D 2-6

2.4 Field Supplies

General data
Currents from 6 to 500 A Minimum field current monitor Integrated external field power converter or completely separate switchgear cubicle 2-phase or 3-phase model Fully digital control (except for the SDCS-FEX-1) We recommend integrating an autotransformer in the field power converter's supply circuit to adjust the AC input voltage and reduce the voltage ripple in the field circuit. All field power converters (except for the SDCS-FEX-1) are controlled by the armature-circuit converter via a serial interface at a speed of 62.5 kBaud. This interface serves to parameterize, control and diagnose the field power converter and thus provides an option for exact control. Moreover, it enables you to control an internal (SDCS-FEX-2) and an external (DCF 503/504) or two external field supply units (2 x DCF 503/504). The respective software function required is available in every DC power converter.

Field power converter types SDCS-FEX-1


Diode bridge 6 A rated current Internal minimum field current monitor, requiring no adjustment. Construction and components have been designed for an insulation voltage of 600 V AC. Output voltage U :
A

SDCS-FEX-2
Half-controlled Microprocessor thyristor/ control, diode bridge (1-Q) with the electronic system being supplied by the armature-circuit converter. Construction and components have been designed for an insulation voltage of 600 V AC. Output voltage U :
A

DCF 503
Half-controlled Microprocessor thyristor/ control diode bridge (1-Q) with the control electronics being supplied separately (115/230 V/1-ph). Construction and components have been designed for an insulation voltage of 690 V AC.

DCF 500
This field power converter is used mainly for armature-circuit converters with rated currents of 2050 to 5150 A. It consists of a modified armature-circuit converter (with different software). The rated currents are the same as with the DCS 500-0025/0520 supply voltage. Output voltage U respecA

units with 500 and 600 V3-ph

100% + 72/ 8 $ = 89 * * 0,9 100%


TOL = tolerance of line voltage in % U

DCF 504
like DCF 503, but fully-controlled antiparallel
V

see SDCS-FEX-1 Recommendation: Field voltage 0.6 to 0.8 *U

tively U

di0

V = Line voltage

thyristor bridges (4-Q) Output voltage/Recommendation:

see table 2.2/1 Recommendation: Field voltage 0.5 to 1.1 *U


V

Recommendation: Field voltage ~ 0,9 * U


V

see SDCS-FEX-2
This unit provides an option for field reversal and fast-response excitation. In the steady-state condition, the fully-controlled bridge runs in half-controlled mode so as to keep ripple the as voltage low With as a

possible. field

quickly alternating current, the bridge runs in fullycontrolled mode.

Unit type

Output current IDC [A] 0.02...6 0.3...16 0.3...50 0.3...50

Supply voltage [V] 110V -15%...500V/1-ph +10% 110V -15%...500V/1-ph +10% 110V -15%...500V/1-ph +10% 110V -15%...500V/1-ph +10%

Installation site

Remarks

SDCS-FEX-1-0006 SDCS-FEX-2-0016 DCF 503-0050 DCF 504-0050

internal internal external external

external fuse, 6 A IFrated ext. fuse, reactor; for C1: 0.3 ... 8 A , not to be used for C4 mod.!

auxiliary supply (115/230V) if necessary via matching transformer; fuse external; Dimensions HxWxD: 370x125x342 [mm]

DCF 50x-xxxx-x1-51xxxxx are based on the hardware of the DCS 500 and additional hardware components (DCF 505/506), but with a different software; see separate documentation. Current reduction see also 2.1 Environmental conditions Fig.: 2.1/1 and 2.1/2 Table 2.4/1: Table of field power converter unit types
II D 2-7

2.5 Options for power converter modules

in-/output signals
The converter can be connected in 4 different ways to a control unit via analogue/digital links. Only one of the four choices can be used at the same time. In addition to this an extension of I/Os by SDCS-IOE 1 is possible.

SDCS-CON-2
X17:

SDCS-CON-2
X17:

X2: X3: X4: X5:

X1: X6: X7:

X2: X3: X4: X5:

X1:

X3: X1:

SDCS-IOB-2 4
Fig. 2.5/1: I/Os via SDCS-CON2 Analogue I/Os: standard Digital I/Os: not isolated Encoder input: not isolated Fig. 2.5/2: I/Os via SDCS-CON2 and SDCS-IOB2 Analogue I/Os: standard digital I/Os: all isolated by means of optocoupler/relay, the signal status is indicated by LED

SDCS-CON-2
X17: X17:

SDCS-CON-2

X2:

X1: X6: X7:

X2:

X1:

X1: X2:

X1: X2:

X3: X1:

SDCS-IOB-3 3
Fig. 2.5/3: I/Os via SDCS-CON2 and SDCS-IOB3 Analogue I/Os: more input capacity digital I/Os: not isolated encoder input: isolated current source for: PT100/PTC element

SDCS-IOB-3 3

SDCS-IOB-2 4

Fig. 2.5/4: I/Os via SDCS-IOB2 and SDCS-IOB3 Analogue I/Os: more input capacity digital I/Os: all isolated by means of optocoupler/relay, the signal status is indicated by LED current source for: PT100/PTC element

II D 2-8

Description of I/O signals SDCS-CON-2


Mechanical system installed in the basic unit

Description of I/O signals SDCS-IOB-2x & SDCS-IOB-3


Mechanical system always external, outside the basic unit

Terminals Screw-type terminals for finely stranded wires up to max. 2.5 mm2 cross-sectional area Functionality 1 tacho input Resolution: 12 bit + sign; differential input; common-mode range 20 V 3 ranges from 8...30...90...270 V- with nmax 4 analogue inputs Range -10...0...+10 V, 4...20 mA, 0...20 mA All as differential inputs; RE = 200 k; time constant of smoothing capacitor 2 ms Input 1: Resolution: 12 bit + sign.; common-mode range 20 V Inputs 2, 3, 4: Resolution: 11 bit + sign; common-mode range 40 V

Terminals Screw-clamp terminals for finely stranded wires up to max. 2.5 mm2 cross-sectional area Functionality of SDCS-IOB-3 1 tacho input Resolution: 12 bit + sign; differential input; common-mode range 20 V Range 8 V- with nmax; if higher tacho voltages are in use the tacho adaptation board PS 5311 is needed. 4 analogue inputs All as differential inputs; time constant of smoothing capacitor 2 ms Input 1: Range -10 V/-20 mA...0...+10 V/+20 mA; 4... 20 mA unipolar; RE = 200 k/ 500/ 500; Resolution: 12 bit + sign; common-mode range 20 V Inputs 2+3: Range as with input 1, in addition -1 V...0...+1 V RE = 200 k/ 500/ 500/ 20k; Resolution: 11 bit + sign; commonmode range with -1 V...0...+1 V range 10 V, otherwise 40 V Input 4: Range as with input 1 RE = 200 k/ 500/ 500; Resolution: 11 bit + sign; common-mode range 40 V Error current detection in combination with analogue input 4 (sum of phase currents 0) 2 outputs +10 V, -10 V, IA 5 mA each; sustained-short-circuit-proof for reference potentiometer voltage supply 1 analogue output Bipolar current feedback - from the power section; decoupled IdN 3 V (at gain = 1); IA 5 mA, UAmax = 10 V, gain can be adjusted by means of a potentiometer between 0.5 and 5, short-circuit-proof 2 analogue outputs Range -10...0...+10 V; IA 5 mA; short-circuit-proof Output signal and scaling can be selected by means of the software Resolution: 11 bit + sign Current source for PT 100 or PTC element evaluation IA = 5 mA / 1.5 mA 1 pulse generator input Voltage supply, output current, input range: as with IOB1 Inputs electrically isolated from 0 V (casing earth) by means of optocoupler and voltage source.

