Sd_5b_e_i1.PMD DCS500 3ADW000066R0901 System Description E I
User Manual: DCS500
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DCS 500 Thyristor Power Converter for DC drive systems 25 to 5200 A 6 to 5000 kW System Description DCS 500B / DCF 500B Hints for printing: A4-format from page 1...56 (System description + Software structure diagrams A4) A3-format from page 57...60 (Software structure diagrams) A1-format page 61 (Software structure overview) These hints will not be printed! 3ADW000066R0901_DCS500_System_description_e_i Latest Technology, High Performance and a User Friendly Concept The DCS 500 series is a complete range of DC converters with high performance and reliability intended for the supply and control of DC machine armatures. DCA 500 is a DCS 500 converter module mounted in a converter enclosure called "Common Cabinet" ( see separate documentation). DCF 500 is a DCS 500 module modified in a way to supply other consumers than armature circuits of DC machines ( e.g. inductive loads like motor field windings, magnets etc.). For revamp projects ABB has created a special "Rebuild Kit" called DCR 500 to polish up your old DC power stack with a new modern digital front end (see separate documentation). TOOLS • Effort, time and cost will be saved with the userfriendly CMT-Tool (Commissioning and Maintenance Tool) for drive programming, commissioning, monitoring and maintenance. A selection of options is available to provide the user with a system meeting the most demanding technical requirements and performance expectations as well as many safety standards. Common control electronics throughout the whole range reduce spare parts, inventory and training. Wide Variety of Industrial Applications The DCS, DCA, DCF and DCR converters can handle most demanding applications like: • Metals • Pulp & Paper • Material handling • Test Rigs • Food & Beverage • Printing • Plastic & Rubber • Oil Rigs • Vessels • Ski lifts • Magnets • MG Sets • Electrolysis • Battery Chargers • and more • Data Logger • Trending • Fault Logger • Parameter/Signals • Local operation • GAD Tool (Graphical Application Designer) contains an extensive library of standard function blocks for the creation of customized software solutions creating conveniently the documentation during programming. Both, CMT and GAD, represent a powerful set for each design, commissioning and service engineer to achieve best results and performance. II D 1-2 3ADW000066R0901_DCS500_System_description_e_i 1 DCS 500 - a State-of-the-art technology ❖ flexible design ❖ user-friendliness DCS 500 is a freely programmable drive to meet almost every application. Templates like Master-Follower, Winder etc. can be obtained. The DCS 500 constitutes a complete program for ratings between 25 A and 5200 A as a power converter module (for 12-pulse parallel connection, up to approx. 10,000 A), suitable for all commonly used threephase systems. All our products are CE marked. DIN EN ISO 9001 DIN EN ISO 14001 The DC drives factory of ABB Automation Products, Drives Division in Lampertheim has implemented and maintains a quality management system according to DIN EN ISO 9001 and an environmental management system according to DIN EN ISO 14001. DCS 500 Drives are also approved according to UL (Underwriters Laboratory). They also comply with the relevant EMC standards for Australia and New Zealand and are C-Tick marked. 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. Basic hardware complements ❋ Thyristor bridge(s) (from size A5 with leg fuses installed) ❋ Temperature monitor for the thyristor bridge(s) ❋ Fan ❋ Power supply for the electronics ❋ Microprocessor board Additional components for integration in the module ❋ Field power converter – uncontrolled full wave diode bridge, 6A or – half-controlled diode/thyristor bridge, 16A ❋ Communication board ❋ Control panel Moreover, the accessories listed below can be used to individually customize the drive package in accordance with the application intended ❋ External field supply units ❋ Additional I/O boards ❋ Interface modules for various communication protocol ❋ EMC filter(s) ❋ Application software packages ❋ PC programs The drive system functionality can be integrated with various fieldbus control systems from simple to factorywide control. Unit range The range comprises of 5 sizes, C1, C2, A5, A6 and A7. We can deliver both modules and standard cubicles. C1 - Module DCA cubicle II D 1-3 3ADW000066R0901_DCS500_System_description_e_i List of contents II D SYSTEM DESCRIPTION 1 DCS 500 - a State-of-the-art technology .... II D 1-3 2 DCS 500 components overview ................. II D 2-1 Environmental conditions ............................................. II D 2-4 DCS 500 Power Converter Modules ............................ II D 2-5 DCS 500B overload capability ..................................... II D 2-8 Field Supply ............................................................... II D 2-10 Options for DCS 500B / DCF 500B converter mod. .. II D 2-12 Inputs/Outputs ........................................................... II D 2-12 Panel (control and display panel) ............................. II D 2-15 Serial interface for operation by PC ................................................... II D 2-16 for drive control ......................................................... II D 2-16 2.6 Options for the drive ................................................... II D 2-18 Line reactors for armature and field supply .............. II D 2-18 Aspects of fusing for armature-circuit and field supplies of DC drives ............................................. ...II D 2-20 Semiconductor type F1 fuses and fuse holders for AC and DC power lines ............................................ II D 2-22 Fuses F3.x and fuse holders for 2-phase field supplyII D 2-22 Transformer T3 for field supply ................................. II D 2-22 Auxiliary transformer T2 for electronic system / fan supply .................................................................. II D 2-23 Commutating reactor ................................................ II D 2-23 Residual current detection ........................................ II D 2-23 EMC filter .................................................................. II D 2-24 2.1 2.2 2.3 2.4 2.5 3 How to engineer your drive ........................ II D 3-1 3.1 Standard drive configuration using an internal field .... II D 3-3 3.2 Drive configuration using the internal field with reduced external components ..................................... II D 3-5 3.3 Standard drive configuration using an external half-controlled field (1-ph) ............................................ II D 3-6 3.4 Standard configuration using a fully-controlled field (3-ph) without armature converter ....................... II D 3-7 3.5 Typical configuration for high power drives ................. II D 3-8 3.6 Typical configuration for high power drives connected in 12-pulse parallel Master-Follower application ....... II D 3-10 4 Overview of Software (Vers. 21.2xx) ......... II D 4-1 4.1 GAD Engineering Program .......................................... II D 4-1 4.2 Introduction to the structure and handling .................... II D 4-2 Software structure diagrams including comments II D 1-4 3ADW000066R0901_DCS500_System_description_e_i 2 DCS 500B components overview Description of the converter Supplementary documentation The documentation in hand describes the functionality of DCS 500 converter 3ADW000066 units as well as the cooperation of all single components belonging to a comVolume III plete drive system. Technical Data 3ADW000165 As additional documentation is available: Volume IV D DCS 500 Technical Data giving inforOperating Instructions DCS 500B mation about all direct technical data 3ADW000055 for components used inside and outside the converter module. DCS 500 Operating Instructions including information and advise to commission the drive. If three phase DCF 500 field supply units are needed please use the same documents as for DCS 500 armature converters. Volume II D1 System Description DCA 500 / DCA 600 Volume II D System Description DCS 500B DCA 500 / DCA 600 Enclosed converters System description for standard cubicles equipped with DC drives. 3ADW000121 Volume V D2 Application Blocks DCS 500B For those, who want to reprogram or adapt the soft3ADW000048 ware of their drive a detailed 3ADW000078 comprehensive description of the software structure of the drive as well as of all available function blocs can be delivered. Volume V D1 SW Description DCS 500B A DCS 500 Service Manual is available for service engiVolume VI A neers. Service Manual DCS 500(B)/600 Engineering and design peo3ADW000093 ple for drive systems can get a separate collection of information with regard to installation, sizing, fusing etc. of DC drives called "Technical guide". Volume VII A Technical Guide DCS 3ADW000163 Scope of delivery The delivery consists of a converter module and some accessories. The document Quick Guide and a CD ROM with all the converter related documentation in different languages and screws to allow the wiring acc. to EMC are always included. For C1 and C2 converters a plug to connect the fan and screws to fix the power cables are added. Depending on the construction type screws for the power cables (A5), a key to open the door (all) and a tool to exchange thyristors will be delivered with the converter. additional parts C1, C2 additional parts A5, A6, A7 Drive configuration DO5 DO6 DO7 0V 3 4 5 6 7 8 FREE FREE ON/OFF DO4 RESET 2 Running Emergency Stop 3ADW000066R0901_DCS500_System_description_e_i DO3 FREE II D 2-1 1 Ready Running 6 DO2 5 Main contactor 4 DO1 DI6 3 Fan Contactor DI5 2 (DO8 on SDCS-POW-1) X7: Digital OUT Excitation contactor DI4 1 Main contactor +48 V 0V DI3 9 10 Motor Fan DI7 DI2 8 Converter Fan DI8 DI1 7 POWER OUT + 9 10 6 SENSE Power out + 3 8 5 0V 2 7 4 SENSE 0 V 8 CH Z - 7 CH B - 6 CH Z + 5 CH A - 4 CH B + 3 X6: Digital IN 0V CH A + AO1 AO2 IACT 0V Actual current -10V 1 0V 9 10 Actual armature voltage AO 2 X5: Encoder Actual speed AO 1 - 2 +10V AI4 1 + - + - 9 10 FREE AI 3 - AI3 8 + 7 Torque reference AI 2 6 Main speed reference AI 1 5 + AI2 4 8...30 V - 30...90 V - AI1 3 TACHO + 2 90...270 V - AITAC 1 X4: Analogue IN / OUT FREE AI 4 X6: Analogue IN In case you want to re-configure terminals by means of software, please read the software description first and inform yourself about the possibilities you have before you start. (Never change any terminal while your drive is still connected to the mains!). After that you need to make sure that the correct signals are provided to your terminals. RUN DCS 500 drives are freely programmable and therefore also terminals with their in and outs can be modified in their functionality. When you receive your converter all terminals from X3: to X7: are set to a default configuration as shown below. This enables you to connect your drive according to connection example (see chapter 3) without any changes. Armature converter components overview DCS 500B converter itself is used for the armature supply and a build-in or external field supply to control the field current. Legend FEX 2 L3 7.1 M M This overview has been designed to help you to familiarize yourself with the system; its main components are shown in the diagram above. The system’s heart is the DCS 500B power converter module. II D 2-2 3ADW000066R0901_DCS500_System_description_e_i 7 PS5311 2 5 3 8 DCS 500B Components overview Field bus to the PLC 8 IOB 2x optical fibre Nxxx-0x 8 4 7 3 +24 V optical fibre IOB 3 X16: X14: X17: X1: X2: µP CDP 312 X33: IOE 1 PIN 51 T T PIN 41 PIN 2x/20x PIR 21 X13: PIN 1x X12: POW 1 X37: CON 2 COM x DCS 50.B....