DCS800

Selection, Installation and Start-up Manual for Optical Rebuild Kits DCS800-R Rebuild Kits



DCS800 Drive Manuals Language

DCS800 Quick Guide DCS800 Tools & Documentation CD DCS800 Converter module Flyer DCS800 Technical Catalog DCS800 Hardware Manual DCS800 Hardware Manual DCS800 update DCF503B/DCF504B Firmware Manual DCS800 Installation according to EMC Technical Guide Service Manual DCS800 12-Pulse Manual CMA-2 Board Flyer Hard - Parallel Drive Tools DriveWindow 2.x - User's Manual DriveOPC 2.x - User's Manual Optical DDCS Communication Link DDCS Branching Units - User’s Manual DCS800 Applications PLC Programming with CoDeSys 61131 DCS800 target +tool description - Application Program DCS800 Crane Drive DCS800 Crane Drive Manual suppl. DCS800 Crane Drive Product note DCS800 Winder ITC DCS800 Winder Product note DCS800 Winder description ITC Winder Questionnaire DCS800-E Panel Solution Flyer DCS800-E Panel solution Hardware Manual DCS800-E DCS800-A Enclosed Converters Flyer DCS800-A Technical Catalogue DCS800-A Installation of DCS800-A DCS800-R Rebuild System Flyer DCS800-R DCS800-R Rebuild Kits DCS800-R Optical Rebuild Kits DCS800-R DCS500/DCS600 Upgrade Kits Extension Modules RAIO-01 Analogue IO Extension RDIO-01 Digital IO Extension RRIA-01 Resolver Interface Module RTAC-01 Pulse Encoder Interface RTAC-03 TTL Pulse Encoder Interface AIMA R-slot extension Door mounting kits Door mounting DCS Control Panel (IP54, click in) Door mounting DCS Control Panel (fix mounting) Door mounting DCS Control Panel (IP66, fix mounting) Serial Communication Drive specific serial communication NETA Remote diagnostic interface Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) Fieldbus Adapter with DC Drives RCAN-02 (CANopen) Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) Fieldbus Adapter with DC Drives RDNA- (DeviceNet) Fieldbus Adapter with DC Drives RMBA (MODBUS) Fieldbus Adapter with DC Drives RETA (Ethernet) x -> existing p -> planned Status 04.2012 DCS800 Drive Manuals-List_k.doc

Public. number 3ADW000191 3ADW000211

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3AST004143 PDC5 EN

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PDC2 EN 3ADW000308 3ADW000253z

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3ADW000210 3ADW000224

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3ADW000213 3ADW000198 3ADW000091

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3ADW000007 3ADW000197 3ADW000415 3ADW000256

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3AFE64484567 3AFE64485733 3AFE68570760 3AFE64486853 3AFE68650500 3AFE64661442

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3AUA0000076085 3AFE68294673 3AFE68829593

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3AFE64605062 3AFE64504215

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3AFE64506005 3AFE64504223 3AFE64498851 3AFE64539736

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DCS800-R Rebuild Kits

Selection, Installation and Start-up Manual for Optical Rebuild Kits

Code: 3ADW000415R0101 Rev A DCS800-R Optical Rebuild Kits e a.doc Effective: Supersedes:

2012 ABB Automation Products GmbH. All rights reserved.

03.2012 -

3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Safety instructions What this chapter contains This chapter contains the safety instructions you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

To which products this chapter applies The information is valid for the whole range of the product DCS800, the converter modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the Rebuild Kit DCS800-R00-9xxx.

Usage 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, and advise on how to avoid the danger. Notes draw attention to a particular condition or fact, or give information on a subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause physical injury or death and/or damage to the equipment. General danger warning warns about conditions, other than those caused by electricity, which can result in physical injury or death and/or damage to the equipment. Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment.

Safety instructions 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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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 and/or damage to the equipment.

WARNING! • •

•

• • •

Only qualified electricians are allowed to install and maintain the drive! Never work on the drive, motor cable or motor when main power is applied. Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that: 1. Voltage between drive input phases U1, V1 and W1 and the frame is close to 0 V. 2. Voltage between terminals C+ and D- and the frame is close to 0 V. Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off. Do not make any insulation resistance or voltage withstand tests on the drive or drive modules. Isolate the motor cables from the drive when testing the insulation resistance or voltage withstand of the cables or the motor. When reconnecting the motor cable, always check that the C+ and D- cables are connected with the proper terminal.

Note: •

•

•

The motor cable terminals on the drive are at a dangerously high voltage when the main power is on, regardless of whether the motor is running or not. Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system (e.g. SDCS-IOB-2 and RDIO). DCS800 with enclosure extension: Before working on the drive, isolate the whole drive system from the supply.

Safety instructions 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Grounding These instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic interference.

WARNING! •

• • •

•

Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and pick-up. Make sure that grounding conductors are adequately sized and marked as required by safety regulations. In a multiple-drive installation, connect each drive separately to protective earth (PE ). Minimize EMC emission and make a 360° high frequency grounding (e.g. conductive sleeves) of screened cable entries at the cabinet lead-through plate. Do not install a drive equipped with an EMC filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system.

Note: • •

Power cable shields are suitable as equipment grounding conductors only when adequately sized to meet safety regulations. As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required.

Safety instructions 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Printed circuit boards and fiber optic cables These instructions are intended for all who handle the circuit boards and fiber optic cables. Ignoring the following instructions can cause damage to the equipment.

WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. Use grounding strip:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

Safety instructions 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Mechanical installation These notes are intended for all who install the drive. Handle the unit carefully to avoid damage and injury.

WARNING! •

•

• •

DCS800 sizes D4 ... D7: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place units D4 and D5 only on its back. DCS800 sizes D5 ... D7: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees. Make sure that dust from drilling does not enter the drive when installing. Electrically conductive dust inside the unit may cause damage or lead to malfunction. Ensure sufficient cooling. Do not fasten the drive by riveting or welding.

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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 and/or damage to the equipment.