2 outputs +10 V, -10 V, IA 5 mA each; sustained-short-circuit-proof for reference potentiometer voltage supply 1 analogue output bipolar current feedback - from the power section; decoupled IdN 3 V; IA 5 mA, short-circuit-proof 2 analogue outputs Range -10...0...+10 V; IA 5 mA Output signal and scaling can be selected by means of the software Resolution: 11 bit + sign 1 pulse generator input Voltage supply for 5 V/12 V/24 V pulse generators (sustained-shortcircuit-proof) Output current with 5 V: IA 0.25 A 12 V: IA 0.2 A 24 V: IA 0.2 A Input range: 12 V/24 V: asymmetrical and differential 5 V: differential Pulse generator as 13 mA current source: differential Line termination (impedance 120), if selected max. input frequency 300 kHz

8 digital inputs The functions can be selected by means of the software Input voltage: 0...8 V "0 signal", 16...60 V "1 signal" Time constant of smoothing capacitor: 10 ms RE = 15 k The signal refers to the unit casing potential Auxiliary voltage for digital inputs: +48 V-, 50 mA, sustained-shortcircuit-proof 7+1 digital outputs The function can be selected by means of the software 7 outputs: relay driver with free-wheel diode, total current limitation 160 mA, short-circuit-proof 1 relay output - on power pack board SDCS-POW-1 (N.O. contact element: AC: 250 V/ 3 A / DC: 24 V/ 3 A or 115/230 V/ 0.3 A) protected by VDR component.

Functionality of SDCS-IOB-2x 3 different designs available: m SDCS-IOB-21 inputs for 24...48 V-; RE = 4.7 k m SDCS-IOB-22 inputs for 115 V AC; RE = 22 k m SDCS-IOB-23 inputs for 230 V AC; RE = 47 k Terminals Screw-clamp terminals up to max. 4 mm2 cross-sectional area 8 digital inputs The functions can be selected by means of the software The signal status is indicated by an LED all isolated by means of optocouplers Input voltage: IOB-21:0...8 V "0 signal", 18...60 V "1 sig." IOB-22:0...20 V "0 signal", 60...130 V "1 sig." IOB-23:0...40 V "0 signal", 90...250 V "1 sig." Filter time constant: 10 ms (channels 1...6), 2 ms (channels 7+8) Auxiliary voltage for digital inputs: +48 V-, 50 mA, sustained- shortcircuit-proof; referenced to the unit casing potential 8 digital outputs The functions can be selected by means of the software The signal status is indicated by an LED 6 of them potential-isolated by relay (N.O. contact element: AC: 250 V/ 3 A / DC: 24 V/ 3 A or 115/230 V/ 0.3 A) , protected by VDR component. 2 of them potential-isolated by optocoupler, protected by Zener diode (open collector) 24 V DC external, IA 50 mA each.
II D 2-9

The digital and analogue inputs can be extended by means of the SDCS-IOE1 board. This is in addition to the a.m. solutions.

SDCS-CON-2
X17:

X17:

X2: X1:

SDCS-IOE-1 5

X3:

X4: 2 x analog

X5:

X6:

X7:

4 x analog 1 x Tacho

Pulsgeber

Fig. 2.5/5: Additional Inputs via SDCS-IOE1 Analogue inputs: extended Digital inputs: all isolated by means of optocoupler, the signal status is indicated by LED current source for: PT100/PTC element

Description of input signals SDCS-IOE-1


Mechanical system always external, outside the basic unit

Terminals Screw-type terminals for finely stranded wires up to max. 2.5 mm2 cross-sectional area Functionality 7 digital inputs The functions can be selected by means of the software The signal status is indicated by an LED Input voltage: 0...8 V "0 signal", 16...31 V "1 signal" Isolated from the units electronics by optocouplers Potentialwise arranged in two groups (DI 9...DI 12 and DI 13...DI 15) Time constant of smoothing capacitor: 2 ms 2 analogue inputs All as differential inputs; common-mode range 40 V Range -10 V/-20 mA...0...+10 V/+20 mA; 4... 20 mA unipolar RE = 200 k /500 /500 Resolution: 11 bit + sign Input 2: range as for input 1, in addition -1 V/-2 mA...0...+1 V/+2 mA, then common-mode range 40 V, RE = 20 k Current source for PT 100 or PTC element evaluation IA = 5 mA / 1.5 mA The signals are referenced to the unit casing potential

Please note:
Unless otherwise stated, all signals are referenced to a 0 V potential. Within the power pack subassembly (SDCS-POW-1) and on all other PCBs, this potential is firmly connected to the units casing by means of plating-through at the fastening points.

II D 2-10

8 x digital

7 x digital

Panel (control and display panel)


The CDP 312 control and display panel communicates with the power converter via a serial connection in accordance with the RS 485 standard at a transmission rate of 9.6 kBaud. It is an option for the converter unit. After completion of the commissioning procedure, the panel is not necessarily required for diagnostic routines, because the basic unit incorporates a 7-segment display for indicating errors, for example.

Equipment
16 membrane pushbuttons in three function groups LCD display comprising four lines with 20 characters each Language: German, English, French, Italian, Spanish Options for the CDP 312: cable, separated from the power converter for utilization kit for mounting the panel in the switchgear cubicle door

Parameters For selecting and adjusting all parameters and signals.


B hq hr Tit hq hr Whyr

0 L 0,0 rpm 17 RAMP GENERATOR 08 ACCEL 1 20.0 s

00

Function Selects the functions operating mode; can be used to perform special functions such as uploading and downloading or application programming.

Th Apvir ryrprq 9vyhph

0 L 0,0 rpm UPLOAD <== DOWNLOAD ==> CONTRAST

00

Actual Selects the display of feedback values plus the signal group and the error memory group.
D9ir sur qvr ryrprq 8y yphv G2yphy 2rr Trrq rsrrpr Hhvphp h 2r 2pyrq Sh 2S 2T

rvt

Drive for subsequent extensions

Th 6phyvthy hrhqhyr

8u urryrprq

0 L 0,0 rpm 00 SPEEED ACT 0,0 rpm CONV CUR 0 A 0 V U ARM ACT

Enter is used in the following modes: Parameter setting: enter new parameter value Feedback value signal display: enter the current signal selection mode Signal selection: accept selection and return to the feedback value signal display mode Arrow keys are used to select parameters within a group. You alter the parameter value or the reference setting in the parameter and reference presetting modes. In the feedback signal display mode, you select the line you want.