-.1-21..... SNAT 6xx PC + CMT/DCS500 X11: T2 F2 ≤ 690V Fig. 2/1: PIN 41 L1 K1 F1 Q1 K5 Earth-fault monitor ≤ 1000V EMC filter * FEX 1 K3 T3 F3 DCF 503 / 504 - detailed description see chapter 7.1 to field Power supply Three-phase field supply DCF 501B / 502B COM x - short designation of components digital input / output analogue input / output alternative * see Technical Data The DCS 500B power converter together with the options or accessories is designed to control DC motors as well as other DC loads. In case of DC motors the Field converter components overview Legend 5 3 8 Field bus to the PLC 8 IOB 2x optical fibre Nxxx-0x 8 4 7 3 +24 V PS5311 2 IOE 1 IOB 3 X16: X17: X1: X2: µP CDP 312 X33: 7 to X16: DCS 500B (Armature converter) ied dif mo PIN 2x/20x PIR 21 PIN 1x X13: X12: POW 1 X37: CZD-0x CON 2 COM x DCF 50.B....-.1-21..... SNAT 6xx PC + DDC-Tool X11: T2 F2 ≤ 690V optical fibre Fig. 2/2: 7.1 M L1 K3 F1 Q1 K5 Earth-fault monitor ≤ 500V EMC filter to a digital input of DCF 500B DCF 506 - detailed description see chapter 7.1 converters differ in some boards, the options and the wiring (the option CZD-0x is not needed in every case; see manual Technical Data). COM x - short designation of components analogue input / output digital input / output alternative The hardware of a DCS 500B converter had been taken as a basis to get the DCF 500B converter which is used to control high inductive loads. Both converters use the same software. Looking on a complete system these two DCF 500B Components overview II D 2-3 3ADW000066R0901_DCS500_System_description_e_i 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 acc. to IEC 60038 ±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. Degree of protection Converter Module and options (line chokes, fuse holder, field supply unit, etc.): IP 00 Enclosed converters: IP 20/21/31/41 Paint finish Converter module: Enclosed converter: Environmental limit values Permissible cooling air temperature - at converter module air inlet: 0 to +55°C with rated DC current: 0 to +40°C w. different DC curr. acc. Fig. 2.1/2: +30 to +55°C - Options: 0 to +40°C Relative humidity (at 5...+40°C): 5 to 95%, no condensation Relative humidity (at 0...+5°C): 5 to 50%, no condensation Change of the ambient temp.: < 0.5°C / minute Storage temperature: -40 to +55°C Transport temperature: -40 to +70°C Pollution degree (IEC 60664-1, IEC 60439-1): 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 Size Sound pressure level LP Vibration (1 m distance) as module enclosed conv. as module C1 59 dBA 57 dBA 0.5 g, 5...55 Hz C2 75 dBA 77 dBA A5 73 dBA 78 dBA 1 mm, 2...9 Hz A6 75 dBA 73 dBA 0.3 g, 9...200 Hz A7 82 dBA 80 dBA NCS 170 4 Y015R light grey RAL 7035 Current reduction to (%) enclosed conv. g, 2...150 Hz g, 2...150 Hz g, 2...150 Hz g, 2...150 Hz g, 2...150 Hz Current reduction to (%) 110 100 90 100 80 90 70 80 60 50 1000 2000 3000 4000 Fig. 2.1/1: Effect of the site elevation above sea level on the converter’s load capacity. 70 5000 m 30 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. European Union Directive Manufacturer's Assurance Machinery Directive 98/37/EEC 93/68/EEC Low Voltage Directive 73/23/EEC 93/68/EEC EMC Directive 89/336/EEC 93/68/EEC Harmonized Standards Conver ter module Enclosed conver ter Declaration of Incor poration EN 60204-1 [IEC 60204-1] EN 60204-1 [IEC 60204-1] Declaration of Conformity EN 60146-1-1 [IEC 60146-1-1] EN 50178 [IEC --] see additional IEC 60664 EN 60204-1 [IEC 60204-1] EN 60439-1 [IEC 60439-1] EN 61800-3 ➀ [IEC 61800-3] EN 61800-3 ➀ [IEC 61800-3] ➀ in accordance with 3ADW 000 032 ➀ in accordance with 3ADW 000 032/ 3ADW 000 091 Declaration of Conformity (Provided that all installation instructions concerning cable selection, cabling and EMC filters or dedicated transformer are followed.) 35 40 45 50 55°C Fig. 2.1/2: Effect of the ambient temperature on the converter module load capacity. North American Standards In North America the system components fulfil the requirements of the table below. Rated supply voltage Standards Converter module Enclosed converter to 600 V UL 508 C Power Conversion Equipment CSA C 22.2 No. 14-95 Industrial Control Equipment, Industrial Products Available for converter modules including field exciter units. Types with UL mark: • see UL Listing www.ul.com / certificate no. E196914 • or on request UL/CSA types: on request > 600 V to 1000 V EN / IEC types: on request (for details see table on the left) II D 2-4 3ADW000066R0901_DCS500_System_description_e_i EN / IEC xxxxx see table on the left Available for converter modules including field exciter units. 2.2 DCS 500B 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 different sizes (C1a/b, C2a/b, A5, A6, A7), graduated in terms of current and voltage ranges. All units are fancooled. 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. The power section is controlled by the unit’s electronic system, which is identical for the entire range. Parts of the unit’s electronic system can be installed in the unit, Accessories such as external fuses, line reactors etc. are also available, to compose 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: • UVN = rated input terminal voltage, 3-phase • Voltage tolerance ±10 % • Internal voltage drop approx. 1% • 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. System connection voltage UVN 230 380 400 415 440 460 480 500 525 575 600 660 690 790 1000 1190 DC voltage (recommended) Udmax 2-Q Udmax 4-Q 265 440 465 480 510 530 555 580 610 670 700 765 800 915 1160 1380 Table 2.2/1: 240 395 415 430 455 480 500 520 545 600 625 685 720 820 1040 1235 Ideal DC voltage without load Udi0 Recommended DCS 500B Voltage class y= 310 510 540 560 590 620 640 670 700 770 810 890 930 1060 1350 1590 4 4 4 4 5 5 5 5 6 6 6 7 7 8 9 1 DCS 500B max. DC voltages achievable with a specified input voltage. If armature voltages higher than recommended are requested, please check carefully, wether your system is still working under safe conditions. Application Armature converter Max. permitted armature voltage depending on Field exciter type SDCS-FEX-1 SDCS-FEX-2A DCF 504A DCF 503A/504A DCF 501B Power always positive (Ua and Ia pos.). Extruder Power often or always negative. Unwinder, suspended load Power sporadically negative. Printing machine at electrical stop 2-Q Udmax 2-Q Udmax 2-Q DCF 502B - 2-Q Udmax 4-Q Udmax 4-Q Udmax 4-Q 2-Q - - Power positive or negative. Test rig Power positive, sporadically negative. 4-Q Udmax 4-Q Udmax 4-Q Udmax 2-Q + change software parameter - 4-Q Udmax 4-Q Udmax 2-Q + change software parameter - Table 2.2/2: Maximum permitted armature voltage II D 2-5 3ADW000066R0901_DCS500_System_description_e_i y→ Converter type x=1 → 2-Q IDC [A] x=2 → 4-Q y=4 (400 V) IAC [A] y=5 (500 V) P [kW] y=6 (600 V) P [kW] P [kW] 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q DCS50xB0025-y1 DCS50xB0050-y1 DCS50xB0050-61 DCS50xB0075-y1 DCS50xB0100-y1 DCS50xB0110-61 DCS50xB0140-y1 25 50 50 75 100 110 140 25 50 50 75 100 100 125 20 41 41 61 82 90 114 20 41 41 61 82 82 102 10 21 12 23 13 26 15 29 31 42 35 47 39 52 44 58 58 58 73 73 DCS50xB0200-y1 DCS50xB0250-y1 DCS50xB0270-61 DCS50xB0350-y1 DCS50xB0450-y1 DCS50xB0520-y1 DCS50xB0680-y1 DCS50xB0820-y1 DCS50xB1000-y1 200 250 270 350 450 520 680 820 1000 180 225 245 315 405 470 610 740 900 163 204 220 286 367 424 555 670 820 147 184 200 257 330 384 500 605 738 83 104 84 105 104 130 104 131 145 187 216 282 340 415 146 188 219 284 344 418 182 234 270 354 426 520 183 235 273 354 429 522 DCS50xB0903-y1 DCS50xB1203-y1 DCS50xB1503-y1 DCS50xB2003-y1 900 1200 1500 2000 900 1200 1500 2000 734 979 1224 1632 734 979 1224 1632 498 623 830 558 698 930 624 780 1040 696 870 1160 DCF50xB0025-y1 DCF50xB0050-y1 DCF50xB0075-y1 DCF50xB0100-y1 DCF50xB0200-y1 DCF50xB0350-y1 DCF50xB0450-y1 DCF50xB0520-y1 25 50 75 100 200 350 450 520 25 50 75 100 180 315 405 470 20 41 61 82 163 286 367 424 20 41 61 82 147 257 330 384 10 21 31 42 83 145 187 216 12 23 35 47 84 146 188 219 13 26 39 52 104 182 234 270 15 29 44 58 104 183 235 273 y=7 (690 V) P [kW] 4Q 2Q 4Q 2Q 31 35 69 70 169 172 281 284 563 630 648 720 938 1050 1400 1080 1200 1600 Table 2.2/3: Table of DCS 500B / DCF 500B units - construction types C1, C2, A5 y→ Converter type y=4 (400 V) y=5 (500 V) y=6 (600 V) y=7 (690 V) y=8 (790 V) y=9 (1000V) y=1 (1190V) IDC [A] IAC [A] 1900 2050 2500 3000 1550 1673 2040 2448 DCS501B2053-y1 DCS501B2603-y1 DCS501B3303-y1 DCS501B4003-y1 DCS501B4803-y1 DCS501B5203-y1 4-Q converters DCS502B1903-y1 DCS502B2053-y1 DCS502B2503-y1 DCS502B3003-y1 2050 2600 3300 4000 4800 5200 1673 2121 2693 3264 3917 4243 1900 2050 2500 3000 1550 1673 2040 2448 DCS502B2053-y1 DCS502B2603-y1 DCS502B3303-y1 DCS502B4003-y1 DCS502B4803-y1 DCS502B5203-y1 2050 2600 3300 4000 4800 5200 1673 2121 2693 3264 3917 4243 2-Q converters DCS501B1903-y1 DCS501B2053-y1 DCS501B2503-y1 DCS501B3003-y1 P [kW] P [kW] P [kW] P [kW] 1160 1395 1190 1450 1740 1430 1750 2090 1640 2000 2400 P [kW] P [kW] P [kW] ➀ 1740 1540 1870 1925 2330 2430 3030 1040 1250 1070 1300 1560 2310 2800 3360 2660 3220 3860 1280 1560 1880 1470 1800 2150 2300 2750 3040 3690 4420 2390 3030 3850 4670 on request on request on request 2390 3030 3440 4170 on request on request on request 1560 1375 1670 1720 2080 2170 2710 2060 2500 3000 2370 2875 3450 2060 2470 2720 3290 3950 ➀ These converters are equipped with additional components. More information on request Table 2.2/4: Table of DCS 500B units - construction type A6 / A7 Higher currents up to 15,000 A are achieved by paralleling converters - information on request. II D 2-6 3ADW000066R0901_DCS500_System_description_e_i Construction type C1 Construction type C2 Construction type A5 Construction type A6 Construction type A7 left busbar connection Converter type ➁ Dimensions HxWxD [mm] Weight DCS50xB0025-y1 DCS50xB0050-y1 DCS50xB0050-61 DCS50xB0075-y1 DCS50xB0100-y1 DCS50xB0110-61 DCS50xB0140-y1 420x273x195 420x273x195 420x273x195 420x273x195 469x273x228 469x273x228 469x273x228 7.1 7.2 7.6 7.6 11.5 11.5 11.5 