WARNING! •

•

Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the base speed. Do not control the motor with the disconnecting device (disconnecting mains); instead, use the control panel keys

•

•

•

and

, or commands via the I/O board of the drive. Mains connection You can use a disconnect switch (with fuses) to disconnect the electrical components of the drive from the mains for installation and maintenance work. The type of disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU regulations, or a circuit-breaker type which switches off the load circuit by means of an auxiliary contact causing the breaker's main contacts to open. The mains disconnect must be locked in its "OPEN" position during any installation and maintenance work. EMERGENCY STOP buttons must be installed at each control desk and at all other control panels requiring an emergency stop function. Pressing the STOP button on the control panel of the drive will neither cause an emergency stop of the motor, nor will the drive be disconnected from any dangerous potential. To avoid unintentional operating states, or to shut the unit down in case of any imminent danger according to the standards in the safety instructions it is not sufficient to merely shut down the drive via signals "RUN", "drive OFF" or "Emergency Stop" respectively "control panel" or "PC tool". Intended use The operating instructions cannot take into consideration every possible case of configuration, operation or maintenance. Thus, they mainly give such advice only, which is required by qualified personnel for normal operation of the machines and devices in industrial installations. If in special cases the electrical machines and devices are intended for use in non-industrial installations - which may require stricter safety regulations (e.g. protection against contact by children or similar) - these additional safety measures for the installation must be provided by the customer during assembly.

Safety instructions 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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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

.

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3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Table of contents DCS800 Drive Manuals .......................................................................................................... 2 Safety instructions 5 What this chapter contains ....................................................................................................... 5 To which products this chapter applies..................................................................................... 5 Usage of warnings and notes ................................................................................................... 5 Installation and maintenance work ........................................................................................... 6 Grounding ..................................................................................................................... 7 Mechanical installation ............................................................................................................. 9 Operation ............................................................................................................................... 10 Table of contents

13

Introduction 15 Chapter overview ........................................................................................................ 15 Before You Start ......................................................................................................... 15 What this manual contains .......................................................................................... 15 Target group ............................................................................................................... 15 Associated publications .............................................................................................. 15 Basic Selection 16 Technical requirements and limits .......................................................................................... 16 Selecting the suitable Optical Rebuild Kit ............................................................................... 16 Hardware conditions ................................................................................................... 16 Drive’s design conditions ............................................................................................ 17 Conditions caused by the application .......................................................................... 17 ID codes and options .................................................................................................. 18 Galvanic isolation ........................................................................................................ 19 Optical Rebuild Kits overview...................................................................................... 20 Hardware 21 Basic components .................................................................................................................. 21 Electronic housing (DCS800-R00-0000-00) ................................................................ 21 Loose parts ................................................................................................................. 23 Optional parts ............................................................................................................. 24 Dimensions ............................................................................................................................ 24 Environmental conditions ....................................................................................................... 24 Measurement board SDCS-PIN-51 ........................................................................................ 25 Wiring ......................................................................................................................... 26 Fastening .................................................................................................................... 26 PTC temperature sensor............................................................................................. 26 Type coding ................................................................................................................ 26 Voltage coding ............................................................................................................ 26 Current coding ............................................................................................................ 27 Firmware adaption ...................................................................................................... 28 Pulse conversion board SDCS-REB-11 ................................................................................. 29 Wiring ......................................................................................................................... 30 Fastening .................................................................................................................... 30 Functionality................................................................................................................ 30

Table of contents 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Gate driver board SDCS-PIN-Rxx .......................................................................................... 31 Wiring ......................................................................................................................... 32 Fastening .................................................................................................................... 32 Functionality ............................................................................................................... 32 Interfacing the Electronics and Thyristors 33 General .................................................................................................................................. 33 Designation of thyristors ............................................................................................. 33 Forward bridge (2-Q) with single thyristors ............................................................................. 34 Forward and reverse bridge (4-Q) with single thyristors ......................................................... 36 Forward bridge (2-Q) with 3 serial / parallel thyristors ............................................................ 38 Forward and reverse bridge (4-Q) with 3 serial / parallel thyristors ........................................ 40 Forward and reverse bridge (4-Q) with 12 serial / parallel thyristors....................................... 42 Installation 44 General .................................................................................................................................. 44 Hints for mounting .................................................................................................................. 44 Hints for cabling ..................................................................................................................... 44 Cables overview ......................................................................................................... 45 Start-up 46 General .................................................................................................................................. 46 Safety Instructions ................................................................................................................. 46 Points to be observed because of the situation ...................................................................... 46 Tools ...................................................................................................................................... 46 Measurements with the ‘old’ equipment still working .............................................................. 47 Mounting the Optical Rebuild Kit ............................................................................................ 48 Wiring the Optical Rebuild Kit ................................................................................................. 48 Commissioning the Optical Rebuild Kit................................................................................... 49

Table of contents 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Introduction Chapter overview This chapter describes the purpose, contents and the intended use of this manual.

Before You Start The purpose of this manual is to provide you with the information necessary to upgrade the electronics of old DC drives using Optical Rebuild Kits. The manual DCS800 Selection, Installation and Start-Up Manual for Rebuild Kits serves as the basic document. It is structured similar to this one. Sometimes cross-references are given to the basic document. Study carefully the Safety instructions at the beginning of this manual before attempting any work on or with the drive. Read this manual before starting-up the drive.

What this manual contains The Safety instructions are at the beginning of this manual. Introduction, the chapter you are currently reading, introduces you to this manual. Basic Selection, this chapter provides the information about the types of Optical Rebuild Kits, their ID codes and available options. Hardware, this chapter provides information about the boards and the components of Optical Rebuild Kits. Interfacing the Electronics and Thyristors, this chapter shows the connections between electronics and power part. Installation, this chapter gives hints for mounting and cabling Optical Rebuild Kits. Start-up, this chapter gives general guidelines and cross references for commissioning and start-up for Optical Rebuild Kits.

Target group This manual is designed to help those responsible for planning, installing, starting up and servicing DC drives. These people should possess: − Basic knowledge of physics, electrical engineering, electrical wiring principles, components as well as symbols used in electrical engineering − Basic experience with DC drives and DC products

Associated publications A list of associated publications is published on the inner page of this manual’s cover, see DCS800 Manuals. The above listed documentation can be found on the CD-ROM being attached to the DCS800 Quick Guide (3ADW000191).

Introduction 3ADW000399R0101 DCS550 Service Manual e a

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Basic Selection Technical requirements and limits This document will often use the term valve instead of thyristor: − A valve is made of several serial / parallel thyristors or a single thyristor − The term thyristor is only used in the context of one single thyristor The technical requirements and limits are identical to the ones listed in the basic document. The Optical Rebuild Kits are dedicated to upgrade the electronics of old DC drives, which: − Use up to 12 thyristors per valve (serial / parallel) − Have long distances between the drive’s electronics and the power part

Selecting the suitable Optical Rebuild Kit The basic structure of a DC drive looks like this:

The Optical Rebuild Kits can be used for armature bridges in non-regenerative or regenerative mode with maximum 12 thyristors in serial / parallel per valve. In case there are more than 12 thyristors per valve please contact your local ABB organization. When selecting an Optical Rebuild Kit the Hardware conditions must be checked first to become aware of critical limitations. If this is done the Drive’s design conditions will give some guidelines for the overall design. During that a decision must be made for the functionality of the interface between the Optical Rebuild Kit and the overriding control. Depending on the above, the Optical Rebuild Kit and additional electronic boards have to be chosen. Afterwards check, if all conditions mentioned under Conditions caused by the application are fulfilled.