Twin arrow keys are used to change the group. In the parameter and reference presetting modes, you can alter the parameter value or the reference setting ten times faster by means of the twin arrow keys than by means of the single arrow key. Local/Remote is used to select local (control panel) or remote control. Reset Error acknowledgement key.
2yhshy !2yhirshy ((2yhi('shy IhrsAhy hyh Uhyvrhsr vpu CCCC)HH)TT

Start starts the drive in local mode. Stop shuts the drive down if you are in local mode.

0 L 0,0 rpm 1 LAST FAULT Emergency stop 3212:59:35:56

00

Reference is used to activate the reference presetting mode.

On in local mode switches the main contactor on.

Off in local mode switches the main contactor off.

Fig. 2.5/6: Function keys and various displays on the removable control and display panel. The panel can also be used to load the same program on different power converters.
II D 2-11

Serial interface
There are various serial interface options available for operation, commissioning and diagnosis, plus for controlling. According to the description in the previous section, there is a serial connection to the control and display panel (X33:/X34: on the SDCS-CON-2 control board). Installing the optional SDCS-COM-x communication board on the SDCS-CON-2 control board creates additional serial interfaces. Both interfaces use optical fibres. One channel is used for drive/PC interfacing. The other for fieldbus module interfacing. All three serial interfaces are independent from each other.

89 Q" !

6'&6&21

electrical connection
3m

X 34:

X 16:

power supply

3&
PE SH
RXD

SHF

DG

D(N) D(P)

X2

Interface

optical fibre 20 m

optical fibre 10 m
X1
PE

T XD

Nxxx-01
xxxxxxxx ADAPTER

WR WKH 3/&
I

XM IT BUS T ERM INAT ION REC ON

OF F
ERRO R

+24V

0V

SH

SHF

DG

D(N) D(P)

2SHUDWLRQ
Fig. 2.5/7: Options for serial communication

&RQWURO
Control
components required:
plastic optical fibre for distances up to 20 m (longer distances on request) field bus module NxxA-0x

Operation by PC
components required:
SDCS-COM-1or SDCS-COM-5 as an option (Com-1 is recommended) PCMCIA interface SNAT 621/622 (Laptop) or SNAT 608 ISA board (Desktop) plastic optical fibre for distances up to 20 m (longer distances on request)

Functionality:
CMT/DCS 500 software package for commissioning, diagnosis, maintenance and troubleshooting; point-to-point connection as well

Functionality:
Depends on the field bus module used, interface e.g. to: PROFIBUS with NPBA-02 CS 31 with NCSA-01 MODBUS with NMBA-01 further modules on request You will find more detailed information on data exchange in the specific fieldbus module documentation.

System requirements/recommendation:
PC with 386 processor or higher hard disk with 1MB free memory. Each graph recorded requires 500 kB of free memory. VGA monitor Windows 3.1, 3.11 3 1/2" floppy disk drive In addition to the options provided by the CDP 312 control and display panel, there are further functions available, and these are described on the following page.

Please note:
For more information of the CMT/DCS 500 software package there is an own documentation available describing the possibilities and the handling of the program.

II D 2-12

Operation by PC (continued)
The program incorporates nine different function windows which can be used to alter the application program on-line, to monitor the drives functionality, to alter the parameter values, to control the drive and to monitor its status. You will find below a brief description of the individual menu options, some of which are shown as a screen display to serve as examples.

Diagrams This window shows the function block diagram created by means of the GAD program. If necessary, the user can also use this window to view the values of selected parameters or connections.

Connect This option is used to trigger special functions such as establishing the connection to the power converter or configuring the program. ParSig The parameter and signal display enables the user to view parameter or signal values in a table and to alter them. One of the functions available for the user is to allocate each parameter or each signal to self-defined groups. He/she can then select only special groups, and trace or alter the values of parameters or signals in this group.

Trending This window can be used to trace the signal characteristics of specified parameters or signals. Up to six parameters or signals can be monitored. The window shows the values in a curve diagram.

Dlog The DC power converter is able to continuously log up to six signals and to store them in non-volatile memory from a trigger condition to be set (level, pre-event and post-event history). These values can then be read out by the program in chronological sequence and processed further. They are available as a table or as a diagram, in forms similar to those with the Trending option, and can also be printed out in these forms. DrvFuncs This display provides the same display and the same pushbuttons for the user as the CDP 312 display and control panel. For that reason, the drive functions are also identical.

Faults This display shows the current fault messages last fed into the fault logger in chronological sequence.

Exit Quitting the program. Help Descriptions of the parameters.


II D 2-13

2.6 Options for the drive

Line reactors
for armature-circuit supply
When power converters are operated with thyristors, the line voltage is short-circuited during commutation from one thyristor to the next. This operation causes voltage dips in the mains. For the connection of a power converter system to the mains, a decision is made between the following configurations:

Assumption: The

system short-circuit power at

the power converters connecting point is 180 times the power converters rated power. The systems relative impedance voltage u can thus be determined:
k

XN /LQH =

1 * 100% = 0.55% 180

In accordance with equation (1), the following applies for the line reactor:

Configuration A

Line
Connecting point

When using the power converter, a minimum of 1% impedance is required to ensure proper performance of the snubber circuit. A line reactor can be used to meet this minimum impedance requirement. The value must therefore not drop below 1% u
k

X N /5 = 4 * 8 . /LQH = 2.2%
Since the line reactor has to be sized specific to a power converter , the relative variable U
k

uk LR ca. 1%

must be converted into an absolute value. For this purpose, the following equation applies:

(relative impedance

voltage). It should not exceed 10% u , due to considerable voltage drops which
k

would then occur.

XN =

, G1 *

2 * 3 * 2 * I 1 * / /5 3 81

Configuration B

Line
LLine

If special requirements have to be met at the connecting point, different criteria must be applied for selecting a line reactor. These re-

IdN: fN : U N: LLR:

rated direct current rated frequency of the system rated line voltage line reactor inductance

Connecting quirements are most often defined point LLR


nominal supply voltage. The combined impedance of Z and Z
LR Line

as a voltage dip in percent of the

Configuration C

Line

In the case of high power converter outputs or high currents, a power converter transformer must fre-

constitute the total series

impedance of the installation. The ratio between the line impedance and the line reactor impedance determines the voltage dip at the connecting point.

Connecting point quently be used for voltage matching. If an autotransformer is used for this purpose, a commutating reactor must additionally be used if special conditions must be complied with as per Configuration B, the reason for this being that the u
k

9ROWDJH GLS =
Example:

= /LQH *100% = /LQH + = /5

LLR

of commonly used autotransformers is generally too small. If you do not have to allow for special conditions of this kind, you must nevertheless check whether the u ing Configuration A.
k

Maximum allowable voltage dip is 20% at the power converter's connecting point. Above equation used and simplified to:

of the au-

totransformer concerned is sufficient for satisfy-

= /5 = 4 * = /LQH

(1)

Since the line impedance is seldom known (it can be determined by means of a measuring routine), and the short-circuit power at the same point is more frequently available, the line reactor can be calculated by means of this value.

II D 2-14

An examination of volume and costs results in the following configuration:

With reference to the power converter:


The line reactors listed in the table below have been allocated to the units in accordance with a load cycle, and are independent of the units voltage classification. Note that the reactors are used for line voltages same V!