150x100x5 150x100x5 150x100x5 150x100x5 250x150x5 250x150x5 250x150x5 C1a C1a C1a C1a C1b C1b C1b < 0.2 < 0.2 < 0.3 < 0.5 < 0.6 230 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 external external external external external external external DCS50xB0200-y1 DCS50xB0250-y1 DCS50xB0270-61 DCS50xB0350-y1 DCS50xB0450-y1 DCS50xB0520-y1 DCS50xB0680-y1 DCS50xB0820-y1 DCS50xB1000-y1 505x273x361 505x273x361 505x273x361 505x273x361 505x273x361 505x273x361 652x273x384 652x273x384 652x273x384 22.3 22.3 22.8 22.8 28.9 28.9 42 42 42 250x150x5 250x150x5 250x150x5 250x150x5 250x150x10 250x150x10 250x150x10 250x150x10 250x150x10 C2a C2a C2a C2a C2a C2a C2b C2b C2b < 0.8 < 1.0 < 1.3 < 1.5 < 1.8 < 1.6 < 2.0 < 2.5 230 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 external external external external external external external external external DCS50xB0903-y1 DCS50xB1203-y1 DCS50xB1503-y1 DCS50xB2003-y1 1050x510x410 1050x510x410 1050x510x410 1050x510x410 110 110 110 110 300x100x20 300x100x20 300x100x20 300x100x20 A5 A5 A5 A5 < 5.2 < 5.5 < 6.6 230 V/1-ph 230 V/1-ph 230 V/1-ph 230 V/1-ph internal internal internal internal DCS50xB1903-81 DCS50xB2053-y1 DCS50xB2503-y1 DCS50xB3003-y1 1750x460x410 1750x460x410 1750x460x410 1750x460x410 180 180 180 180 ➂ x0x50 ➂ x0x50 ➂ x0x50 ➂ x0x50 A6 A6 A6 A6 < 7.9 < 9.3 < 11.9 DCS50xB2053-y1L➀ DCS50xB2603-y1L➀ DCS50xB3203-y1L➀ DCS50xB3303-y1L➀ DCS50xB4003-y1L➀ DCS50xB4803-y1L➀ DCS50xB5203-y1L➀ 1750x770x570 1750x770x570 1750x770x570 1750x770x570 1750x770x570 1750x770x570 1750x770x570 315 315 315 315 315 315 315 to be installed in cubicle A7 A7 A7 A7 A7 A7 A7 < 15 < 16 < 20 [kg] Clearances top/bottom/side [mm] Construct. type Power loss at 500V PV [kW] Fan connection 400...500 V/3-ph at y = 4, 5, 8 500...690 V/3-ph at y = 6, 7 400/690 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 Semiconductor Fuses internal internal ➀ Busbar connection on the right side is optional Example for the type designation: connection left DCS50xB5203-y1L; connection right DCS50xB5203-y1R) ➁ x=1 → 2-Q; x=2 → 4-Q; y=4...9/1 → 400...1000 V/1190 V supply voltage ➂ Exhaust air must leave enclosure via air channel also available as field supply converter DCF50xB (for 500 V s. also table 2.2/3). Data are the same as the armature current converter DCS50xB Table 2.2/5: Table of DCS 500B units II D 2-7 3ADW000066R0901_DCS500_System_description_e_i 2.3 DCS 500B Overload Capability To match a drive system’s components as efficiently as possible to the driven machine’s load profile, the armature power converters DCS 500B 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 Table 2.3/1: Power converter module currents with corresponding load cycles. The characteristics are based on an ambient temperature of max. 40°C and an elevation of max. 1000 m a.s.l. IDC II IDC I 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 501B0680-41/51 DCS 502B0680-41/51 DCS 501B0820-41/51 DCS 502B0820-41/51 DCS 501B1000-41/51 DCS 502B1000-41/51 DCS 50xB1203-41/51 DCS 50xB1503-41/51 DCS 50xB2003-41/51 DCS 50xB2053-51 DCS 501B2503-41/51 DCS 502B2503-41/51 DCS 501B3003-41/51 DCS 502B3003-41/51 DCS 50xB3303-41/51 DCS 50xB4003-41/51 DCS 50xB5203-41/51 600 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 50xB0903-61/71 DCS 50xB1503-61/71 DCS 501B2003-61/71 DCS 50xB2053-61/71 DCS 501B2503-61/71 DCS 502B2503-61/71 DCS 501B3003-61/71 DCS 502B3003-61/71 DCS 50xB3303-61/71 DCS 50xB4003-61/71 DCV 50xB4803-61/71 790 V DCS 50xB1903-81 DCS 501B2503-81 DCS 502B2503-81 DCS 501B3003-81 DCS 502B3003-81 DCS 50xB3303-81 DCS 50xB4003-81 DCS 50xB4803-81 1000 V DCS 50xB2053-91 DCS 50xB2603-91 DCS 50xB3303-91 DCS 50xB4003-91 1190 V continuous [A] 25 50 75 100 125 140 180 200 225 250 315 350 405 450 470 520 610 680 740 820 900 1000 1200 1500 2000 2050 2500 2500 3000 3000 3300 4000 5200 100 % 15 min IDC III 150 % 60 s 100 % 15 min 24 44 60 71 94 106 133 149 158 177 240 267 317 352 359 398 490 544 596 664 700 766 888 1200 1479 1550 1980 2000 2350 2330 2416 2977 3800 36 66 90 107 141 159 200 224 237 266 360 401 476 528 539 597 735 816 894 996 1050 1149 1332 1800 2219 2325 2970 3000 3525 3495 3624 4466 5700 50 100 110 245 270 405 450 900 1500 2000 2050 2500 2500 3000 3000 3300 4000 4800 44 79 87 193 213 316 352 684 1200 1479 1520 1940 1940 2530 2270 2416 3036 3734 1900 2500 2500 3000 3000 3300 4000 4800 2050 2600 3300 4000 IDC IV 150 % 120 s 100 % 15 min 23 42 56 69 91 101 132 146 155 173 233 258 306 340 347 385 482 538 578 648 670 736 872 1156 1421 1480 1880 1930 2220 2250 2300 2855 3669 35 63 84 104 137 152 198 219 233 260 350 387 459 510 521 578 732 807 867 972 1005 1104 1308 1734 2132 2220 2820 2895 3330 3375 3450 4283 5504 24 40 56 68 90 101 110 124 130 147 210 233 283 315 321 356 454 492 538 598 620 675 764 1104 1361 1450 1920 1790 2280 2080 2277 2795 3733 48 80 112 136 180 202 220 248 260 294 420 466 566 630 642 712 908 984 1076 1196 1240 1350 1528 2208 2722 2900 3840 3580 4560 4160 4554 5590 7466 66 119 130 290 320 474 528 1026 1800 2219 2280 2910 2910 3795 3405 3624 4554 5601 43 76 83 187 207 306 340 670 1104 1421 1450 1840 1870 2410 2190 2300 2900 3608 65 114 125 281 311 459 510 1005 1656 2132 2175 2760 2805 3615 3285 3450 4350 5412 40 75 82 169 187 282 313 594 1104 1361 1430 1880 1740 2430 2030 2277 2950 3700 80 150 165 338 374 564 626 1188 2208 2722 2860 3760 3480 4860 4060 4554 5900 7400 1500 1920 1910 2500 2250 2655 3036 3734 2250 2880 2865 3750 3375 3983 4554 5601 1430 1820 1850 2400 2160 2540 2889 3608 2145 2730 2775 3600 3240 3810 4334 5412 1400 1860 1710 2400 2000 2485 2933 3673 2800 3720 3420 4800 4000 4970 5866 7346 1577 2000 2551 2975 2366 3000 3827 4463 1500 1900 2428 2878 2250 2850 3642 4317 1471 1922 2458 2918 2942 3844 4916 5836 [A] [A] [A] Data on request x=1 → 2-Q; x=2 → 4-Q II D 2-8 3ADW000066R0901_DCS500_System_description_e_i 200 % 10 s Types of load Operating cycle Load for converter DC I IDC I continuous (IdN) Typical applications Load cycle pumps, fans 100% DC II DC III * DC IV * IDC II for 15 min and 1,5 * IDC II for 60 s extruders, conveyor belts IDC III for 15 min and 1,5 * IDC III for 120 s extruders, conveyor belts 15 min 150% 100% 15 min 150% 100% 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 DriveSize program ! Table 2.3/2: Definition of the load cycles If the driven machine’s load cycle does not correspond to one of the examples listed, you can determine the necessary power converter using the DriveSize software program. This program can be run under Microsoft® Windows, 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 the converter´s software is structured similar as the inputs made at the program. Because of that many of the data can be directly utilized at the converter like high current, line voltage and others. Fig. 2.3/1: Entry screen of the PC for the dimensioning program. Microsoft is a registered trademark. Windows is a designation of the Microsoft Corporation. II D 2-9 3ADW000066R0901_DCS500_System_description_e_i 2.4 Field Supply General data • Currents from 6 to 520 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 SDCS-FEX-1) We recommend integrating an autotransformer in the field power converter's supply circuit to adjust the AC input voltage to the field voltage and for reducing the voltage ripple in the field circuit. All field power converters (except for the SDCS-FEX1) 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-2A) and an external (DCF 501B/2B/3A/ 4A) or two external field supply units (2 x DCF 501B/ 2B/3A/4A). The respective software function required is available in every DC power converter. Field converter types SDCS-FEX-1 SDCS-FEX-2A • 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 UA: • Half-controlled thyristor/diode bridge (1-Q) • Microprocessor control, 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. • Fast-response excitation is possible with an appropriate voltage reserve; de-excitation takes place by field time constant. • Output voltage UA: ⎛ 100% + TOL ⎞ U A = UV * ⎜ ⎟ * 0,9 ⎝ ⎠ 100% ⎛ 100% + TOL ⎞ U A = UV * ⎜ ⎟ * 0,9 ⎝ 100% ⎠ TOL = tolerance of line voltage in % UV = Line voltage • Recommendation: Field voltage ~ 0,9 * UV TOL = tolerance of line voltage in % UV = Line voltage • Recommendation: Field voltage 0.6 to 0.8 * UV SDCS-FEX-1 SDCS-FEX-2A II D 2-10 3ADW000066R0901_DCS500_System_description_e_i DCF 503A DCF 500B • Half-controlled thyristor/diode bridge (1-Q) • Microprocessor control 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. • Output voltage UA: This field power converter is used mainly for armaturecircuit converters with rated currents of 2050 to 5200 A. It consists of a modified armature-circuit converter. • Output voltage UA respectively Udmax 2-Q : see table 2.2/1 • Recommendation: Field voltage 0.5 to 1.1 * UV • The three-phase field supply converters DCF 501B/ 502B need a separate active Overvoltage Protection unit DCF 506 for protecting the power part against inadmissibly high voltages. The overvoltage protection unit DCF 506 is suitable for 2-Q converters DCF 501B and for 4-Q converters DCF 502B. ⎛ 100% + TOL ⎞ U A = UV * ⎜ ⎟ * 0,9 ⎝ 100% ⎠ TOL = tolerance of line voltage in % UV = Line voltage • Recommendation: Field voltage 0.6 to 0.8 * UV DCF 504A • Fully-controlled antiparallel thyristor bridges (4-Q) • This unit is permissible -in difference to the SDCSFEX-2- for fast-response excitation / de-excitation as well as field reversal. For fast-response excitation an appropriate voltage reserve is necessary. In the steady-state condition, the fully-controlled bridge runs in half-controlled mode so as to keep the voltage ripple as low as possible. With a quickly alternating field current, the bridge runs in fullycontrolled mode. • Same design as DCF 503A Assignment Field supply converter to Overvoltage protection unit Field supply converter for motor fields DCF50xB0025-51 ... DCF50xB0140-51 DCF506-0140-51 DCF50xB0200-51 ... DCF50xB0520-51 DCF506-0520-51 DCF 503A / 504A Unit type DCF501B/502B Output current IDC ➀ [A] Supply voltage [V] Installation site SDCS-FEX-1-0006 SDCS-FEX-2A-0016 0.02...6 0.3...16 110V -15%...500V/1-ph +10% 110V -15%...500V/1-ph +10% internal internal DCF 503A-0050 DCF 504A-0050 0.3...50 0.3...50 110V -15%...500V/1-ph +10% 110V -15%...500V/1-ph +10% external external see table 2.2/3 200V...500V/3-ph external DCF 50xBxxxx-51 Overvoltage Protection DCF506-140-51, without cover Remarks external fuse, 6 A ⇒ IFrated ext. fuse, reactor; for C1: 0.3 ... 