Hardware conditions If an Optical Rebuild Kit is taken into consideration, the items listed below give some help to decide whether an Optical Rebuild Kit a new converter module or a complete drive cabinet is the best solution: − Before an existing DC power part is upgraded by an Optical Rebuild Kit, it should be checked if a new converter module is easier to install or is a more reliable solution (the power part is factory tested) − The existing power part should have maximum 12 thyristors per valve (more thyristors per valve on request). It does not matter if the thyristors are in serial and / or parallel. − The maximum distance between the drive’s electronics and the power part is 30 m (longer distances on request) − The supply voltage (phase to phase) used for the existing power part can be up to 2,500 VAC because of the firing pulse board used to interface the electronics to the power part − The thyristors must be disk type thyristors

Basic Selection 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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− The minimum DC current of a power part should be higher than 1,000 ADC (no serial / parallel thyristors). In case the DC current is lower, it is strongly recommended to use a new converter module. − 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 using a thyristor tester. In case the actual blocking voltage gives a lower ratio the thyristor needs to be replaced. In such a case, please check if a new converter module is better choice.

Drive’s design conditions It is intended to install the Optical Rebuild Kit into the existing drive cabinet whereas the firing pulse board (SDSC-PIN-Rxx) has to be next to the thyristors. The following drive equipment will be reused and should therefore be in good condition: − All parts in the AC supply like busbars / cables, main disconnecting switch with fuses, main contactor or similar − The thyristor bridges itself (fuses, fixing devices, press clamps for thyristor mounting, …) including the cooling equipment (e.g. heat sinks, fans, …) − All parts in the DC supply like Motors and motor cables − Analogue tachos and pulse encoders can be reused, more details see DCS800 Hardware Manual − All auxiliary devices like relays, contactors, external power supplies, transformers, etc. If an Optical Rebuild Kit is used for the armature supply it is strongly recommended to upgrade the field exciter: − DCF803-0016 up to 16 A field current, single-phase or 3-phase supply maximum 500 VAC − FEX-425-Int up to 25 A field current, single-phase or 3-phase supply maximum 500 VAC − DCF803-0035 up to 35 A field current, single-phase or 3-phase supply maximum 500 VAC − DCF80x-0050 / DCF50xB-0050 up to 50 A field current, single-phase supply maximum 500 VAC − A standard DCS800 module up to 520 A field current (more on request), 3-phase supply maximum 525 VAC The Rebuild kit needs an armature current feedback signal for the current control loop. This signal is normally taken from two current transformers (CTs) mounted at the AC side of the thyristor bridge. The CTs output current should be between 0.5 A - 0.85 A, which corresponds to the nominal current of the thyristor bridge (additional solutions on request). Additionally a 115 VAC or 230 VAC supply for the Optical Rebuild Kit electronics is needed.

Conditions caused by the application It has to be checked if the selected Optical Rebuild Kit type can handle the application of the existing drive. As long as the existing one was used in a B6 configuration, there is usually no limitation. If the existing bridge has been used in a configuration different to a B6 configuration, additional engineering is needed: − It should be checked at first, if a new converter module can be used for such a configuration − The optical rebuild kit is also equipped to support 12-pulse configurations, M3, double M3 and M6 configurations. For more details contact your local ABB organization. − There are drives used in the past in a configuration sometimes named MASTER - FOLLOWER, MASTER - SLAVE or similar. In all these applications, one drive generates references or commands for the second, third, … drive. The Optical Rebuild Kit is basically prepared for those configurations. For more details, please refer to the DCS800 Manuals. − If the existing converter has been used in a non motor application usually a prepared solution is not available, but it is possible to find an engineered solution. For more details contact your local ABB organization.

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ID codes and options The main mechanical construction for all the different versions of the Optical Rebuild Kit is shown in the next figure as DCS800-R00-0000-00. All other parts have to be placed in and around the power part (Attention: Engineering needed!). Due to the versatility of the Optical Rebuild Kit the ordering has to be done using ID codes: Electronics / Printed circuit boards Electronic housing (DCS800-R00-0000-00) SDCS-PIN-51 mounted on a card holder, including resistor SDCS-REB-11 mounted on a card holder SDCS-PIN-R00 mounted on a card holder, no BOD SDCS-PIN-R15 mounted on a card holder, 2 * 1,500 BOD SDCS-PIN-R22 mounted on a card holder, 2 * 2,200 BOD

ID code 3ADT220142R0001 3ADT783025R0022 3ADT317500R0001 3ADT317100R9999 3ADT317100R0015 3ADT317100R0022

Cables Flat cable, 16 pole, not shielded, 0.55 m X12 Flat cable, 16 pole, not shielded, 0.55 m X13, X113 Voltage measurement, single core, 6.3 mm faston on one end, U1, V1, W1, C1 and D1 Current measurement, twisted pair, system plug on one end, X23, X25 Plastic fiber optic single cable with plugs 5 m Plastic fiber optic single cable with plugs 10 m Plastic fiber optic single cable with plugs 15 m Plastic fiber optic single cable with plugs 20 m Plastic fiber optic single cable with plugs 30 m Forward firing pulse cables, twisted pair, system plug on one end, 1 m V11 - V16 Reverse firing pulse cables, twisted pair, system plug on one end, 1 m V21 - V26

ID code 3ADT693564P0001 3ADT693558P0001 DCA0020441P0001 DCA0020450P0001 3ADT693324R0004 3ADT693324R0006 3ADT693324R0007 3ADT693324R0008 3ADT693324R0009 3ADT693662R0001 3ADT693662R0002

The options available for the Optical Rebuild Kits are identical to the ones for the DCS800 converter modules. They can be ordered by means of ID codes. All applications, which can be done with a DCS800, are available after a rebuilt. For engineering support refer to the DCS800 Manuals. This manual focuses on items related to the engineering of the Optical Rebuild Kits.