Configuration D

Line

If an isolation transformer is used, it is often possible to comply with Configuration B without using an

Connecting certain connecting conditions per point


additional line reactor. The condition described in Configuration A will then likewise be satisfied, since the u is >1 %.
k

690

For units >2000 A or >690 V, we recommend using one isolation transformer per power converter.

Line reactors L1
DCS Type 400V-690V DCS50xB0025-41/51 DCS50xB0050-41/51 DCS50xB0050-61 DCS50xB0075-41/51 DCS50xB0100-51 DCS50xB0110-61 DCS50xB0140-41/51 DCS50xB0200-41/51 DCS50xB0250-41/51 DCS50xB0270-61 DCS50xB0350-41/51 DCS50xB0450-41/51 DCS50xB0450-61 DCS50xB0520-41/51 DCS50xB0700-41/51 DCS50xB0900-41/51/61/71 DCS50xB1200-41/51 DCS50xB1500-41/51/61/71 DCS50xB2000-41/51 Line choke type ND01 ND02 ND03 ND04 ND06 ND05 ND06 ND07 ND07 ND08 ND09 ND10 ND11 ND10 ND12 ND13 ND14 ND15 ND16 Fig. 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3

Fig. 2

Table 2.6/1: Line reactors (for more information see publication Technical Data)

Fig. 1

Fig. 3

II D 2-15

Aspects of fusing for the armature-circuit and field supplies of DC drives

Unit configuration
AC supply: public mains / plants mains Cabinet

Possible causes include: - network malfunctions (line undervoltage) - overspeed due to the load involved (load accelerates motor) or due to a control error - field supply generates a field current larger

. .

. . .

than IF

RATED

or control error in the field

weakening range

For field supply see Fig. 2.6/2

Faults caused by components Semiconductor faults can be manifested in that


a thyristor no longer fires, for example, (5a) or in that it is permanently conductive (5b). Depending on the system condition (fourquadrant operation, regeneration, etc.), these two cases will then exhibit similar symptoms to those of cases 3 and 4. Faults:

Fig. 2.6/1 Arrangement of the switch-off elements in the armature-circuit converter


Switching elements such as fuses or overcurrent trips are used whenever overcurrents cannot entirely be ruled out. In some configurations, this will entail the following questions: firstly, at what point should which protective element be incorporated? And secondly, in the event of what faults will the element in question provide protection against damage? Possible sources of faults are:

5a, 5b

Insulation faults may occur within the cabling of the mains supply, the power converter and the motor. These can be subdivided into faults finally resulting in a short-circuit and those leading to an earth fault. - In the event of a short-circuit, the following generally applies: I >> I
RATED

Faults within the unit electronics The power converters working

- In the event of an earth fault, depending on mode will where the fault has occurred, the current may range between I = I Fault:
RATED

usually be current-limiting; the maximum current corresponds to the current limitation set; if this limitation feature or one of the requisite components fails, then the current will frequently rise sharply; output current I>> IRATED ; Fault:

and I >> I

RATED

Fusing of the armature-circuit supply


The table below shows the fault cases in which semiconductor fuses (super-quick-acting) can protect the drive system consisting of motor and unit. Those cases marked (X) would protect the motor only, and not the unit.

If one or more than one false firing pulses are produced, e.g. due to component faults or other influencing factors, then the current will likewise rise sharply; output current I >> IRATED ; Fault:

The following general rule applies: Analogue systems are more sensitive and more susceptible to malfunctions than digital systems. Digital systems are able to detect critical situations much easier and deliver facilities to prevent the equipment from shut down.

If (with four-quadrant units) thyristors of both bridges become conductive, circulating current is the consequence; the causes involved may be component defects or other influencing factors; the current on the three-phase side will rise substantially; IAC >> IRATED ; Fault:

Fault 1 2 3 4 5a 3 5b 4 6

Semiconductor fuses on the AC side on the DC side X (X) X (X) X X X X X X

Defective system conditions leading to commutation failure In the case of regeneration, the ratio of motor
voltage and line voltage rises above 1.05, which is followed by a situation called shootthrough; the current rises substantially; output current I >> IRATED ; Fault:

Before deciding whether fuses are going to be incorporated only on the DC side, you must first check in which working points the drive is used how often (proportion of time as compared to the overall duration of operation). The fault listing is independent of the electronics used.

II D 2-16

Supply and fusing for the field supply


Basically, similar conditions apply for both field supply and armature-circuit supply. Depending on the power converter used (diode bridge, halfcontrolled bridge, fully controlled 4-quadrant bridge), some of the fault sources may not always be applicable. Due to special system conditions, such as supply via an autotransformer or an isolating transformer, new protection conditions may additionally apply. In contrast to the armature-circuit supply, fuses are

The following configurations are relatively frequent:


F3.1 2

F3.2 F3.1 2

F3.3 F3.1 2

never

used on the DC side for the field

supply, since a fuse trip might under certain circumstances lead to greater damage than would the cause tripping the fuse in the first place (small, but long-lasting overcurrent; fuse ageing; contact problems; etc.). Fault No. 4 can also occur in the case of field supply units, but will not cause such a rapid and substantial current rise as encountered with an armature-circuit supply; this is due to the significantly higher inductance of the field winding. If conditions similar to those for armature-circuit supply are to apply, like for example protection of the field supply unit and the field winding, then a semiconductor fuse (super-quick-acting F3.1) must be used.

Fig 2.6/2 Configurations for field supplies

Possible field supply units: - SDCS-FEX-1: Fault: Fault: Fault: Fault: uncontrolled diode bridge; half-controlled bridge, 1Q; half-controlled bridge, 1Q; fully controlled bridge, 4Q;

5a, 6 1, 5a, 6 1, 5a, 6 1, 3, 4, 6

- SDCS-FEX-2: - DCF 503: - DCF 504:

The faults listed here are described under Aspects of fusing for the armature-circuit and field supplies. Note: in the case of 1, 4, and 6, the current is limited to relatively small overcurrents due to the ohmic content of the field winding, so that the fuses may perhaps not be tripped.

See the text below in the Commutating reactor section

The F3.2 and F3.3 fuse types serve as line protectors and cannot protect the field supply unit. Only pure HRC fuses or miniature circuitbreakers may be used. Semiconductor fuses would be destroyed, for example, by the transformers starting current inrush.

