DCS800Selection, Installation and Start-Up Manual for Rebuild KitsDCS800 Drives

ABB DCS800 Installation And Start-up Manual

DCS800 Single Drive Manuals

What this chapter contains

Installation and maintenance work

Grounding

Fibre optic cables

Operation

Type code

Main circuit and control

Armature circuit converter DCS800 D5...D7

Rebuild system DCR800

Unpacking the unit

Before installation

Mounting the converter module D6 inside an enclosure

Mounting the converter module D7 inside an enclosure

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

Semiconductor type F1 fuses and fuse holders for AC and DC power lines

Single-phase Transformer T3 for field supply to match voltage levels

Single-phase Commutating reactor

Three-phase filters

Converters D1...D4 drive configuration using 'on board' field exciter

Converters D5 drive configuration using 'FEX-425-Int' field exciter

Converters D5...D7 drive configuration using 'external' field exciter DCF803, DCF804

START, STOP and E-STOP control

Drive configuration with reduced components

Power section cooling

Thermal overload and short-circuit protection

Cross-sectional areas - Tightening torques

Selecting the control cables

Connection of a motor temperature sensor to the drive I/O

Electrical installation

IT (ungrounded) systems

I/O Board Configuration

Pulse encoder connection

Pulse encoder receiver

Connecting the signal and control cables

DSL Link Wiring

Checklist

Heatsink

Current ratings

Sizing

Control Board SDCS-CON-4

Seven segment display

Digital and analogue I/O connection of the SDCS-CON-4

Interface Board SDCS-COM-8

DSL Board

Digital I/O board SDCS-IOB-2

Analogue and encoder I/O board SDCS-IOB-3

Power Supply Board SDCS-POW-4

Interface Board SDCS-PIN-4

Power supply

Armature circuit interface

Power Interface SDCS-PIN-46/SDCS-PIN-48/SDCS-PIN-5x

Galvanic isolation - T90, A92

DC-DC transducer A92

Transformer T90

Module D1

Module D4

Module D5

Module D6

Module D7 left-hand

Module D7 right-hand

Fuses installed inside the converter

DCF803-0035 and FEX 425 internal

Electrical data

DCS LINK communication

Diagnosis

RS232-Port

Fuses and fuse holders

Line chokes

Line chokes type ND 07...ND 12

Line chokes type ND 401...ND 413

Autotransformer T3

Supply transformer T2 for electronics and fan

Optical cables

DCS800

Safety instructions

Mechanical installation

Introduction

Storage and transport

Current and voltage ratings

Fault Tracing Thyristors

Additionally for service and preventive maintenance

DC-current pulses measured by an oscilloscope

How to find a faulty thyristor

Converters size D5, D6, and D7 (900...5200 A)

Handling the Semiconductors

Exchange of Thyristors for Size D1 to D4

Remove faulty thyristor modules

Install new thyristor modules

Remove faulty OnBoard bridge (V1)

OnBoard bridge (V1) and thyristor module location in DCS800-S01 (2-Q) units

OnBoard bridge (V1) and thyristor module location in DCS800-S02 (4-Q) units

OnBoard bridge and thyristor module terminals

Exchange of Thyristors for Size D5

Disk type thyristors

Find faulty thyristor

Remove faulty thyristor

Install new thyristor

Exchange of Thyristors for Size D6

BCT thyristors

Exchange of Thyristors for Size D7

Exchange of SDCS-CON-4

Service

How to remove the converter fans in a frame D3 (four fans)

How to remove the converter fan in a frame D6

How to remove the converter fan in a frame D7

DCS800 firmware download

Add firmware or text files

Create a workspace

Download SDCS-COM-8 firmware

Set type code

Type code table

DC-Motor neutral zone adjustment

Recommended regular maintenance

Annual preventive maintenance

years preventive maintenance

DCS800 Drive Manuals

Armature circuit converter DCS800-S0x D5...D7

Rebuild system DCS800-R0x

Terminal options converter size D1...D4

Line reactors LL1

Conclusion for the field supply

EMC filters

Converters D1...D3 3-phase field exciter configuration

Fan cooling

Typical Cable Sizing and Tightening Torque – North America

Location R-Extension and Interface Modules

DCS Link Wiring

Current ratings - IEC non regenerative

Current ratings - IEC regenerative

Current ratings – North America non-regenerative

Current ratings – North America regenerative

Ch2 SDCS-COM-8 Master-Follower connections

Ch0 Connection to overriding control (Nxxx fieldbus adapter)

Ch3 Star connection to PC tool DriveWindow

DDCS Branching unit NDBU-95

SDCS-DSL Board

Interface Board SDCS-SUB-4

Dimensions

DCF505 / DCF506 Overvoltage Protection

Fuses and fuse holders IEC

Fuses and fuse holders - North America

Line reactors IEC

Line reactors type ND 07...ND 12

Line reactors type ND 401...ND 413

Line reactors – North America

DCS800-R