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Galvanic isolation Usually the DC- and AC-voltage is measured via high ohmic resistors with a scaling of 1 Mohm per 100 V. Galvanic isolation is used to isolate the DC- and AC- high resistance voltage measurement circuits of the converter modules from high DC- and AC-voltages. It is typically used when either the supply voltage (phase to phase) or the motor voltage is greater than 690 V. Only the DC- and AC- high resistance voltage measurement circuits have to be galvanically isolated, because the current measurement is already isolated via current transformers (CTs). To isolate the AC-voltage measurement a special isolation AC transformer for all three phases is needed. The DC-voltage measurement is isolated by means of a DC transducer. To complete the galvanic isolation of the voltage measurement circuit a modified SDCS-PIN-5x-1190 board is needed. The transformer, the DC-DC transducer and the modified SDCS-PIN-5x-1190 are provided by ABB. Part SDCS-PIN-5x-1190 3-phase AC transformer for supply voltages up to 1,200 VAC Single-phase AC transformer for supply voltages up to 4,000 VAC DC transducer P42000D3 for motor voltages up to UMotN = 1,200 VDC* DC transducer P42001D3 for motor voltages up to UMotN = 1,600 VDC* DC transducer P42100D3 for motor voltages up to UMotN = 2,600 VDC* *max. supply voltage (phase to phase) is 1.35 * UMotN

ID code 3ADT780007R0002 3ADT745047P0001 3ADT745054P0001 3ADN260008P0001 3ADV050096P0007 3ADV050096P0021

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Optical Rebuild Kits overview

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Hardware This chapter gives information about all the components and boards being used in the Optical Rebuild Kits. Components which are used in DCS800 standard converters are simply mentioned within this chapter, but not described in detail. It will be described here if those components need special handling. For better and easy engineering environmental conditions, dimensions and additional hints are listed in this chapter too. All other components which may come or have been ordered together with the Optical Rebuild Kits are described in detail within the DCS800 Manuals.

Basic components All Optical Rebuild Kits can be ordered according to chapter Basic Selection via ID code. The delivery can be subdivided into several parts: − The electronic housing (DCS800-R00-0000-00) is pre-assembled − The electronic boards SDCS-PIN-51, SDCS-REB-11 and SDCS-PIN-Rxx, all mounted on card holders, as loose parts − The cables to interconnect the electronic boards and control the existing thyristors, as loose parts or supplied by the customer − The ordered options, either built-in (plus code) or as loose parts (ID code)

Electronic housing (DCS800-R00-0000-00)

The electronic housing is pre-assembled and consists of: − The electronic housing, see figure above − DCS Control Panel, see figure above − Control board SDCS-CON-4 (including interconnecting flat cables) − Drive-to-drive interface board SDCS-DSL-4 − Power supply SDCS-POW-4, needs a single phase auxiliary voltage of 115 VAC or 230 VAC − Flat cable interconnection board SDCS-CCB4 − As stated at the end of chapter Basic Selection it is possible to order options using a plus code.

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Weight: 7 kg

 4.2

90

100

Such options are usually used together with the SDCS-CON-4. They will be plugged into their correct place during production and therefore will come within the housing. Since the electronic housing is equipped with the components mentioned before, no cooling fan is needed. Nevertheless 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 upright - see figure above - so that the convection is not blocked.

20 43.5

225

270

40

80

264

M6

screen clamp for flat cable X12: for flat cable X13:

MG_800_001_ext_a.dsf

f. M6

307

370.5 350 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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34.8 198

Hardware

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Loose parts The Optical Rebuild Kits are available in 2-Q or 4-Q depending on the usage of the SDCS-REB-11. Both of them are available for power parts with up to 12 thyristors per valve (serial / parallel). Due to the versatility of the Optical Rebuild Kit the ordering has to be done using ID codes. Some components will be part of the delivery in every case like the DCS800-R00-0000-00 and the SDCSPIN-51 all others depend on the configuration. The following table shows examples for a B6 configuration:

2-Q

4-Q

1 - 4 thyristors per valve 1 DCS800-R00-0000-00 1 SDCS-PIN-51 1 SDCS-REB-11 1*6 SDCS-PIN-Rxx or 2*6 SDCS-PIN-Rxx or 3*6 SDCS-PIN-Rxx or 4*6 SDCS-PIN-Rxx 1 DCS800-R00-0000-00 1 SDCS-PIN-51 2 SDCS-REB-11 1*12 SDCS-PIN-Rxx or 2*12 SDCS-PIN-Rxx or 3*12 SDCS-PIN-Rxx or 4*12 SDCS-PIN-Rxx

5 - 8 thyristors per valve 1 DCS800-R00-0000-00 1 SDCS-PIN-51 2 SDCS-REB-11 5*6 SDCS-PIN-Rxx or 6*6 SDCS-PIN-Rxx or 7*6 SDCS-PIN-Rxx or 8*6 SDCS-PIN-Rxx 1 DCS800-R00-0000-00 1 SDCS-PIN-51 4 SDCS-REB-11 5 *12 SDCS-PIN-Rxx or 6 *12 SDCS-PIN-Rxx or 7 *12 SDCS-PIN-Rxx or 8 *12 SDCS-PIN-Rxx

9 - 12 thyristors per valve 1 DCS800-R00-0000-00 1 SDCS-PIN-51 3 SDCS-REB-11 9*6 SDCS-PIN-Rxx or 10*6 SDCS-PIN-Rxx or 11*6 SDCS-PIN-Rxx or 12*6 SDCS-PIN-Rxx 1 DCS800-R00-0000-00 1 SDCS-PIN-51 6 SDCS-REB-11 9*12 SDCS-PIN-Rxx or 10*12 SDCS-PIN-Rxx or 11*12 SDCS-PIN-Rxx or 12*12SDCS-PIN-Rxx

This is different for M3, double M3 and M6 configurations. The parts serve different purposes: − DCS800-R00-0000-00 The electronic housing contains the control board SDCS-CON-4 and the power supply SDCSPOW-4 - see also chapter Electronic housing. Note: The 230 VAC cables have to be supplied by the customer - see Cable overview. − SDCS-PIN-51 The measuring board is mounted on a card holder. A pluggable resistor for X22 is included. For the interconnections 5 cables for the AC- and DC voltage measurement (single core, 6.3 mm faston on one end), 2 cables for the current measurement via CTs (twisted pair; system plug on one end) have to be ordered separately via ID code. For cable lengths, please refer to chapter Interfacing the Electronics and Thyristors. − SEDS-REB-11 The pulse conversion board for up to 4 thyristors per valve (serial / parallel) is mounted on a card holder for fast installation on 35 mm conventional rails or DIN rails . The flat cables for interconnections (16-pole) have to be ordered separately via ID code. For cable lengths, please refer to chapter Interfacing the Electronics and Thyristors. − SDCS-PIN-Rxx: The gate driver board for one single thyristor is mounted on a card holder for fast installation on 35 mm conventional rails or DIN rails . The fiber optic cable for the interconnections (plastic fiber optic single cable with plugs) and the firing pulse cable (twisted pair, system plug on one end) have to be ordered separately via ID code. For cable lengths, please refer to chapter Interfacing the Electronics and Thyristors.