II D 2-17

Fuses and fuse holders for armature supply


The converter units are subdivided into two groups: Unit sizes C1 and C2 with rated currents up to 700 A require external fuses. In unit sizes C3 and C4 with rated currents of 930 A to 5150 A, the semiconductor internally (no fuses are installed external additional

Fuse F1 and fuse holders


Type of converter DCS50xB0025-41/51 DCS50xB0050-41/51 DCS50xB0050-61 DCS50xB0075-41/51 DCS50xB0100-51 DCS50xB0110-61 DCS50xB0140-41/51 DCS50xB0200-41/51 DCS50xB0250-41/51 DCS50xB0270-61 DCS50xB0350-41/51 DCS50xB0450-41/51/61 DCS50xB0520-41/51 DCS50xB0700-41/51 Manufacturer / Type Bussman 170M 1564 Bussman 170M 1566 Bussman 170M 1568 Bussman 170M 1568 Bussman 170M 3815 Bussman 170M 3815 Bussman 170M 3815 Bussman 170M 3819 Bussman 170M 3819 Bussman 170M 5810 Bussman 170M 5810 Bussman 170M 6811 Bussman 170M 6811 Bussman 170M 6813 Fuse holder OFAX 00 S3L OFAX 00 S3L OFAX 00 S3L OFAX 00 S3L OFAX 1 S3 OFAX 1 S3 OFAX 1 S3 OFAX 1 S3 OFAX 1 S3 OFAX 2 S3 OFAX 2 S3 OFAS B 3 OFAS B 3 OFAS B 3

semiconductor fuses are needed). The semiconductor fuses for the C1 and C2 unit sizes are blade fuses. The relevant data is listed in the table below. The fuses type of construction requires special fuse holders. Fuse holders of the OFAX/OFAS type series are available.

Table 2.6/2: Fuses and fuse holders (for more information see publication Technical Data)

Additional components for field supply


The field supply units insulation voltage is higher than the rated operating voltage (see Chapter Field supplies), thus providing an option in systems of more than 500 V for supplying the power section of the converter directly from the mains for purposes of armature supply, and using an autotransformer to match the field supply to its rated voltage. Moreover, you can use the autotransformer to adjust the field voltage (SDCS-FEX-1 diode bridge) or to reduce the voltage ripple. Different types (primary voltages of 400...500 V and of 525...690 V) with different rated currents each are available.

Transformer T3
Field converter type for field current IF 6 A 12 A 16 A 30 A 50 A 6 A 12 A 16 A 30 A 50 A Transformer type Uprim = 500 V T 3.01 T 3.02 T 3.03 T 3.04 T 3.05 Uprim = 600 V T 3.11 T 3.12 T 3.13 Uprim = 690 V T 3.14 T 3.15

SDCS-FEX-1 SDCS-FEX-2 SDCS-FEX-2 DCF503/4-0050 DCF503/4-0050 SDCS-FEX-1 SDCS-FEX-2 SDCS-FEX-2 DCF503/4-0050 DCF503/4-0050

Fig. 2.6/3: T3 autotransformer

Table 2.6/3: Autotransformer data (for more information, e.g. fuse data, see publication Technical Data)

Commutating reactor
When using the SDCS-FEX-2 field power converter, you should additionally use a commutating reactor because of EMC considerations. A commutating reactor is not necessary for the SDCSFEX-1 (diode bridge); and in the DCF 503/504 field power converters, it is already installed.

Converter SDCS-FEX-2

Reactor ND 30

Table 2.6/4: Commutating reactor (for more information see publication Technical Data)

II D 2-18

Electronic system / fan supply


The converter unit requires various auxiliary voltages, e.g. the units electronics require 115 V/ 1-ph or 230 V/1-ph, the unit fans require 230 V/ 1-ph or 400 V/690 V/3-ph, according to their size. The T2 auxiliary transformer is available to supply the units electronic system and the singlephase fans.

EMC Filters
Selection of electrical components in conformity the EMC Guideline is described below. The aim of the EMC Guideline is, as the name itself implies, to achieve electromagnetic compatibility with other products and systems. The Guideline is designed to ensure that a product's emissions are so low that they do not impair the interference immunity of another product. Within the context of the EMC Guideline, two aspects have to be considered: the product's the product's

Auxiliary transformer T2
Input voltage: 380...690 V/1-ph Output voltage: 115/230 V/1-ph

interference immunity emissions

The EMC Guideline does of course expect EMC to be taken into account while a product is being developed, but EMC cannot be designed in, only quantitatively measured.

Note on EMC conformity


The conformity procedure lies within the responsibility both of ABB Industrietechnik AG of the machine manufacturers or system erectors con-

Fig. 2.6/4: T2 auxiliary transformer

cerned, according to their share in expanding the electrical equipment. In order to comply with the protection targets of the relevant EMC legislation (EMVG in Germany) in systems and machines, the following EMC standards have to be met:

Earth fault monitor


An earth fault monitor is provided by the standard software. If needed, the analogue input AI4 has to be activated, a current signal of the three phase currents should be supplied to AI4 by a current transformer. If the addition of the three current signal is different from zero, a fault is indicated (for more information, see publication Technical

EN 50082-2 Generic standard for noise immunity Industrial environment EN 50081-2 Generic standard for noise emission Industrial environment EN 50081-1 Generic standard for noise emission Light industrial environment
You will find further information on the following

Data).

Installation of converters for armature and field supply in accordance with EMC).
pages (see as well publication

II D 2-19

Classification
Medium-voltage line Converter transformer with grounded screen and grounded iron core Supply transformer of a industry region (rated power normally 1.2 MVA) Insulated industrial low voltage line for up to 1000V with ground conductor Grounded star point Medium-voltage line Supply transformer of a residental region with light industry (rated power normally 1.2 MVA)

Grounded star point

Grounded public 400V line with neutral conductor

Grounded public 400V line with neutral conductor

Mounting plate

Mounting plate

Line filter

Line filter

Commutation choke

Line choke

Line choke

Converter
alternative

Converter
alternative

Converter

Converter

Mounting plate

M
Operation at the public low voltage line together with other loads of all kinds

M
A separation transformer with grounded screen and with grounded iron core makes the line filter and the line choke unnecessary. To other loads which must be protected against line pollution caused by converters (HF disturbance and commutation notches).

Operation with separate converter transformer. If there are other loads at the same secondary winding they have to withstand the commutation notches, caused by the converter. In some cases commutation chokes are necessary (see 1.4).

Operation at the public low voltage line together with other loads of all kinds except some kinds of sensitive communication means.

Industrial or "Second" environment

Light industrial / Residental or "First" environment

EN 50081-2

EN 50081-1

The field supply is not shown in this synopsis drawing. The rules for the field supply cables are the same as for the armature supply cables.

Figures e.g.

see 3.1 or explanation available in chapter 3, paragraph 1 screened cable, see 2.4.2 unscreened cable with limitation, see 2.5

Fig. 2.6/5: Classification


II D 2-20

Legend

Filter in a grounded line (earthed TN or TT network)


The filters are suitable for grounded lines only, for example in public European 400 V lines. According to EN 61800-3 filters are not needed in insulated industrial lines with own supply transformers. Furthermore they could cause safety risks in such floating lines (IT networks).