8 A ➀, not to be used for A6/A7 mod.! ⎫auxiliary supply (115...230V) if necessary via matching transformer; ⎬fuse external; Dimensions HxWxD: 370x125x342 [mm] ⎭ are based on the hardware of the DCS 500B and additional hardware components (DCF 506); auxiliary supply (115/230V) ➀ Current reduction see also 2.1 Environmental conditions Fig.: 2.1/1 and 2.1/2 Table 2.4/1: Table of field converter units II D 2-11 3ADW000066R0901_DCS500_System_description_e_i 2.5 Options for DCS 500B / DCF 500B 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/O´s by SDCS-IOE 1 is possible. SDCS-CON-2 SDCS-CON-2 X17: X17: X2: X3: X4: X2: X1: X5: X6: 1 X7: X3: X4: 2 X1: X5: 1 X3: X1: SDCS-IOB-2 4 Fig. 2.5/1: I/O´s via SDCS-CON2 Analogue I/O´s: standard Digital I/O´s: not isolated Encoder input: not isolated Fig. 2.5/2: I/O´s via SDCS-CON2 and SDCS-IOB2 Analogue I/O´s: standard digital I/O´s: all isolated by means of optocoupler/relay, the signal status is indicated by LED SDCS-CON-2 SDCS-CON-2 X17: X17: X2: X2: X1: X6: X7: 2 X1: X2: X1: SDCS-IOB-3 X1: X2: X3: X1: SDCS-IOB-3 3 3 Fig. 2.5/3: I/O´s via SDCS-CON2 and SDCS-IOB3 Analogue I/O´s: more input capacity digital I/O´s: not isolated encoder input: isolated current source for: PT100/PTC element SDCS-IOB-2 4 Fig. 2.5/4: I/O´s via SDCS-IOB2 and SDCS-IOB3 Analogue I/O´s: more input capacity digital I/O´s: all isolated by means of optocoupler/relay, the signal status is indicated by LED current source for: PT100/PTC element II D 2-12 3ADW000066R0901_DCS500_System_description_e_i Description of I/O signals SDCS-CON-2 Description of I/O signals SDCS-IOB-2x & SDCS-IOB-3 Mechanical system Mechanical system installed in the basic unit always external, outside the basic unit Terminals Screw-type terminals for finely stranded wires up to max. 2.5 mm2 crosssectional area Terminals Screw-clamp 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 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 kΩ/ 500Ω/ 500Ω; 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 kΩ/ 500Ω/ 500Ω/ 20kΩ; 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 kΩ/ 500Ω/ 500Ω; Resolution: 11 bit + sign; common-mode range ±40 V Residual 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. 4 analogue inputs Range -10...0...+10 V, 4...20 mA, 0...20 mA All as differential inputs; RE = 200 kΩ; 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 Current source for PTC element evaluation via jumper and input 2 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 120Ω), 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 kΩ 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: SDCS-IOB-21 inputs for 24...48 V-; RE = 4.7 kΩ SDCS-IOB-22 inputs for 115 V AC; RE = 22 kΩ SDCS-IOB-23 inputs for 230 V AC; RE = 47 kΩ 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 2-13 3ADW000066R0901_DCS500_System_description_e_i 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: X5: X6: X7: 7 x digital X4: 8 x digital 4 x analog 1 x Tacho 5 X3: 2 x analog SDCS-IOE-1 Pulsgeber X2: X1: 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 unit’s 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 kΩ /500 Ω /500 Ω 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 kΩ 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 unit’s casing by means of plating-through at the fastening points. II D 2-14 3ADW000066R0901_DCS500_System_description_e_i Panel (control and display panel) Equipment 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. • 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; 3 m long – kit for mounting the panel in the switchgear cubicle door Parameters For selecting and adjusting all parameters and signals. Group and name Subgroup and name Value 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. Status row Functions to be selected Display contrast setting Actual Selects the display of feedback values plus the signal group and the error memory group. Control location L = local = remote ID number of the drive selected Status row Actual signal name and value Cursor shows the row selected Speed reference rpm Main contactor status 0 = open 1 = closed Run status 1 = Run 0 = Stop 0 L 0,0 rpm 00 SPEEED ACT 0,0 rpm CONV CUR 0 A 0 V U ARM ACT 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. 1 = last fault 2 = last-but-one fault 99 = last-but-98 fault Name of Fault or alarm Total time after switch-on HHHH:MM:SS.ss 0 L 0,0 rpm 1 LAST FAULT Emergency stop 3212:59:35:56 00 0 L 0,0 rpm UPLOAD <== DOWNLOAD ==> CONTRAST 00 Drive for subsequent extensions 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. Start starts the drive in local mode. Stop shuts the drive down if you are in local mode. 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 2-15 3ADW000066R0901_DCS500_System_description_e_i 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-5 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. CDP 312 SDCS-CON-2 Nxxx SDCS-COM-5 electrical connection X16: X34: ≤3m Power supply to the PLC V260 FCI AC70 PC Interface optical fibre ≤ 20 m optical fibre ≤ 10 m Operation Control Fig. 2.5/7: Options for serial communication Operation by PC Control System requirements/recommendation: • Laptop PC with Windows NT ™ or Windows 2000 ™ operating system (desktop PC on request) • hard disk with 4MB free memory; each graph recorded requires additional 500 kB of free memory. • CD rom drive • PCMCIA slot Components required: • SDCS-COM-5 as an option • DDCTool 4.x package for Windows NT ™ or DDCTool 4.x package for Windows 2000 ™ (DDCTool 4.0 package for Windows XP ™ on request) The package contains of: • CD rom with installation software • SNAT624 PCcard (PCMCIA) • NDPC-02 connector (interface from SNAT624 to plastic optical fibre cable) • plastic optical fibre cable (10m) Functionality: • DDCtool starts program part CMT/DCS 500, when a DCS500B is connected • CMT/DCS 500 is the core program (this name will be used further on as a cross-reference) for commissioning, diagnosis, maintenance and trouble-shooting based on point-to-point connection. In addition to the functionality provided by the CDP 312 control panel, there are further functions available described on next page. components required: • plastic optical fibre for distances up to 20 m (longer distances on request) • field bus module Nxxx-0x Functionality: Field bus Profibus CANopen DeviceNet ControlNet ModBus AC70 / FCI Module NPBA-12 NCAN-02 NDNA-02 NCNA-01 NMBA-01 ----- Number Parameter of cyclic exchange words from/ possible to drive ≤ 6 ➀➁ Yes ≤6➀ Yes ≤6➀ Yes ≤6➀ Yes ≤6➀ Yes ≤6➀ No Baudrate ≤ 12 MB ≤ 1 MB ≤ 1 MB ≤ 5 MB ≤ 19.2 KB ≤ 4 MB ➀ Four of them are predefined via the profile variable speed drives done by the Profibus user organization; they can be altered, if necessary. ➁ The module supports the PPO types 1 to 5; depending on the PPO type in use less words will be transferred or they will be empty. You will find more detailed information on data exchange in the specific fieldbus module documentation. II D 2-16 3ADW000066R0901_DCS500_System_description_e_i 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 drive’s 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. 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. 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. Faults This display shows the current fault messages last fed into the fault logger in chronological sequence. 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. Exit Quitting the program. Help Descriptions of the parameters. II D 2-17 3ADW000066R0901_DCS500_System_description_e_i 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. 2.6 Options for the drive Line reactors for armature (DCS 50xB) and field (DCF 50xB) supply When thyristor power converters operate, the line voltage is short-circuited during commutation from one thyristor to the next. This operation causes voltage dips in the mains (point of common coupling). For the connection of a power converter system to the mains, one of the following configurations can be applied: Line PCC uk LR > 1% Line Configuration A Configuration C1 When using the power converter, a minimum of 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% uk (relative short circuit voltage). It should not exceed 10% uk, due to considerable voltage drops which would then occur. If 2 or more converters should be supplied by one transformer the final configuration depends on the number of drives in use and their power capability. Configuration A or B has to be used which are based on commutation chokes, if the drive system consists of any of the converters Line (C1, C2, A5, A6, A7). In case only two PCC converters type A7 are involved no commutation chokes are necessary because the LLR LLR LLR .... design of these converters is adapted to that wiring. Configuration B If special requirements have to be met at the PCC (standards like EN 61 800-3, DC and AC drives at the same line, etc), different criteria must be applied for PCC selecting a line reactor. These requirements are often defined as a voltage dip LLR in percent of the nominal supply voltage. The combined impedance of ZLine and ZLR 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. In such cases line chokes with an impedance around 4% are often used. LLine Line PCC Configuration C If an isolation transformer is used, it is possible to comply with certain connecting conditions per Configuration B without using an additional line reactor. The condition described in Configuration A will then likewise be satisfied, since the uk is >1 %. Netzdr_f.dsf With reference to the power converter: The line reactors listed in table (2.6/1) - have been allocated to the units nominal current - are independent of converter's voltage classification; at some converter types the same line choke is used up to 690 V line voltage - are based on a duty cycle - can be used for DCS 500B as well as for DCF 500B converters You will find further information in publication: Technical Guide chapter: Line reactors II D 2-18 3ADW000066R0901_DCS500_System_description_e_i Line reactors L1 DCS Type 400V-690V 50/60 Hz Line choke Design type for Fig. configur. A Line choke type for configur. B Design Fig. DCS50xB0025-41/51 DCS50xB0050-41/51 DCS50xB0050-61 DCS50xB0075-41/51 DCS50xB0100-41/51 DCS50xB0110-61 DCS50xB0140-41/51 ND01 ND02 ND03 ND04 ND06 ND05 ND06 1 1 1 1 1 1 1 ND401 ND402 on request ND403 ND404 on request ND405 4 4 5 5 5 DCS50xB0200-41/51 DCS50xB0250-41/51 DCS50xB0270-61 DCS50xB0350-41/51 DCS50xB0450-41/51 DCS50xB0450-61 DCS50xB0520-41/51 DCS50xB0680-41/51 DCS501B0820-41/51 DCS502B0820-41/51 DCS50xB1000-41/51 ND07 ND07 ND08 ND09 ND10 ND11 ND10 ND12 ND12 ND13 ND13 2 2 2 2 2 2 2 2 2 3 3 ND406 ND407 on request ND408 ND409 on request ND410 ND411 ND412 ND412 ND413 5 5 5 5 5 5 5 5 5 DCS50xB0903-61/71 DCS50xB1203-41/51 DCS50xB1503-41/51/61/71 DCS50xB2003-41/51 DCS501B2003-61/71 ND13 ND14 ND15 ND16 ND16 * 3 3 3 3 3 on request on request on request on request on request - * with forced cooling Table 2.6/1: Line reactors (for more information see publication Technical Data) Fig. 1 Fig. 4 Fig. 2 Fig. 3 Fig. 5 II D 2-19 3ADW000066R0901_DCS500_System_description_e_i Aspects of fusing for the armature-circuit and field supplies of DC drives General Conclusion for the armature supply Unit configuration Protection 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? Due to cost saving standard fuses are used instead of the more expensive semiconductor fuses at some applications. Under normal and stable operating conditions, this is understandable and comprehensible, as long as fault scenarios can be ruled out. AC supply: public mains / plant's mains Cabinet 2 3 . . . . . For field supply see Fig. 2.6/2 M 2 In the event of a fault , however, the saving may cause very high consequential costs. Exploding power semiconductors may not only destroy the power converter, but also cause fires. Adequate protection against short-circuit and earth fault, as laid down in the EN50178 standard, is possible only with appropriate semiconductor fuses. ABB's recommendations Semiconductor fuses Semiconductor fuses Fig. 2.6/1 Arrangement of the switch-off elements in the armature-circuit converter You will find further information in publication: Technical Guide chapter: Aspects for fusing DCS converter DCS converter 2-Q non-regen. 