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Note: The 230 VAC cables and the cable from the thyristors anode to X3 (6.3 mm faston) on the SDCSPIN-Rxx have to be supplied by the customer - see Cable overview.

Optional parts The options available differ in their usage. Some of them are related to the Optical Rebuild Kit, some to the drive itself or to the application the drive is used for: − Fex-425-Int (plus code +S164): The FEX-425-Int is build into the electronic housing, when ordered via plus code. It can be connected to a single-phase or 3-phase supply with up to 500VAC. Field current ratings: Single-phase supply: up to 16 A field current 3-phase supply: up to 25 A field current − Subassembly SDCS-IOB-2x/IOB-3: This subassembly is a part of the DCS800 converter module options. In case the standard inputs or outputs of the SDCS-CON-4 do not fit to the application, 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 Optical Rebuild Kit overview.

Dimensions See chapter Electronic housing.

Environmental conditions For environmental conditions, please see the manual DCS800 Selection, Installation and Start-Up Manual for Rebuild Kits.

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Measurement board SDCS-PIN-51

10

This board is always required using the Optical Rebuild Kits. Usually one SDCS-PIN-51 is used per Optical Rebuild Kit. The SDCS-PIN-51 supports following functions:  Connection to the controller board SDCS-CON-4  Connection to the pulse conversion board / boards SDCS-REB-11  Interface for the heat sink temperature measurement with a PTC  Measurement and scaling of AC and DC voltage via high resistance resistors  Measurement and scaling of the armature current SDCS-PIN-51 mounted on a card holder:

80

Card holder for SDCS-PIN-51

10

5

8

331

~ 60

347

W5

PTC

W2

W1

S3

80

W1 C1

Isolating supports

W21

D1 4.8

W9 W16

W20

W26

W8 W15

W19

W25

W7

W6

W14

W13

W18

W24

R1

1 X25 2

.......

R21 R22

W80 W81 W82

X12S X413S W83 X13S X313S

R26

W17

W23

W22

S2 S1

SDCS-PIN-51 305

5 10

W12

X24 2

1

W10 W70 W71 W72

X13

W11

X12

V1

1 X23 2 X22 X122 4 3 Two PTC 1 2 One PTC

100

W3

X313

W4

X413

W5

121.5

X213

U1

line potential !

X113

168.5

Conductive supports

see diagram power part

X513

R123

182.5

100.7

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Wiring EXISTING PART X12:

SDCS-PIN-51 a

A

b

B

*

a

A

b

B * Fuse data 1A, suitable voltage

* * * * X22: X22: X122: X122:

SS_800_001_rebuild_a.dsf

− 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 figure above − Make sure, that the CTs are mounted and wired properly, see figure above

Fastening The SDCS-PIN-51 is mounted on a card holder, which got six M4 mounting holes. Using this card holder care must be taken to have a good connection to ground.

PTC temperature sensor If there is no temperature sensor in the power part a separate resistor (2.21 kOhm; 0.5 W; 1 % is included) must be connected between terminals X22:1 and X22:3 of the SDCS-PIN-51. Set jumper S3 to position 1-2. Thus the temperature measurement reads a fixed value and is disabled.

Type coding The type coding is done via parameters in the firmware, thus all jumpers W70 to W72 and W80 to W83 and W10 should be kept uncut (default condition). In case a modified board is used, with the above listed jumpers cut, nothing needs to be done. The board can be used without further modification. Just leave the jumpers as they are. They will not be read by the converter’s firmware and therefore not taken into consideration.

Voltage coding Use the settings given by the table below. Depending on the supply voltage of power part the jumpers need to be removed accordingly (supply voltages under 200 VAC on request). Note: For power parts connected to high supply voltages the option Galvanic isolation should be taken into consideration because of personal and functional safety reasons.

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Voltage applied to the power stack Value for S ConvScaleVolt (97.03) W1, 6, 12, 17, 22 W2, 7, 13, 18, 23 W3, 8, 14, 19, 24 W4, 9, 15, 20, 25 W5, 11, 16, 21, 26

appr. 200...500 V 501...600 V 601...700 V 701...800 V 801...990 V

500

600

690

800

1000

indicates a removed jumper

Current coding Ratio of the CTs is either 2,500:1 or 4,000:1 If the ratio of the CTs is either 2,500:1 or 4,000:1 (standard ABB CTs) use the table below to scale the nominal converter current IdN. Note: As long as the nominal converter current IdN is close to the currents listed in the table below and the ratio of the CTs is either 2,500:1 or 4,000:1 use this coding for current scaling. Remove the jumpers on the SDCS-PIN-51 board according to the selected nominal converter current IdN and set S ConvScaleCur (97.02) accordingly. 900

2500:1 1200 1500

2000 2500

3000 2600

3300

4000:1 4000 4800

5200

Zero current detection

Rated current scaling

Current transf. ratio Nominal current IdN [A] 18 Ω R1-R4 18 Ω R5 R6 18 Ω 18 Ω R7 18 Ω R8 18 Ω R9 18 Ω R10 18 Ω R11 18 Ω R12 18 Ω R13 18 Ω R14 18 Ω R15 18 Ω R16 33 Ω R17 68 Ω R18 120 Ω R19 270 Ω R20 560 Ω R21 R22 47 Ω R23 47 Ω R24 47 Ω 47 Ω R25 100 Ω R26

indicates a removed jumper

DCS800-R volt & curr coding.dsf

For all other configurations For all other configurations the burden resistor has to be calculated. The scaling is done by cutting resistors R1 to R21. Following definitions are important: − The nominal converter current IdN is equivalent to 1.5 V across the nominal current burden

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resistors (R1 to R21) − The current measurement is designed to handle peak currents Ipeak up to two times IdN (equivalent to 3 V) − The zero current detection is done automatically (no cutting required) Most often the nominal converter current IdN is the thermal current of the power part and the peak current Ipeak is the highest current running through the motor. In case the peak current Ipeak is higher than two-times IdN the nominal converter current needs to be redefined. As new nominal current of the Optical Rebuild Kit IdNDCR has to be used. For IdNDCR is valid:

I dnDCR = 0.5 • I peak Calculate the needed total burden resistance Rbr:

Rbr = roct •

1.5V I dN

with:

IdN = nominal converter current roct = ratio of CT (e.g. 2,500:1)

Calculate the resistors which will remain within R1 to R21 according to the following formula. The resulting resistance should be as close as possible to the above calculated burden resistance Rbr:

1 1 1 1 1 = + + + ... + Rbr R1 R2 R3 R21 All resistors not used in this formula have to be cut. For values of resistors R1 to R21 click here. The minimum available value for Rbr is: 1.06 ohm.