Three - phase filters


EMC filters are necessary to fulfill EN 50081 if a converter shall be run at a public low voltage line, in Europe for example with 400 V between the phases. Such lines have a grounded neutral conductor. ABB offers suitable three - phase filters for 400 V and 25 A....600 A and 500 V filters for 440 V lines outside Europe. Lines with 500 V to 1000 V are not public. They are local lines inside factories, and they do not supply sensitive electronics. Therefore converters do not need EMC filters if they shall run with 500 V and more.

xxx = Voltage [A] DCS500B0025-x1 DCS500B0050-x1 DCS500B0075-x1 DCS500B0100-x1 DCS500B0140-x1 DCS500B0200-x1 DCS500B0250-x1 DCS500B0350-x1 DCS500B0450-x1 DCS500B0520-x1 DCS500B0700-x1 DCS500B0900-x1 DCS500B1200-x1 DCS500B1500-x1 DCS500B2000-x1 DCS500B2500-x1 25 50 75 100 140 200 250 350 450 520 700 900 1200 1500 2000 2500

[kg] NF3-xxx-25 3 NF3-xxx-50 3.1 NF3-xxx-64 3.1 NF3-xxx-80 9.5 NF3-xxx-110 9.5 NF3-xxx-320 28 NF3-xxx-320 28 NF3-xxx-320 28 NF3-xxx-600 49 NF3-xxx-600 49 NF3-xxx-600 49 NF3-xxx-1000 90 NF3-xxx-1000 90 NF3-xxx-1600 130 NF3-xxx-1600 130 NF3-xxx-2500 200

Weight appr.

Converter type

Rated dc current

Filter type

Dimensions LxWxH

[mm] 200x150x65 200x150x65 200x150x65 400x170x90 400x170x90 450x285x171 450x285x171 450x285x171 590x305x158 590x305x158 590x305x158 610x305x198 610x305x198 840x465x210 840x465x210 955x520x293

The filters 25... 2500 A are available for 440 V and 500 V, and the filters 600...2500 A are available for 690 V too.

The filters can be optimized for the real motor currents: IFilter = 0.8 IMOT max ; the factor 0.8 respects the current ripple.

Many field supply units are single - phase converters for up to 50 A excitation current. They can be supplied by two of the three input phases of the armature supply converter. Then a field supply unit does not need its own filter. If the phase to neutral voltage shall be taken (230V in a 400 V line) then a separate filter is necessary. ABB offers such filters for 250 V and 6...30 A.

Weight appr. [kg]

Single - phase filters for field supply

Converter type of field supply unit

dc current

Filter type Umax = 250 V

Dimensions LxWxH [mm] 139x105x59 139x105x59 139x105x59 230x115x60 230x115x60 139x105x59 148x105x57

[A] SDCS-FEX-1 SDCS-FEX-2 SDCS-FEX-2 DCF 503-0050 DCF 504-0050 further filters for 6 8 16 50 50 12 30 NF1-250-8 NF1-250-8 NF1-250-20 NF1-250-55 NF1-250-55 NF1-250-12 NF1-250-30

0.7 0.7 1.0 1.8 1.8 0.9 1.0

The filters can be optimized for the real field currents: IFilter = IField

II D 2-21

Commutation and line chokes


(see also Section transformers (P

Installation hints
in this chapter) I = 1732 A) All metal cubicles available on the market can be used. The mounting plate must be made from steel with zinc surfaces and without any painting. It shall be connected with the PE copper bar by several bolts. The converter, the line choke, fuses, contactors and the EMC filter are to be placed on the mounting plate so that the connections can be made as short as possible, especially those from the converter via the line choke to the filter. The cables for digital signals which are longer than 3m and all cables for analogue signals must be screened. Each screen must be connected at

Line reactors
= 1.2 MVA

Due to the maximum power of public 400 V and due to their relative voltage drop 6% or 4% the maximum AC current which is available for a converter is 346 A or 520A (I

MAX

MAX

DC 422 A or 633 A).

Separation transformers
A separation transformer makes line chokes unnecessary because of its leakage inductance, and a grounded screen between its windings saves an EMC filter. The screen and the iron core must be well connected with the mounting plate of the converter.

Converter transformers
A converter transformer transfers high power directly from a medium voltage line to a single large converter or to a local low voltage line for several converters. Furthermore it acts as separation transformer. If such a converter transformer has no screen the EMC demands are nevertheless fulfilled in most cases because the RF interference energy can hardly get via the medium-voltage line and the transformer of the public line to the loads which must be protected against pertubances.

both

ends by metal clamps or

comparable means directly on clean metal surfaces. In the converter cubicle this kind of connection must be made directly on the sheet metal close to the terminals. The necessity of a screen depends on the length of the cable and on the environmental demands. If a screen is necessary then it must be pressed by a well conducting metal clamp directly against the mounting plate or the PE bar of the converter cubicle. Screened cables to the armature and to the excitation winding cause the lowest noise level. The armature current cable must contain a third wire for a PE connection if the copper cross section of the screen cannot fulfil the PE safety demands. If a screen is not necessary the armature current cable must be a fourwire cable because two wires are needed as conductors for the parasitic RF currents from the motor to the RF filter in the cubicle.
PE

PE

II D 2-22

Connection example in accordance with EMC


Mounting plate I/O L1 L2 L3 PE PE 1 7 PE PE Filter U1 V1 W1 C1 D1

T
A

M
F

Field supply unit

3 5 PE

Mounting plate with PE bar and terminals

DC motor

F1

Screens

Tacho

PE bar

Contact to the motor housing at the whole screen perimeter

Mounting plate with PE bar and terminals

DC motor

F1

Tacho

Tacho

PE bar

Encoder inputs and analogue I/O at the PCB

Important hint:
The example shows the principle structure of a DC drive and its connections. It is a not binding recommendation, and it cannot respect all conditions of a plant. Therefore each drive must be considered separately and with respect to the special application. Additionally the general installation and safety rules must be taken in account.

lower edge of the PCB carrier

Fig. 2.6/6: Connection example in accordance with EMC


II D 2-23

Screen

Armature and field cables without screens suitable for "second environment"

F2 A1 A2

Tacho

Armature and field cables with screens for "first environment"

F2 A1 A2

3 Overview of software (Version 21.22x)


3.1 Introduction to the structure and handling

connected function blocks. Each of these individual funcThe entire software is made up of tion blocks constitutes a subfunction of the overall functionality. The function blocks can be subdivided into two categories: Function blocks which are permanently active, are almost always in use; these are described on the following pages. Function blocks which, although they are available within the software as standard features, have to be expressly activated when they are needed for special requirements. These include, for example: AND gates with 2 or 4 inputs, OR gates with 2 or 4 inputs, adders with 2 or 4 inputs, multipliers/dividers, etc. or closed-control-loop functions, such as integrator, PI controller, D-T1 element, etc. All function blocks are characterized by input and output lines, equipped with numbers. These inputs/outputs can likewise be subdivided into two categories:

Parameters

for setting values, such as ramp-

up time / ramp-down time, controller amplification, reference values, e.g.:

R AM PG E N ER ATO R
P 2 P 4 P 6 V alue V alue V alue 1708 1709 1710

Param eter

Default setting

For pin/parameter selection, e.g. with the CDP31x control panel, the following applies: Ignore the two right-hand digits; the remaining digits are the

group

and are selected at the and .

panel, using keys

The two right-hand digits are the and . E.g.:

subgroup

and are selected at the panel, using keys

DI7

10713

Group Subgroup

107 13

When you want to alter connections between function blocks, proceed as follows: first select

input,

and then connect to

output.
All those connections possessing one pin each at their beginning and end can be altered.