4-Q resp. 2-Q regenerative Semiconductor fuses M Complies with Basic Principles on: 1 – Explosion hazard yes 2 – Earth fault yes 3 – “Hard“ networks yes 4 – Spark-quenching gap yes 5 – Short-circuit yes 6 – 2Q regenerative yes II D 2-20 3ADW000066R0901_DCS500_System_description_e_i M Conclusion for the field supply Basically, similar conditions apply for both field supply and armature-circuit supply. Depending on the power converter used (diode bridge, half-controlled 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. The following configurations are relatively frequent: In contrast to the armature-circuit supply, fuses are 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.). Semiconductor fuse F3.1 (super-fast acting) should be used, 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. F3.1 ND30 / built-in 2 Fig 2.6/2 Configuration for field supplies 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 circuit-breakers may be used. Semiconductor fuses would be destroyed, for example, by the transformer’s starting current inrush. F3.2 F3.1 F3.3 F3.1 2 ND30 / built-in 2 FF_ASP_b.dsf Fig 2.6/3 Configurations for field supplies II D 2-21 3ADW000066R0901_DCS500_System_description_e_i Semiconductor type F1 fuses and fuse holders for AC and DC power lines (DCS 501B /DCS 502B - DCF 501B/DCF 502B) The converter units are subdivided into two groups: – Unit sizes C1 and C2 with rated currents up to 1000 A require external fuses. – In unit sizes A5, A6 and A7 with rated currents of 900 A to 5200 A, the semiconductor fuses are installed internally (no additional external semiconductor fuses are needed). The table on the right assigns the AC fuse type to the converter type. In case the converter should be equipped with DC fuses according to the hints use the same type of fuse used on the AC side now in the plus and minus line. Blade type fuses are used for all the converters construction type C1 and C2 except the biggest one. Type of converter Type Fuse holder 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 DCS50xB0680-41/51 DCS50xB0820-41/51 DCS50xB1000-41/51 170M 1564 170M 1566 170M 1566 170M 1568 170M 3815 170M 3815 170M 3815 170M 3816 170M 3817 170M 3819 170M 5810 170M 6811 170M 6811 170M 6163 170M 6163 170M 6166 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 1 S3 OFAX 2 S3 OFAX 3 S3 OFAX 3 S3 3x 170H 3006 3x 170H 3006 3x 170H 3006 Table 2.6/2: Fuses and fuse holders (details see Technical Data) Fuses F3.x and fuse holders for 2-phase field supply Depending on the protection strategy different types of fuses are to be used. The fuses are sized according to the nominal current of the field supply device. If the field supply unit is connected to two phases of the network, two fuses should be used; in case the unit is connected to one phase and neutral only one fuse at the phase can be used. Table 2.6/ 3 lists the fuses currents with respect to table 2.6/2. The fuses can be sized according to the maximum field current. In this case take the fuse, which fits to the field current levels. Field conv. Field F3.1 F3.2 F 3.3 current SDCS-FEX-1 IF ≤ 6 A SDCS-FEX-2A 170M 1558 OFAA 00 H10 10 A SDCS-FEX-2A IF ≤ 12 A 170M 1559 OFAA 00 H16 16 A SDCS-FEX-2A IF ≤ 16 A DCF 503A DCF 504A 170M 1561 OFAA 00 H25 25 A DCF 503A DCF 504A IF ≤ 30 A 170M 1564 OFAA 00 H50 50 A DCF 503A DCF 504A IF ≤ 50 A 170M 1565 OFAA 00 H63 63 A Type of protection elements Semiconduct. LV HRC type circuit breaker type fuse for for 690 V; fuse for 500 V or fuse holder hold. OFAX 00 690 V type OFAX 00 Table 2.6/3: Fuses and fuse holders for 2-phase field supply Transformer T3 for field supply to match voltage levels Fig. 2.6/4: T3 autotransformer 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. Field converter type ≤ 500 V; 50/60 Hz for field current IF Transformer type 50/60 Hz SDCS-FEX-1 SDCS-FEX-2A SDCS-FEX-2A DCF503A/4A-0050 DCF503A/4A-0050 ≤6 A ≤12 A ≤16 A ≤30 A ≤50 A Uprim = ≤ 500 V T 3.01 T 3.02 T 3.03 T 3.04 T 3.05 SDCS-FEX-1 SDCS-FEX-2A SDCS-FEX-2A ≤6 A ≤12 A ≤16 A Uprim = ≤ 600 V T 3.11 T 3.12 T 3.13 DCF503A/4A-0050 DCF503A/4A-0050 ≤30 A ≤50 A Uprim = ≤ 690 V T 3.14 T 3.15 Table 2.6/4: Autotransformer data (details see Technical Data) II D 2-22 3ADW000066R0901_DCS500_System_description_e_i Commutating reactor When using the SDCS-FEX-2A field power converter, you should additionally use a commutating reactor because of EMC considerations. A commutating reactor is not necessary for the SDCS-FEX-1 (diode bridge). With DCF 503A/504A field power converters, it is already installed. Converter Reactor ≤ 500 V; 50/60 Hz SDCS-FEX-2A ND 30 Table 2.6/4: Commutating reactor (for more information see publication Technical Data) Auxiliary transformer T2 for electronic system / fan supply The converter unit requires various auxiliary voltages, e.g. the unit’s 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 designed to supply the unit’s electronic system and all the single-phase fans including the fan of the A5 converter. Input voltage: 380...690 V/1-ph; 50/60 Hz Output voltage: 115/230 V/1-ph Power: 1400 VA Fig. 2.6/5: T2 auxiliary transformer Residual current detection This function 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 message is indicated (for more information, see publication Technical Data). II D 2-23 3ADW000066R0901_DCS500_System_description_e_i EMC filters You will find further information in publication: Technical Guide chapter: EMC Compliant Installation and Configuration for a Power Drive System The paragraphs below describe selection of the electrical components in conformity with the EMC Guideline. The aim of the EMC Guideline is, as the name implies, to achieve electromagnetic compatibility with other products and systems. The guideline ensures that the emissions from the product concerned are so low that they do not impair another product's interference immunity. In the context of the EMC Guideline, two aspects must be borne in mind: • the product's interference immunity • the product's actual emissions The EMC Guideline expects EMC to be taken into account when a product is being developed; however, EMC cannot be designed in, it can only be quantitatively measured. Note on EMC conformity The conformity procedure is the responsibility of both the power converter's supplier and the manufacturer of the machine or system concerned, in proportion to their share in expanding the electrical equipment involved. First environment (residential area with light industry) with restricted distribution Not applied, since general distribution sales channel excluded Not applicable satisfied satisfied Medium-voltage network Residential area Light industry Supply transformer for a residential area (rating normally ≤ 1.2 MVA) Residential area Earthed neutral Converter M M Line reactor + Y-capacitor Converter M An isolating transformer with an earthed screen and earthed iron core renders mains filter and line reactor superfluous. To other loads, e.g. drive systems Mains filter Line reactor Line reactor Converter Converter Converter M M M M M Operation at public low-voltage network together with other loads of all kinds. Fig. 2.6/5: Classification II D 2-24 3ADW000066R0901_DCS500_System_description_e_i Operation at public low-voltage network together with other loads of all kinds. To other loads which have to be protected from the system disturbances caused by power converters (HF interference and commutation notches) Converter Mains filter alternative Line reactor Earthed public 400-V network with neutral conductor Earthed public 400-V network with neutral conductor alternative To other loads, e.g. drive systems Mains filter To other loads which have to be protected from the system disturbances caused by power converters (HF interference and commutation notches) Earthed public 400-V network with neutral conductor To other loads, e.g. drive systems Earthed neutral Operation at public low-voltage network together with other loads of all kinds. Medium-voltage network Supply transformer for a residential area (rating normally ≤ 1,2 MVA) An isolating transformer with an earthed screen and earthed iron core renders mains filter and line reactor superfluous. For compliance with the protection objectives of the German EMC Act (EMVG) in systems and machines, the following EMC standards must be satisfied: For emitted interference, the following apply: EN 61000-6-3 Specialised basic standard for emissions in light industry can be satisfied with special features (mains filters, screened power cables) in the lower rating range *(EN 50081-1). EN 61000-6-4 Specialised basic standard for emissions in industry *(EN 50081-2) Product Standard EN 61800-3 EMC standard for drive systems (PowerDriveSystem), interference immunity and emissions in residential areas, enterprise zones with light industry and in industrial facilities. For interference immunity, the following apply: EN 61000-6-1 Specialised basic standard for interference immunity in residential areas *(EN 50082-1) EN 61000-6-2 Specialised basic standard for interference immunity in industry. If this standard is satisfied, then the EN 61000-6-1 standard is automatically satisfied as well *(EN 50082-2). This standard must be complied with in the EU for satisfying the EMC requirements for systems and machines! * The generic standards are given in brackets Standards The following overview utilises the terminology EN 61000-6-3 and indicates the action required in accordance EN 61000-6-4 with Product Standard EN 61800-3 EN 61000-6-2 For the DCS 500B series, EN 61000-6-1 the limit values for emitted interference are complied with, provided the action indicated is carried out. This action is based on the term Restricted Distribution used in the standard (meaning a sales channel in which the products concerned can be placed in the stream of commerce only by suppliers, customers or users which individually or jointly possess