Firmware adaption The following settings have to be done by firmware parameters: Converter Type code Nominal current Nominal voltage Power part temperature 2-Q or 4-Q mode

Parameter TypeCode (97.01) S ConvScaleCur (97.02) S ConvScaleVolt (97.03) S MaxBrdgTemp (97.04) S BlockBridge2 (97.07)

Settings None xxxx A xxxx V xxxx°C BlockBridge2 RelBridge2

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Remarks as coded as coded inactive when set to 150°C 2-Q power part 4-Q power part

29

Pulse conversion board SDCS-REB-11 This board is always required using the Optical Rebuild Kits. Up to 6 SDCS-REB-11 can be used per Optical Rebuild Kit. The SDCS-REB-11 supports following functions: − Connection to the controller board SDCS-CON-4 − Connection to the measurement board SDCS-PIN-51 − Defining if used for forward or reverse bridge − Setting of the optical power between 20 mA and 40 mA − Providing connections for the measurement of the firing pulses via oscilloscope − Quadruplicate the electrical firing pulses and converting them into optical firing pulses − Connection to the gate driver boards SDCS-PIN-Rxx via fiber optic cables SDCS-REB-11 mounted on a card holder using an UM 72-profile:

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Wiring − The firing pulses coming from X13 of the SDCS-CON-4 and connected to X13 of the SDCSREB-11. Then the firing pulses are transferred from X113 to either X13 of the next SDCS-REB11 or to X13 of the SDCS-PIN-51. − The optical firing pulse cables can be connected from V1:A to V6:D

Fastening The SDCS-REB-11 is mounted on a card holder for fast installation on 35 mm conventional rails or DIN rails

.

Functionality At the input connector X13 firing pulses 1 to 6 are received including the forward / reverse bridge signals SR1 and SR2. Theses signal are routed directly to X113 and can be connected for further use. The board quadruplicates the electrical firing pulses converts them into optical firing pulses and distributes them to fiber optic connectors V1:A to V6:D. Electrical characteristics of the SDCS-REB-11 − The SDCS-REB-11 is supplied from the SDCS-CON-4. The SDCS-CON-4 is able to support up to 3 SDCS-REB-11 boards in each direction (maximum 3 forward and maximum 3 reverse). Thus maximum 6 SDCS-REB-11 boards can be connected to one SDCS-CON-4. − Each SDCS-REB-11 provides up to 4 optical firing pulses per valve. Thus it is possible to control up to 12 thyristors per valve (serial / parallel). − Due to the nature of the fiber optic cables it is possible to have long distances, up to 30 m, between the drive’s electronics and the power part Switches − S1 to S6 define the optical current and thus the length of the fiber optic cable. Switch open provides 20 mA for a length of 5 - 10 m. Switch closed provides 40 mA for a length of 10 - 30 m. − S7 defines the used bridge. SR1 is the forward bridge and SR2 is the reverse bridge. − At XP it is possible to measure the firing pulses 1 to 6 including the forward / reverse bridge signals SR1 and SR2 via a scope

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Gate driver board SDCS-PIN-Rxx This board is always required using the Optical Rebuild Kits. Per thyristor one SDCS-PIN-Rxx is needed. The SDCS-PIN-Rxx supports following functions: − Connection to the gate driver boards SDCS-PIN-Rxx via fiber optic cables − Converting the optical firing pulse into an electrical firing pulse − Amplifying the electrical firing pulse and sending it to the thyristor − In case of a control electronics failure a forced firing of the thyristor via two BOD elements is provided. The voltage threshold over the thyristor depends on the used BOD elements. There are 3 versions of the SDCS-PI-Rxx: 1. SDCS-PIN-R00 without BOD elements 2. SDCS-PIN-R15 with two 1,500 V BOD elements in series. Thus the thyristor is fired at a peak voltage of 3,000 V. 3. SDCS-PIN-R22 with two 2,200 V BOD elements in series. Thus the thyristor is fired at a peak voltage of 4,400 V. SDCS-PIN-Rxx mounted on a card holder using an UM 72-profile:

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Wiring − The SDCS-PIN-Rxx is supplied by 230 VAC at X1:1. The supply voltage needs to be supervised (e.g. by a relay connected to a DI on the SDCS-CON-4 and external fault) - see also Optical Rebuild Kit overview. − The optical firing pulse is coming from the SDCS-REB-11 and connected to U100 of the SDCSPIN-Rxx − The thyristor is connected to X3 (Anode), X4 (Gate) and X5 (Cathode). The cable length should be less than 1 m. Use 6.3 mm faston plugs. Run a twisted pair cable for X4 / X5 to the thyristor and route the cable connected at X5 next to it. Note: Keep the cables isolation strength in mind. The SDCS-PIN-Rxx can be used for supply voltages (phase to phase) up to 2,500 VAC!

Fastening The SDCS-PIN-Rxx is mounted on a card holder for fast installation on 35 mm conventional rails or DIN rails

.

Functionality The gate driver board SDCS-PIN-Rxx is used to fire one single thyristor. The optical firing pulse is received at the fiber optic connector U100 and indicated by the LED. The board converts the optical firing pulse into an electrical firing pulse and amplifies it. The firing pulse is send to the thyristor via connectors X3 to X5. Electrical characteristics of the SDCS-PIN-Rxx: − The SDCS-PIN-Rxx is supplied by 230 VAC, ± 10 %, 50 Hz / 60 Hz. Connector X1 provides two additional terminals to easily daisy chain the supply voltage for up to 24 boards in series. The maximum current consumption is 50 mA per board. − The SDCS-PIN-Rxx amplifies the firing pulse and provides an insulation voltage of 2,500 VAC

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Interfacing the Electronics and Thyristors General There is basically only one possibility to connect the firing pulses from the control electronic to the interface boards and then to the thyristors. The assignment of power part, mains connection and wiring to the SDCS-PIN-51 is fixed. The SDCS-CON-4 uses this assignment as the basis for generating the firing pulse sequence. With an existing power part, we recommend to follow our configuration when numbering the thyristors to avoid problems. The arrangement of the thyristors in an anti-parallel B6 bridge is shown in the figure below. Thyristors for the forward bridge (SR1) are numbered V111, V112, ..., V116 and thyristors for the reverse bridge (SR2) are numbered V121, V122, ..., V126: C1 (+) V111

(L1) U1

A

B

a

b

V124

V113

V126

V115

V122

(L2) V1

A

B

a

b

(L3) W1

V114

V121

V116

V123

V112

V125

(-) D1 SS_800_002_u-i-meas_a.dsf

I actual

U AC actual

U DC actual

to SDCS-PIN-51

Note: In a 2-Q converter only the forward bridge is used.