Pins for
DI7

designating connections, e.g.:


10713 901

DRIVE LOGIC

Pin

The following pages correspond to what you get printed from the GAD tool. Explanations are given on the last page (unfolder) of this document

Please note:
The following pages describe the as-delivered Either the desired signal does already exist, but - due to its complexity - is not easy to describe, which is why it appears in a signal listing given in the software description. Or it can be generated with available signals and additionally available function blocks.

wired

functionality. If a desired signal or a

certain function seems to be missing, it can in most cases be implemented very easily:

In addition to that please note that the functionality described on the next pages is available a second time for Motor Set 2. There are two parameter sets (groups 1 to 24) available within the drive's memory.
II D 3-1

1/16
II D 3-2

2/16
II D 3-3

3/16
II D 3-4

4/16
II D 3-5

5/16
II D 3-6

6/16
II D 3-7

7/16
II D 3-8

8/16
II D 3-9

9/16
II D 3-10

10/16
II D 3-11

11/16
II D 3-12

12/16
II D 3-13

13/16
II D 3-14

14/16
II D 3-15

15/16
II D 3-16

16/16
II D 3-17

3.2 GAD Engineering-Program

GAD is a PC program for application programming. When the function-block library for converter equipped with software version 21.xxx was set up, an option was included for programming customized system packages for typical applications. The program features the following functions: application design and programming graphics editor for drawing and altering program diagrams

program under MS-Windows, including the complete range of functions, such as window, zoom, copy, etc. user-controlled document depiction option for defining new documentation symbols recommended software and hardware: 486 PC, MS-Windows 3.1, 4 MB RAM, 120 MB hard disk

Standard function block

Applications function block

Fig. 3.2/1 Standard and Applications function blocks utilized with GAD

Please note:
For more information of the GAD PC program there is a manual available describing the possibilities and the handling of the program.

II D 3-18

230V 50Hz L1 MP L1 L2 L3

400V 50Hz

F1 1 1 F4 2 2 2 F3 F5 1
F6

Connection examples

II D 4-1
OFF 96:1
96:2

Figure 4/1:
STOP ON K1 K21
START K20

Proposal 1

1 K20 K21 K1 K3 K1
2

3
4

5 K3
6

1
2

3
4

This way of wiring the drive is based on the standard drives logic which was modified in a way, that only line contactor on feedback is required. To make sure, that the configuration works properly, the following modifications must be done:

DCS 500 Wiring diagram - Proposal 1


L1

L3

X96: 1

X99: 1

X2: 4

X2: 1

U1

V1

W1 PE

X1: 1

IN3

V5

Communication board (COM-x) Control board (CON-2)


DO8

OUT3

V6

IN1

V1

M ~
Power supply (POW-1)
depending on the unit type (C1, C2, C3, C4) an other configuration is possible

OUT1

V2

S4

X33
+10V -10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V

Converter module
DO1 DO2 DO3 DO4 DO5 DO6 DO7

AITAC _ +

AI1 _ +

AI2 _ +

5 6 AI3 _ + 0V
2 3 4 5 6 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9

AI4 _ +

Field exciter unit (FEX-1/2)


0V

0V

0V

0V
10 X7: 1 2 3 4 5 6 7

Connection from 910 to 10701 911 to 10703 906 to 10709

X3: 1

10 X4: 1

X5: 1...10
+

C1

PANEL CDP 312


K20

D1 _

X1: 5 e.g. Pressure switch at C4 module the polarities are shown for motor operation
+

3 _

Software wirings - to be changed

K1

K21

if there are intermediate terminals

T
+

must be changed to 910 to 10908 911 to 10908 906 to 12502

M
T
_

U V

Proposal 2

0a 
W

2 4 400V 50Hz
L1 L2 L3

F7 1 3 4 3 F1 4 3 F3 5 500V 12 460V 11 415V 10 400V 9 6 5 6 5 2 K6 1 2 K22 F6 1

This way of wiring the drive is based on the standard drive logic which was not modified. The standard drives logic requires all given feedbacks from the drive system.
T3

Figure 4/2:
STOP K10 K11
96:2

OFF 96:1

T2
1 1 F5 2 1 115V 13 2 2 4 F2 230V 12 1 3

ON K21
X2:5

START

K1

F6

X2:4 F4

365V 350V 265V 250V 90V 60V 30V

8 7 6 5 4 3 2 1

EMER. STOP S1 2 K21 K6 K5 K3 K1 K22 14


2 K20

11 690V 10 660V 9 600V 8 575V 7 525V 6 500V 5 450V 4 415V 3 400V 2 380V 1 K1
4 6

5 K3

1
2

3
4

K20

DCS 500 Wiring diagram - Proposal 2


1 K5 2 2 3 4 U1 V1 W1 PE X1: 1 7 X96: 1 2 X99: 1 2 X2: 4 5 X2: 1 3
L1

L3

IN3

V5

Communication board (COM-x) Control board (CON-2)


DO8

OUT3

V6

IN1

V1

M ~
Power supply (POW-1)
depending on the unit type (C1, C2, C3, C4) an other configuration is possible

OUT1

V2

S4

X33
AI4 _ + +10V -10V AO1 AO2 IACT DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V

Converter module
DO1 DO2 DO3 DO4 DO5 DO6 DO7

AITAC _ +

AI1 _ +

AI2 _ +

5 6 AI3 _ + 0V
2 3 4 5 6 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 10 X7: 1

Field exciter unit (FEX-1/2)


0V

0V

0V

0V
2 3 4 5 6 7

X3: 1

10 X4: 1

X5: 1...10
+

C1

PANEL CDP 312


K6 e.g. Pressure switch at C4 module 1 S1 2
K5 K1 K21

D1 _

X1: 5
+

3
_

K20 K10 K11

if there are intermediate terminals

the polarities are shown for motor operation

II D 4-2

T
+

M
T
_

Since we aim to always meet the latest state-ofthe-art standards with our products, we are sure you will understand when we reserve the right to alter particulars of design, figures, sizes, weights, etc. for our equipment as specified in this brochure.

ABB Industrietechnik GmbH Antriebe und Automation Postfach 1180 D-68619 Lampertheim Telefon +49(0) 62 06 5 03-0 Telefax +49(0) 62 06 5 03-6 09