technical EMC expertise). Second environment (industry) with restricted distribution EN 61800-3 Not applicable satisfied on customer's request satisfied satisfied Medium-voltage network Medium-voltage network Supply transformer for a residential area (rating normally ≤ 1.2 MVA) Industrial zone Converter transformer with earthed Industrial zone Converter transformer Earthed neutral Converter Converter Converter Converter alternative alternative alternative Line reactor alternative Line reactor I > 400 A and/or U > 500 V To other loads, e.g. drive systems Case-referenced EMC analysis To other loads, e.g. drive systems Mains filter Line reactor + Y-capacitor iron core (and earthed screen where appropriate) Earthed 400-V network with neutral conductor; 3~ ≤ 400 A M M M M Operation at low-voltage network together with other loads of all kinds, apart from some kinds of sensitive communication equipment. M M Classification M M Operation with separate power converter transformer. If there are other loads at the same secondary winding, these must be able to cope with the commutation gaps caused by the power converter. In some cases, commutating reactors will be required. For power converters without additional components, the following warning applies: This is a product with restricted distribution under IEC 61800-3. This product may cause radio interference in residential areas; in this case, it may be necessary for the operator to take appropriate action (see adjacent diagrams). The field supply is not depicted in this overview diagram. For the field current cables, the same rules apply as for the armaturecircuit cables. Legend Screened cable Unscreened cable with restriction II D 2-25 3ADW000066R0901_DCS500_System_description_e_i 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 fulfil the standard for emitted interference 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. The filters can be optimized for the real motor currents: IFilter = 0.8 • IMOT max ; the factor 0.8 respects the current ripple. 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. IDC [A] Const. type Filter type for y=4 Filter type for y= 5 Filter type for y=6 or 7 DCS50xB0025-y1 DCS50xB0050-y1 DCS50xB0075-y1 DCS50xB0100-y1 DCS50xB0140-y1 DCS50xB0200-y1 DCS50xB0250-y1 DCS50xB0270-61 DCS50xB0350-y1 DCS50xB0450-y1 DCS50xB0520-y1 25A 50A 75A 100A 140A 200A 250A 250A 350A 450A 520A C1a C1a C1a C1b C1b C2a C2a C2a C2a C2a C2a NF3-440-25 NF3-440-50 NF3-440-64 NF3-440-80 NF3-440-110 NF3-500-320 NF3-500-320 NF3-500-320 NF3-500-320 NF3-500-600 NF3-500-600 NF3-500-25 NF3-500-50 NF3-500-64 NF3-500-80 NF3-500-110 NF3-500-320 NF3-500-320 NF3-500-320 NF3-500-320 NF3-500-600 NF3-500-600 --------------NF3-690-600 ➀ --NF3-690-600 ➀ --- DCS50xB0680-y1 DCS501B0820-y1 DCS502B0820-y1 DCS50xB1000-y1 680A 740A 820A 1000A C2b C2b C2b C2b NF3-500-600 NF3-500-600 NF3-690-1000 ➀ NF3-690-1000 ➀ NF3-500-600 NF3-500-600 NF3-690-1000 ➀ NF3-690-1000 ➀ --------- DCS50xB0903-y1 DCS50xB1203-y1 DCS50xB1503-y1 DCS50xB2003-y1 900A 1200A 1500A 2000A A5 A5 A5 A5 NF3-690-1000 ➀ NF3-690-1000 ➀ NF3-690-1600 ➀ NF3-690-1600 ➀ NF3-690-1000 ➀ NF3-690-1000 ➀ NF3-690-1600 ➀ NF3-690-1600 ➀ NF3-690-1000 ➀ NF3-690-1000 ➀ NF3-690-1600 ➀ NF3-690-1600 ➀ ≤ 3000A A6 NF3-690-2500 ➀ NF3-690-2500 ➀ NF3-690-2500 ➀ Converter ➀ Filter only available on request Single - phase filters for field supply 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 (230 V in a 400 V line) then a separate filter is necessary. ABB offers such filters for 250 V and 6...30 A. Converter type of field supply unit dc current Filter type ➊ Umax = 250 V [A] SDCS-FEX-1 SDCS-FEX-2A SDCS-FEX-2A DCF 503A-0050 DCF 504A-0050 further filters for ➊ 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 The filters can be optimized for the real field currents: IFilter = IField II D 2-26 3ADW000066R0901_DCS500_System_description_e_i 3 How to engineer your drive This chapter will give engineering hints for different drive configurations. In the first place converters are shown with all possible field supply options using wiring diagrams. Afterwards wiring diagrams are only shown for the most common configurations. • Standard drive configuration using an internal field (see chapter 3.1) The first configuration shows a speed controlled drive, using a very flexible external wiring and a build in field supply. With these components, it will fit to most drives of the smaller power range . This configuration can only be used together with construction types C1 - A5, because bigger power stacks (C4, A6, A7) do not allow to incorporate an internal field supply. • Drive configuration using the internal field with reduced external components (see chapter 3.2) The second configuration uses the same basic components as the one first, but a reduced external wiring schematics. This configuration can only be used together with construction types C1 - A5, because bigger power stacks (C4, A6, A7) do not allow to incorporate an internal field supply. • Standard drive configuration using an external halfcontrolled field (1-ph) (see chapter 3.3) The third configuration uses the external wiring of the first one, but a more powerful and flexible field supply unit. This configuration can be used for all construction types. • Typical configuration for very high power drives using two parallel converter modules with symmetrical load share Another configuration is the paralleling of converters. In this case converters of the same construction type (A7) are placed close to each other having connected their AC and DC terminals directly. They will behave like one bigger converter, which is not available as a single standard module. Such a system uses additional electronic boards for safety functions as well as interfacing and monitoring the converters. More information on request. • Standard configuration using a fully-controlled field (3-ph) without armature converter (see chapter 3.4) The fourth configuration shows a 3-phase field supply unit DCF 501B/2B as stand alone unit. This configuration shows a system in field current control mode and is used, if any type of existing DC-motor-field supply should be upgraded to a digital controlled one with all modern options like serial link etc. There are other than field applications, magnets for example, which can be controlled with this equipment in current or voltage control mode without any additional components. • Typical configuration for high power drives (see chapter 3.5) The fifth configuration is used for quite big drives and is based on the diagrams used for configuration 3.3 and 3.4. Now all the components used for the other two are shown all together with all interconnections and interlockings needed. It is adapted to the converter construction types A5, A6 and A7. • Revamp of existing DC Equipment If existing drives need modernization in some cases brand new drives shown in one of the first configurations will replace them. Because of space or economical reasons in some cases the existing power stack will remain and only the control part is upgraded. For these cases a construction kit based on electronic boards, normally used in DCS- A7 type converters, called DCR revamp kit, is available. All options shown and explained in chapter 2 are suitable for this kit. Additional boards enable this kit to be used for power stack constructions with up to four thyristors in parallel. For more information please see manual Selection, Installation and Start-up of Rebuild Kits. dedicated power transformer + - 3 3 DCS ... xxxx ..Rxx ....... DCS ... xxxx ..Lxx ....... M Figure 3/1: Hard paralleling for high currents Figure 3/2: Rebuild Kit II D 3-1 3ADW000066R0901_DCS500_System_description_e_i • Master-Follower-Applications - Drives connected in Master-Follower application If motors have to run with the same speed / torque they are often controlled in a way called MASTER - FOLLOWER. Drives used for such systems are of the same type and may differ in power, but will be supplied from the same network. Their number normally is not limited. From the control point of view different conditions and demands need to be matched. Examples are available on request from ABB Automation Products GmbH. Master DCS 500B Follower DCS 500B CON 2 CON 2 MASTERFOLLOWER D1 C1 C1 M D1 M connected via load Figure 3/3: Application with two mechanically connected motors - Typical configuration for high power drives connected in Master-Follower application (two motors with one common shaft) Y Master DCS 500B CON 2 CON 2 MASTERFOLLOWER D1 C1 C1 M D1 M Tandem motors Figure 3/4: 12-Pulse application with two mechanically connected motors - Typical configuration for high power drives connected in 12-pulse parallel Master-Follower application (see chapter 3.6) This configuration shows a 12-pulse parallel drive system. It is an easy option to increase the power of a drive system. Depending on the engineering features , redundancy or emergency operation, if one converter fails, is made available. Such drives use two identical 6-pulse converters and an especially designed choke called T-reactor or 12-pulse choke or interface reactor. The converters are fed by a 12-pulse line transformer with separated secondary windings whose phase positions differ by 30°el. An example is the transformer configuration Ì/ /Ì. This configuration gives a reduced level and a reduced order number of harmonics on the AC side. Only the 11th and 13th, the 23rd and 25th, the 35th a.s.o. are existing. The harmonics on the DC side are reduced too, which gives a higher efficiency. (The field supply is not shown on the wiring diagram 3.6. Depending on the field supply selected, the connections to the network, the interlocking and the control connections can be taken from any other wiring diagram showing the selected field supply.) It is not possible to connect two 12-pulse systems (2 converters, Treactor and 1 motor) to one 12-pulse transformer. For more information, please see manual 12-pulse operation. Follower DCS 500B ∆ ∆ Y This configuration is often used, if two motors have to share the load half and half. They are mechanically fixed to each other via a gearbox or any other device. The converters are fed by a 12-pulse line transformer with separated secondary windings whose phase positions differ by 30°el. Each motor is connected to its own converter and field supply. The converters exchange signals to make sure, that each motor takes half of the load. This configuration delivers the same advantages concerning harmonics to the network as a standard 12- pulse application (see next item), but no T-reactor is needed. Depending on the mechanical configuration commissioning personal needs some experience to adapt control accordingly. Master DCS 500B Follower DCS 500B CON 2 CON 2 MASTERFOLLOWER D1 C1 C1 M Figure 3/5: 12-Pulse parallel application II D 3-2 3ADW000066R0901_DCS500_System_description_e_i