Designation of thyristors In a power part with parallel / serial thyristors every thyristor is assigned a 3 digit number Vxyz: − x = parallel / serial numbers of thyristors (e.g. 3 with 3 parallel thyristors) − y = 1 forward bridge, y = 2 reverse bridge − z = normal firing sequence number

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Forward bridge (2-Q) with single thyristors The SDCS-REB-11, set to forward bridge, is connected to the 6 SDCS-PIN-Rxx for the thyristors.

Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Forward and reverse bridge (4-Q) with single thyristors One SDCS-REB-11, set to forward bridge, is connected to the 6 SDCS-PIN-Rxx for the forward thyristors. The other SDCS-REB-11, set to reverse bridge, is connected to the 6 SDCS-PIN-Rxx for the reverse thyristors.

Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Forward bridge (2-Q) with 3 serial / parallel thyristors One SDCS-REB-11, set to forward bridge, is connected to the 18 SDCS-PIN-Rxx for the forward thyristors.

Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Forward and reverse bridge (4-Q) with 3 serial / parallel thyristors One SDCS-REB-11, set to forward bridge, is connected to the 18 SDCS-PIN-Rxx for the forward thyristors. The other SDCS-REB-11, set to reverse bridge, is connected to the 18 SDCS-PIN-Rxx for the reverse thyristors.

Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Forward and reverse bridge (4-Q) with 12 serial / parallel thyristors Maximum 3 SDCS-REB-11, set to forward bridge, are connected to the 6 * 12 SDCS-PIN-Rxx for the forward thyristors. The other maximum 3 SDCS-REB-11, set to reverse bridge, are connected to the 6 * 1 SDCS-PIN-Rxx for the reverse thyristors.

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Interfacing the Electronics and Thyristors 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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Installation General The information given within this chapter shall help the installation personnel to select a place for the different components of the Optical Rebuild Kit, to mount them and do the interconnections between the boards and the existing hardware.

Hints for mounting The installation of the kit can be subdivided into 2 parts: − Part 1 is the electronic housing (DCS800-R00-0000-00) with the electronic power supply SDCSPOW-4 and the control board SDCS-CON-4. All options which can be connected to the SDCSCON-4 are left out for easier reading. They are listed in chapter the Optical Rebuild Kits overview. The detailed description of these options is in the DCS800 Hardware Manual. All components belonging to the first and second part should be mounted close to each other in the existing drive cabinet. − Part 2 covers the SDCS-PIN-51 and the SDCS-REB-11 boards. The amount of SDCS-REB-11 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. All components belonging to the first and second part should be mounted close to each other in the existing drive cabinet. − Part 3 consists of the SDCS-PIN-Rxx boards, which have to be mounted as close as possible to their thyristor

Hints for cabling The cables / parts have to be ordered by ID code. The next table lists all cables / parts. Together with the figure below it is possible to identify the proper cable / part for all connections. Name Cable / Part A Resistor (2.21 kohm; 0.5 W; 1 %), part of ID code B Flat cable, 16 pole, not shielded, 0.55 m, X12 Flat cable, 16 pole, not shielded, 0.55 m, X13, X113 C Voltage measurement, single core, 6.3 mm faston on one end, U1, V1, W1, C1 and D1 D Current measurement, twisted pair, system plug on one end, X23, X25 E Plastic fiber optic single cable with plugs 5 m Plastic fiber optic single cable with plugs 10 m Plastic fiber optic single cable with plugs 15 m Plastic fiber optic single cable with plugs 20 m Plastic fiber optic single cable with plugs 30 m F Forward firing pulse cables, twisted pair, system plug on one end, 1 m, V11 - V16 Reverse firing pulse cables, twisted pair, system plug on one end, 1 m, V21 - V26 G Cable for 230 VAC H Firing pulses, single core, 6.3 mm faston on one end, e.g. cable type: AWG20, UL10203, 2

Installation 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

ID code 3ADT783025R0022 3ADT693564P0001 3ADT693558P0001 DCA0020441P0001 DCA0020450P0001 3ADT693324R0004 3ADT693324R0006 3ADT693324R0007 3ADT693324R0008 3ADT693324R0009 3ADT693662R0001 3ADT693662R0002 by customer by customer

45

Cables overview

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Start-up General This chapter describes the commissioning procedure for an Optical Rebuild Kit. This is done based on the procedure used for DCS800 converter modules. Only the actions and steps, which are different, are listed here.

Safety Instructions The Optical 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 drive cabinet. Thus the danger installation and commissioning personal is exposed to during the work is similar, sometimes even higher than for ready made converter modules. There is some work, which will only become necessary together with an Optical Rebuild Kit. Because of that the Safety Instructions at the beginning of this manual have 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 this procedure as a general guideline and be prepared to take individual decisions concerning safety and security.

Points to be observed because of the situation All relevant safety regulations must be observed during installation, commissioning and maintenance work, since it is possible to touch the main and auxiliary connections and other electrical parts without any protection during installation of the Optical Rebuild Kit. After the supply voltage is disconnected by means of the main switch, make sure by measuring that no part of the system has either voltage or the system is protected with sufficient protection against touch before any work is started. Be aware of live terminals inside the drive cabinet even after the supply voltage has been disconnected by the main switch, e.g. incoming busbars before the main switch itself or external auxiliary power supplies. Avoid unnecessary voltage withstand tests on any part of the unit. General Hint: In addition to the work specifics for the installation of the Optical Rebuild Kits attention should be paid to features related to drives in general. There is the engineering and the interface to other components in general, the selection of control cables their routing, 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 System. 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 an Optical Rebuild kit. Nevertheless using some of the ideas will make the complete system safer.