3ADW 000 066 R0201 REV B 3_98

Explanations to the GAD Drawings


Sheet 2/16 The SETTINGS block serves for scaling all important signals, such as line voltage, motor voltage, motor current and field current. The language, in which you want to read your informations on the panel, can be selected. The MANUAL TUNING block provides reference values and test conditions so as to enable all controllers to be adjusted in the power converter. If the panel is used as a meter in the cubicle door, an assortment of signals can be defined here. The CONSTANTS and FREE SIGNALS blocks can be used for setting limitations or special test conditions. The AO2 block represents a scalable analogue output. Sheet 3/16 The DRIVE LOGIC block reads in various signals from the system via digital inputs DIx, processes them, and generates commands, which are outputted to the system via digital outputs DOx, e.g. for controlling the power converters line contactor, the field-circuit contactor or contactors for various fans, or for outputting status messages. Sheet 4/16 This page depicts the conditioning routine for speed feedback and reference values. The AITAC block is used to read in the speed feedback from an analogue tacho. The SPEED MEASUREMENT block processes the 3 possible feedback signals: analogue tacho, pulse generator or the converter's output voltage (SPEED_ACT_EMF) - conditioned by the EMF TO SPEED CALC block (if 2102=5 , no field weakening function possible). Parameters are used for activating smoothing functions, selecting the feedback value and where applicable for setting the maximum speed. This parameter also serves for scaling the speed control loop. The RAMP GENERATOR block contains a ramp function generator with 2 ramp-up and ramp-down ramps, 2 times for the S-curve, limitation for upper and lower limits, hold function and the functions for Follow the speed reference or Follow the speed feedback. There is a special signal available for the treatment of acceleration and deceleration. The speed reference for the ramp function generator is formed by the REF SEL blocks, which can be used to select the reference value required, the CONST REF block, which generates a maximum of 4 permanently settable reference values, the SOFTPOT block, which reproduces the function of a motorpotentiometer in conjunction with the block RAMP GENERATOR, or by the AI1 block (analogue input 1). Sheet 5/16 The SPEED CONTROL block contains the speed controller with P, I and DT1 contents. For adaptation it receives a variable P-amplification. The REF SUM block enables the output of the ramp function generator and a userdefinable signal to be added. The result is compared to the speed feedback from the SPEED MEASUREMENT block, using the SPEED ERROR block, and then passed to the speed controller. This block permits evaluation of the system deviation by means of a filter. Moreover, it is possible here to make a few settings which are needed for the Window operating mode. If the drives speed feedback is within a window around the reference value, then the speed controller is bypassed (provided Window Mode has been activated; the drive is controlled by means of a torque reference value at the TORQ REF HANDLING block). If the speed feedback is outside the window, the speed controller will be activated, and will lead the drives actual speed back into the window. The SPEED MONITOR block contains motor stalled - and tacho monitoring function, and compares a selected speed feedback value against overspeed, minimum speed and 2 settable thresholds. The AO1 block represents a scalable analogue output. Sheet 6/16 The torque reference generated by the speed controller is passed to the input of the CURRENT CONTROL block via the TORQ REF HANDLING block, and there it is converted into a current reference value and used for current regulation. The TORQUE / CURRENT LIMITATION block is used for generating the various reference values and limitations; this block contains the following functions: speed-dependent current limitation, gear backlash compensation, generation of the values for static current limitation and torque limitation. The values for the various limitations are used again at some other points, for instance at the following blocks: SPEED CONTROL, TORQ REF HANDLING, TORQ REF SELECTION, and CURRENT CONTROL. The TORQ REF SELECTION block contains a limitation with upstream addition of two signals, one of which can be routed through a ramp function generator; the other signals evaluation can be dynamically altered using a multiplier. The AI2 block (analogue input 2) is used for reading in an analogue signal. Sheet 7/16 The TORQ REF HANDLING block determines the drives operating mode. When in position 1, the speed control mode has been activated, whereas in position 2 it is torque control mode (no closed-loop control since there is no genuine torque feedback available in the unit). In both cases, the reference value required comes from outside. Positions 3 and 4 are a combination of the first two options stated above. Note that with position 3 the smaller value out of external torque reference and speed controller output is passed to the current controller whereas with position 4 it is the larger one. Position 5 uses both signals, corresponding to the method of functioning of Window Mode. The CURRENT CONTROL block contains the current controller with a P and I content, plus an adaptation in the range of discontinuous current flow. This block also contains functions for current-rise limitation, the conversion of torque reference value into current reference value by means of the field crossover point, and some parameters describing the supply mains, and the load circuit. Sheet 8/16 The EMF CONTROL block contains the armature-circuit voltage controller (e.m.f. controller). It is based on a parallel structure comprising a PI controller and a precontrol feature, generated with a characteristic of 1/x. The ratio between the two paths can be set. The output variable of this block is the field current reference value, which is produced from the flux reference value by another characteristic function using linearization. Since a DCS power converter can control 2 field units, some of the function blocks are duplicated. This means that, depending on the mechanical configuration of the drives concerned, you can control 2 motors either in parallel or alternatively. The requisite configuration of the software structure can be generated by designing the blocks appropriately during the commissioning routine. The MOTOR1 FIELD / MOTOR2 FIELD block reads in the field current reference value and all values which are specific to the field supply unit, and transfers these to the field power converter via an internal serial link; the field power converter is scaled to suit its hardware, and performs field current regulation. The field current direction for motor 1 can be determined using binary commands, while for motor 2 it can be generated in the course of an application upstream of the block concerned. The MOTOR1 FIELD OPTIONS / MOTOR2 FIELD OPTIONS block controls the freewheeling function in the event of line undervoltage, and the field current reversal function with field reversal drives (only for motor 1). In case of field reversal drives, there is an option for selectively influencing the moment of armature-circuit and field current reduction and build-up. Sheet 9/16 The CONVERTER PROTECTION block monitors the armature circuit for overvoltage and overcurrent, and monitors the mains for undervoltage. It provides an option for reading in the total current of the 3 phases through an additional external sensor and monitoring it for not equal to zero. The MOTOR1 PROTECTION block, in its upper part, evaluates either the signal from an analogue temperature sensor, or from a Klixon. In its lower part, it computes motor heat-up with the aid of the current feedback value and a motor model, after which a message is outputted. The MOTOR2 PROTECTION block works in the same way as the MOTOR1 PROTECTION block, but without Klixon evaluation. Sheet 10/16 The BRAKE CONTROL block generates all signals needed for controlling a mechanical brake. Sheet 11/16 The AI3 and AI4 blocks represent another 2 analogue inputs which have as yet not been assigned to any particular functions. The blocks A15 and A16 represent another 2 additional inputs which are only active, if the board SDCS-IOE1 is connected. Another 7 digital inputs DI 9 .. DI15 are available with this additional hardware. Sheet 12/16 A fieldbus module with serial communicated references should be used, if analogue and digital signals are not sufficient for the control of the drive (equipment for the installation of Profibus, CS31, Modbus etc. is available). This type of module is activated by means of the block FIELDBUS. The data transferred from the control to the converter are stored in the blocks DATASET1 and DATASET3 as 16-bit-information. Depending on the application the output pins of these blocks have to be connected to input pins of other blocks in order to transport the message. The same procedure is valid for blocks DATASET2 and DATASET4, if they are connected. These blocks are transmitting information from the converter to the control system. Sheet 13/16 The converter is able to be configurated in a 12-pulse parallel application. In this case you need: - two identical armature converters - one field supply unit - one T-reactor - communication via ribbon cable connected to X 18 of both converters The 12-PULSE LOGIC must be activated and guarantees a synchronous control of the MASTER and the SLAVE drive. Sheet 14/16 The block DATA LOGGER is able to record up to six signals. The values of these signals will be stored in a battery buffered RAM and are still available after a break down of the supply voltage. The time of recording can be influenced by a trigger signal, as well as the number of recorded values before and after the trigger signal. The function DATA LOGGER can be set with both panel and PC tool. For evaluation of the recorded values a PC tool is recommended. Sheet 15/16 By using the blocks USER EVENT1 to USER EVENT6 six different messages are created, which are displayed as faults or alarms on the panel. Sheet 15/16 By using the block FLTHNDL (faulthandling ) the faults and alarms of the drive are regrouped as 16-bit information.