D1 3.1 Standard drive configuration using an internal field Wiring the drive according to this diagram gives the most flexibility and offers the highest degree of standard monitoring functions done by the drive. There are no software modifications to adapt the drive to the external wiring. A C L1 L1 N L2 L3 Voltage levels see description D E L1 N L1 L2 L3 T2 230V 1 1 1 F5 F7 F8 2 2 115V 2 K15 OFF STOP ON START F1 690V 660V 600V 575V F2 525V 500V 450V 415V 400V 380V 1 3 2 4 T3 500V 460V 415V 400V F3 K11 X96:2 13 F6 14 K21 K1 X2:4 1 3 5 13 14 365V 350V 265V 250V 90V 60V 30V X96:1 K10 F6 I> I> I> 2 4 6 1 3 5 2 4 6 X2:5 1 EMER. STOP K20 K8 S1 1 3 2 4 K1 1 3 5 2 4 6 1 3 2 4 X1: 1 7 K3 K6 2 K20 K21 IN3 V5 OUT3 V6 IN1 V1 OUT1 V2 K6 K8 K3 K1 X96: 1 Communication board (COM-x) 2 X99: 1 2 X2: 4 AITAC _ + 2 3 4 AI2 _ + 5 6 AI3 _ + 6 7 8 9 2 3 U1 V1 W1 PE M ~ Power supply (POW-1) AI1 _ + 5 X2: 1 DO8 depending on the unit type an other configuration is possible Converter module AI4 _ + +10V -10V 0V X3: 1 5 Control board (CON-2) S4 X33 L3 L1 K15 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 DO1 DO2 DO3 DO4 DO5 DO6 DO7 0V 0V X6: 1 2 3 4 5 6 7 8 9 10 X7: 1 2 3 4 5 6 7 8 X5: 1...10 C1 D1 _ + K6 e.g. Pressure switch at C4 module 1 X1: 5 + 3 _ K20 S1 K10 2 K8 Field exciter unit (SDCS-FEX-1/2) K1 K21 K11 the polarities are shown for motor operation if there are intermediate terminals T M + U V W M 3~ T _ Figure 3.1/1: Standard drive configuration using an internal field • Selection of components For this wiring diagram a DCS 500B converter construction type C1 / C2 / A5 (for A7 types, please use diagram 3.3 or higher) was selected together with a SDCS-FEX-1 or 2A field supply. This field supply can be used at line voltages up to 500V and will give field current up to 6 / 16A. For higher field currents, use the next bigger field supply unit DCF 503A/4A (wiring is shown at 3.3/1) or a 3-phase supply DCF 500B (wiring is shown at 3.5/2). • Power supply There are several components, which need a power supply: - Converter´s power part: 200 V to 1000 V, depending on converter type; see chapter 2 - Converter´s electronics power supply: 115V or 230V, selectable by jumper - Converter cooling fan: 230V 1-ph; see Technical Data - Power part field supply: 115 V to 500 V; together with an isolating / auto transformer up to 600 V; see chapter 2 and / or Technical Data - Motor cooling fan: depending on motor manufacturer / local demands - Relay logic: depending on local demands The fuses F1 are used because the converter construction type C1 and C2 don´t have them build in. All components, which can be fed by either 115/230 V have been combined and will be supplied by one isolating transformer T2. All components are set to 230 V supply or selected for this voltage level. The different consumers are fused separate. As long as T2 has the right tappings it can be connected to the power supply, used to feed the converter´s power part. The same can be applied to the field supply circuit. There are two different types of matching transformers available. One can be used for supply voltages up to 500 V, the other for voltages up to 690 V. Do not use the 690 V primary tapping together with the SDCS-FEX-1/2A field supply! Depending on the motor fan voltage the power can be taken from the same source which is used for the converter´s power part. In case the power for A, D and E should be taken from the source, used for C, a decision must be made, whether the fuses F1 can be used for two reasons (protection of the power part + auxiliary power supply) or not.In addition it has to be checked, if the consumers can be supplied with this voltage wave form (see chapter Line Chokes) before connecting to C. If the converter is supplied directly by a high-voltage converter transformer at point C, additional conditions are to be considered during engineering of the drive (more details on request). II D 3-3 3ADW000066R0901_DCS500_System_description_e_i • Control The relay logic can be split into three parts: a: Generation of the ON/OFF and START/STOP command: The commands represented by K20 and K21 (latching interface relay) can be generated by a PLC and transferred to the terminals of the converter either by relays, giving galvanic isolation or directly by using 24V signals. There is no absolute need to use hardwired signals. These commands can be transferred via a serial link system too. Even a mixed solution can be realized by selecting the one or the other possibility for the one or the other signal. b: Generation of control and monitoring signals: The main power contactor K1 for the armature circuit is controlled by a dry contact located on the electronic power supply board. The status of this contactor is checked by the converter via binary input 3. The field supply contactor K3 is controlled by the auxiliary contact K11 connected to a binary output of the converter. The binary outputs consist of relay drivers, capable to give appr. 50 mA each and a current limitation of around 160 mA for all of the outputs. The contactors K6 and K8 control the fans of the drive system. They are controlled by the auxiliary contact K10 (similar to K11). In series with K6 is an auxiliary contact of the circuit breaker F6, which monitors the motor fan supply. For the converter fan supply monitoring the contact of the temperature detector is used in series with K8. Auxiliary contacts K6 and K8 are used and connected to the binary inputs 1 and 2 to monitor the status of the fan supplies by the converter. The function of K15 is described at the next point. c: Stop mode beside ON/OFF and START/STOP: This chapter tries to explain the reaction of the drive when the input named EMERGENCY_STOP (906) or COAST_STOP (905) is operated. Please take the external wiring used for this explanation as an example only! For EMERGENCY STOP different preconditions have to be taken into account. This description focus on the functionality and does not take special safety conditions depending on the type of machine into account. In this case, if emergency stop is hit, the information is transferred to the converter via binary input 5. The converter will act according to the function programmed (stop by ramp, current limit or coasting). If the converter will not manage to get the drive to standstill within the time set at K15, the auxiliary contact will switch off the control power. Because of this the main power contactors K1 and all the others will be switched off. This may result in failure of components (see Operating Instructions). This danger can be minimized by adding another time delay (grey-shaded parts below). By doing so another stop mode is available. - Emergency stop signal initializes the ramp down function inside the converter in that way described before. If the drive comes to standstill within the time specified by K15, the converter will switch off the main power contactor K1. If the converter doesn´t manage to get the drive to standstill within this time, K15 will start the function ELECTRICAL DISCONNECT with the time delay specified by K16. This information will be transferred to the converter to a free binary input. This input has to be connected to the COAST_STOP input of the drive logic. The COAST_STOP input forces the current down to zero as fast as possible. The delay time of K16 has to be slightly higher than the time needed by the current controller to get the current to zero. When the time K16 has elapsed the control voltage will be switched off and all power contactors will drop off. K16 ELEC. DISCONN. 1 EMER. STOP S1 K15 2 K15 K16 CON-2 DIx X6:9 K15 - If no care should be taken to the speed of the drive the function of K16 can be initialized by the command ELECTRICAL DISCONNECT. d: Main contactor handling by the PLC only because of safety reasons: This mode is not recommended to be used as a standard switch on or switch off sequence. Nevertheless it is sometimes used to fulfill safety regulations or other needs. In such cases it´s recommended to follow the next guidelines: - It´s assumed that the PLC´s contact is in serial with the K1 (underneath the terminals named X96: 1 and 2) or in serial with the auxillary contact of K16 or replaces this one - Switching off the main power contactor in regenerative mode may result in failure of components (see Operating Instruction) - The PLC generates the command “main contactor off”. Two types of contacts are needed: - A pretriggered contact should then be connected to an unused binary input of the converter; this input has to be connected to the signal START_INHIBIT (908). This will block the controllers, trying to get the current to zero and switch off the main contactor from the converter point of view (independent, if the converter´s command is used or not). - A normal contact can then handle the main contactor. - Caused by the final timing alarms or error may be detected; they should be reset or bypassed (e.g. by the auto reclosing function • Sequencing When the ON command is given to the converter and there is no error signal active, the converter closes the fan, field and main contactor, checks the supply voltage and the status of the contactors and without error messages, releases the regulators and starts waiting for the RUN command. When the RUN command is given, the speed reference is released and speed control mode is active (for more details, see Software Description). II D 3-4 3ADW000066R0901_DCS500_System_description_e_i 3.2 Drive configuration using the internal field with reduced external components Wiring the drive according to this diagram gives the same control performance, but a lower degree of flexibility and nearly no external monitoring functions done by the drive. The software has to be adapted to the external wiring. 