Tools Following software tools are mandatory: − DriveWindow Light including commissioning wizard and DWL AP for Adaptive Program − DriveWindow for fast drive monitoring using SDCS-COM-8 Following tools are mandatory in addition to standard tools: − A scope including memory function with either galvanically isolating transformer or isolating

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amplifier (probe) for safe measurements. It can also be a hand held (portable) oscilloscope. − A clamp on current probe. An AC type is sufficient for gate firing pulse measurements. In case the scaling of the DC load current needs to be checked, a DC type is needed. − A voltmeter (at least CAT III 1000 V):

− 3,000 V probes and test leads:

− An ESD-field service kit (ABB Service Finland code 0001ESD / MS-Antistatic):

Attention: Make sure, all equipment in use is suitable for the voltage level applied to the power part!

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. Record the actual signals of: − Speed − Armature and field current − Line, armature and field voltage − Other application related signals Record line and armature voltage to determine their names on the single line and confirm the positive and negative DC - terminals. 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 per valve record the firing pulse and the thyristor current of each thyristor to be sure, all of them are conducting.

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Mounting the Optical Rebuild 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 Interfacing the Electronics and Thyristors show all the components needed for the different configurations possible. Use the one which fits the best to the actual power part, depending on the number of thyristors per valve and the configuration. Mounting the parts of the Optical Rebuild Kit can be subdivided into 3 steps: − Select a place for the electronic housing (DCS800-R00-0000-00) and mount it. Be aware of the cable lengths between SDCS-CON-4, SDCS-REB-11 board(s), SDCSPIN-51, CTs and voltage measurement (AC and DC voltage). − Select a place for the SDCS-REB-11 board(s), the SDCS-PIN-51 and mount them. Be aware of the cable lengths between SDCS-CON-4, SDCS-REB-11 board(s), SDCS-PIN-51, CTs and voltage measurement (AC and DC voltage). All components have to be mounted on the same metal plate to ensure good contact between conductive supports / card holders and the drives cabinet. Make sure, that the metal plate has good contact with the drives cabinet and that the drives cabinet is grounded as well. − Select a place for all SDCS-PIN-Rxx boards as close as possible beside their thyristor

Wiring the Optical Rebuild Kit The system still has to be in a safe condition! The figures within chapter Interfacing the Electronics and Thyristors used for the mechanical work should now be used for the electrical wiring too. Take the hints given in chapter Interfacing the Electronics and Thyristors into consideration especially the part about the Designation of thyristors. Before the wiring work is started, check for labels on the existing power part naming the thyristors and phases according to figure Arrangement of thyristors in an anti-parallel bridge. In case of existing labels check, if they are correct and fit to each other. If there are no or incorrect labels do the following: − Search phase U1 (L1) and mark it. Do the same for V1 (L2) and W1 (L3) − Search thyristor V11 and mark it. If this turns out to be difficult do this: 1. Follow the busbar U1. The thyristor connected to that busbar is either V11 or V24. 2. The cathode of V11 (or the heatsink) has electrical contact to the C1(+) of the power part 3. The disk type thyristors orientation can easily be recognized by the shorter distance between cathode and gate compared to the longer distance between gate and anode 4. In case the location of V11/V24 is found, but the orientation is not clear or the thyristor is not visible take both firing pulse leads (one of them is connected to the cathode) and check both for electrical contact to C1(+) of the power part using an ohm-meter − Search the other thyristors and mark them accordingly − Parallel connected thyristors or thyristor bridges have to be marked as well Following cable connections have to be made: − All I/O connections of SDCS-CON-4 and SDCS-POW-4, including power part monitoring (e.g. klixon, fan monitoring) − The auxiliary voltage for the SDCS-POW-4 Start-up 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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− All flat cable connections between SDCS-CON-4, SDCS-REB-11 board(s) and SDCS-PIN-51 − Voltage-, current- and temperature measurement of the SDCS-PIN-51 − The auxiliary voltage for all SDCS-PIN-Rxx boards − The fiber optic cables between SDCS-REB-11 and all SDCS-PIN-Rxx boards Attention: Do not connect any of the firing pulse cables between the SDCS-PIN-Rxx and their thyristors! This will be done during the commissioning of the Optical Rebuild Kit.

Commissioning the Optical Rebuild Kit The commissioning of a DC drive equipped with an Optical Rebuild Kit is based on the manuals used for a standard DCS800 converter module. Please refer to the DCS800 Manuals. Some additional steps are needed and are shown below. Start with the commissioning steps used for standard DCS800 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 the parameters in group 97 according to table Firmware adaption 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 wiring or unknown data. − Check for proper routing of the firing pulses for each valve (including all thyristors) using parameter TestFire (97.28) - see DCS800 Firmware Manual and the LED on the SDCS-PIN-Rxx boards − After all valves have been checked connect the gate leads to valves V11, V13 and V15 − Before the drive is released the first time, set ArmAlphaMin (20.15) = 150°. 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 a turning motor (disable the field current and lock the motor), if the drive will be released. − Give an On command and make sure, no Run command is given. This causes the pulse firing logic to work and to generate single firing pulses: 1. Now no current should flow. Check with a scope connected to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3). 2. Check the firing pulses using a current probe 3. Make sure, that ArmAlpha (3.13) = 150° − Remove the On command − Connect the gate leads to valves V14, V16 and V12 − Give an On command and make sure, no Run command is given. This causes the pulse firing logic to work and to generate single firing pulses: 1. Now no current should flow. Check with a scope connected to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3). 2. Check the firing pulses using a current probe 3. Make sure, that ArmAlpha (3.13) = 150° − If everything is fine, give a Run command − Give a small current reference using CurSel 43.02 and CurRefExt (43.03). If the current follows the current reference, everything is fine - see MotCur (1.06). Check

Start-up 3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

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for the proper amount of current pulses with a scope connected to the fixed AO I-act (X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3):

− − − − −

Depending on the setting of ArmAlphaMin (20.15) there might be no current at all or only a very small one. In this case lower ArmAlphaMin (20.15) step by step until a value around 100° is reached. Remove the Run and On command In case of problems check the wiring to the CTs, the routing of the fiber optic cables and the gate leads for open loops or wrong connections In case everything is fine and the power part consists of a reverse bridge repeat the procedure used for the forward bridge. Keep the value of ArmAlphaMin (20.15) and check for correct connections. If current is flowing in forward and reverse direction in a controlled manner set ArmAlphaMin (20.15) back to default Continue the commissioning by using the wizard in DWL

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3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

Ident. No.: 3ADW000415R0101 Rev A 04.2012

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