230V 50Hz L1 400V 50Hz MP L1 L2 L3 F1 1 1 F8 2 OFF 1 F5 F7 2 2 X96:1 STOP X96:2 START ON K21 K1 1 3 5 2 4 6 K1 K20 F6 K20 K21 K1 F3 L1 1 3 5 13 14 L3 I> I> I> IN3 V5 OUT3 V6 IN1 V1 OUT1 V2 X96: 1 Communication board (COM-x) 2 X99: 1 2 X2: 4 AITAC _ + DO8 Power supply (POW-1) AI1 _ + AI2 _ + 5 6 AI3 _ + AI4 _ + +10V -10V 0V X3: 1 2 3 4 5 X2: 1 6 7 8 9 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 2 3 4 5 6 7 8 if there are intermediate terminals U1 V1 W1 PE X1: 1 7 2 4 6 9 Converter module Field exciter unit (SDCS-FEX-1/2) DO1 DO2 DO3 DO4 DO5 DO6 DO7 10 0V X7: 1 2 3 4 5 6 7 8 X5: 1...10 C1 D1 _ + e.g. Pressure switch at C4 module K20 K1 3 depending on the unit type an other configuration is possible 0V X6: 1 2 M ~ S4 X33 5 Control board (CON-2) X1: 5 + 3 _ K21 the polarities are shown for motor operation T M + U V W M 3~ T _ Figure 3.2/1: Drive configuration using the internal field with reduced external components • Selection of components same as figure 3.1/1 • Power supply There are several components, which need a power supply. Because of the wiring preconditions have to be taken into account: - Converter´s power part: 200 V to 500 V, depending on converter type; see chapter 2 - Converter´s electronics power supply: use only 230 V possibility, selected by jumper - Converter cooling fan: 230V 1-ph; see Technical Data - Power part field supply: 200 V to 500 V; see chapter 2 and / or Technical Data - Motor cooling fan: select the motor voltage acc. to the voltage used for the armature supply - Relay logic: select the components for 230 V! This configuration is basically identical to the one shown at figure 3.1/1. Please check the sizing of F1 for the additional load like field and motor fan. All components are either selected for 230V or set to 230V to be able to combine them and to supply them by an auxiliary power supply. The different consumers are fused separately. • Control and safety The relay logic can be split into three parts: a: Generation of the ON/OFF and START/STOP command: same as figure 3.1/1 b: Generation of control and monitoring signals: The main power contactor K1 is handled in the same way it was done at figure 3.1/1. The field and motor fan supply is picked up at the output of K1. So all 3 consumers are controlled in the same way. The fan monitoring is not taken into consideration. Because of this these parameter settings have to be made: Connection (default) must be changed to: 910 from 10701 10908 911 from 10703 10908 906 from 10709 12502 c: Stop mode beside ON/OFF and START/STOP: Not taken into consideration! • Sequencing When the ON command is given to the converter and there is no error signal active, the converter closes the fan, field and main contactor, checks the supply voltage and the status of the contactors and without an error messages, releases the regulators and starts waiting for the RUN command. When the RUN command is given, the speed reference is released and speed control mode is active (for more details, see Software Description). II D 3-5 3ADW000066R0901_DCS500_System_description_e_i 3.3 Standard drive configuration using an external half-controlled field (1-ph) Wiring the drive according to this diagram gives the most flexibility and offers the highest degree of standard monitoring functions done by the drive. There are no software modifications to adapt the drive to the external wiring. A Voltage levels see description C L1 N L1 L2 L3 D E L1 N L1 L2 L3 T2 230V 1 1 F7 F5 1 F9 2 1 F8 2 2 115V 2 K15 OFF F1 690V 660V 600V 575V F2 525V 500V 450V 415V 400V 380V 1 3 2 4 T3 500V 460V 415V 400V F3 K10 K11 X96:2 START ON X2:4 13 F6 14 K21 K1 1 3 5 13 14 365V 350V 265V 250V 90V 60V 30V X96:1 STOP F6 I> I> I> 2 4 6 1 3 5 2 4 6 X2:5 1 EMER. STOP K20 K8 S1 1 3 2 4 1 3 5 2 4 6 U1 V1 K1 1 3 2 4 K6 * K3 2 K20 K21 IN3 V5 OUT3 V6 IN1 V1 OUT1 K6 K8 K3 K1 L1 K15 X96: 1 Communication board (COM-x) 2 X99: 1 AI1 _ + AI2 _ + 5 6 AI3 _ + 2 3 4 5 X2: 1 6 7 8 9 2 3 W1 PE +10V -10V 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 2 3 4 5 6 7 8 9 10 0V e.g. Pressure switch at C4 module 1 S1 K1 2 3 4 5 6 7 8 X5: 1...10 1 2 3 C1 D1 _ 1 2 3 C1 + D1 _ K10 K21 K11 the polarities are shown for motor operation if there are intermediate terminals Field exciter unit (DCF503A/504A) * K20 2 K8 V1 X2: X16: X7: 1 + K6 U1 DO1 DO2 DO3 DO4 DO5 DO6 DO7 0V X6: 1 X3: 1 2 depending on the unit type an other configuration is possible Converter module AI4 _ + 0V X3: 1 5 M ~ Power supply (POW-1) V2 AITAC _ + X2: 4 DO8 S4 X33 2 Control board (CON-2) T + M U V W M 3~ T _ Figure 3.3/1: Standard drive configuration using an external half-controlled field (1-ph) • Selection of components For this wiring diagram a DCS 500B converter was selected together with a DCF 503A/4A field supply. If a DCF 504A is used for field supply, field reversal is possible. Then a DCS 501B (2-Q) for the armature supply is sufficient for low demanding drives. This field supply can be used at line voltages up to 500 V and will give field current up to 50 A. For higher field currents, a 3-phase supply DCF 500B (wiring is shown at 3.5/2). • Power supply There are several components, which need a power supply: - Converter´s power part: 200 V to 1000 V, depending on converter type; see chapter 2 - Converter´s electronics power supply: 115 V or 230 V, selected by jumper - Converter cooling fan: 230 V 1-ph; 400 V / 690 V 3-ph. at A6/A7; see Technical Data - Power part field supply: 115 V to 500 V; together with an isolating/auto transformer up to 690 V; s. chap. 2 and/or Technical Data - Electronics supply of field unit: 115 V to 230 V - Motor cooling fan: depending on motor manufacturer / local demands - Relay logic: depending on local demands This configuration is basically identical to the one shown at figure 3.1/1. In addition to figure 3.1/1 the field supply unit needs an electronic power supply, which is separately fused and taken from the 230V level, generated by T2. This field controller is controlled via a serial link, connected to X16: at the armature converter. The 690V primary tapping can be used together with this type of field supply! In case the power for A, D and E should be taken from the source, used for C, a decision must be made, whether the fuses F1 can be used for two reasons (protection of the power part + auxiliary power supply) or not. In addition it has to be checked, if the consumers can be supplied with this voltage wave form (see chapter Line Chokes) before connecting to C. • Control The relay logic can be split into three parts as decribed in figure 3.1/1. Basically the logic shown at figure 3.2/1 could be used for this configuration. The size of the drive and/or it´s value may be a criteria to select the logic according to figure 3.1/1 or to figure 3.2/1 or a combination of both. * Recomendation: Keep the control of K3 as shown, if a DCF 504A field supply is used! • Sequencing same as figure 3.1/1 II D 3-6 3ADW000066R0901_DCS500_System_description_e_i 3.4 Standard configuration using a fully-controlled field (3-ph) without armature converter The DCS 500B converter is used as a DCF 500B version in a non-motoric application. If the drive should be wired according to this example or to the one shown at figure 3-2.1 it has to be decided depending on the application and it´s demands. The software structure has to be adapted and is described within the Operating Manual. Voltage levels see description C A L1 L1 N L2 L3 T2 230V 1 1 F7 1 F5 F8 2 2 115V 2 K15 OFF F1.2 690V 660V 600V 575V F2 525V 500V 450V 415V 400V 380V 1 3 2 4 X96:1 STOP K10 X96:2 START ON X2:4 K21 K1 X2:5 1 EMER. STOP K20 K8 S1 1 3 2 4 1 3 5 2 4 6 U1 V1 K1 2 K20 K21 IN3 V5 OUT3 V6 IN1 V1 OUT1 V2 K8 K1 K15 L1 X96: 1 Communication board (COM-x) 2 X99: 1 AITAC _ + 2 3 4 AI1 _ + 5 5 X2: 1 AI2 _ + 5 6 AI3 _ + 6 7 8 9 2 3 DCF 506 depending on the unit type an other configuration is possible Overvoltage protection Converter module AI4 _ + +10V -10V 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 X4:1 DO1 DO2 DO3 DO4 DO5 DO6 DO7 0V 0V 10 X7: 1 2 3 4 5 6 7 8 X4:2 X5: 1...10 C1 + K1 1 S1 K8 D1 _ X11 + X12 _ K20 K10 2 Figure 3.4/1: W1 PE M ~ Power supply (POW-1) 0V X3: 1 X2: 4 DO8 S4 X33 2 Control board (CON-2) K21 Standard configuration using a fully-controlled field (3-ph) without armature converter • Selection of components For this wiring diagram a DCF 500B converter construction type C1 or C2 was selected together with a DCF 506 unit, which serves as an overvoltage protection. • Power supply There are several components, which need a power supply: - Converter´s power part: 200 V to 500 V, depending on converter type; see chapter 2 - Converters electronics power supply: 115 V or 230 V, selected by jumper - Converter cooling fan: 230 V 1-ph at C1 + C2; see Technical Data - Relay logic: depending on local demands Basically according to figure 3.1/1. If the converter is supplied directly by a high-voltage converter transformer at point C , make sure that the high voltage switch is not opened, as long as field current flows. Additional conditions are to be considered during engineering of the drive (further information on request). • Control The relay logic can be split into three parts. a: Generation of the ON/OFF and START/STOP command: same as figure 3.1/1 b: Generation of control and monitoring signals: Basically identical to figure 3.1/1. Instead of the monitoring of the motor fan at binary input 2, which is not existing here but may exist as a cooling device for the inductance, the overvoltage protection DCF 506 is monitored by the same input. If any type of additional cooling device should be monitored extra function blocks can be used. c: Stop mode beside ON/OFF and START/STOP: Basically identical to figure 3.1/1 In this case it may be much more important to focus on a reduction of the current than on something else. If so, select coasting at the parameter EMESTOP_MODE. • Sequencing same as figure 3.1/1 II D 3-7 3ADW000066R0901_DCS500_System_description_e_i 3.5 Typical configuration for high power drives This wiring diagram has been generated to show the configuration for big drives with preferably more than 2000 A for the armature supply and a 3-phase field supply. For such drives the converter construction type A6 or A7 is used. The basic idea is identical to figure 3.1/1. A B L1 N L1 C L2 L3 L1 L2 L3 Voltage levels see description E L1 L2 L3 T2 230V 690V 660V 600V 575V F2 525V 500V 450V 415V 400V 380V 1 1 F7 F5 115V 2 2 K15 OFF STOP ON START 1 3 2 4 F8 1 3 5 F6 13 1 3 5 14 X96:1 14 I> I> I> K10 2 4 6 1 3 5 2 4 6 13 I> I> I> 2 4 6 1 3 5 2 4 6 X96:2 1 X2:TK 13 F6 14 K21 K1 2 X2:TK 3 1 EMER. STOP K20 K8 S1 1 3 5 2 4 6 U1 V1 K6 K1 2 K20 K21 IN3 V5 OUT3 V6 IN1 V1 OUT1 V2 K6 K8 K1 L1 K15 X96: 1 Communication board (COM-x) 2 X99: 1 2 AITAC _ + M ~ DO8 Power supply (POW-1) AI1 _ + AI2 _ + 5 6 AI3 _ + 2 3 4 5 6 7 8 9 depending on the unit type and supply voltage an other configuration is possible Converter module AI4 _ + +10V -10V 0V X3: 1 W1 PE F1 S4 X33 X2: U1 V1 W1 PE X2: TK TK Control board (CON-2) 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 DO1 DO2 DO3 DO4 DO5 DO6 DO7 0V 0V X6: 1 2 3 4 5 6 7 8 9 10 X16: X7: 1 2 3 4 5 6 7 8 X5: 1...10 1 2 3 C1 D1 _ + K6 e.g. Pressure switch at C4 module 1 K20 S1 K10 2 K8 if there are intermediate terminals K1 K21 the polarities are shown for motor operation T U M + V W M 3~ _ Figure 3.5/1: 1 2 3 X16: T Typical configuration for high power drives (armature unit DCS 500B) • Selection of components For this wiring diagram a DCS 500B converter construction type A6 or A7 was selected together with a 3-phase field supply. This field supply can be used at line voltages up to 500 V and will give field current up to 540 A. • Power supply There are several components, which need a power supply: - Armature converter´s power part: 200 V to 1000 V, depending on converter type; see chapter 2 - Field converter´s power part: 200 V to 500 V - Converters electronics power supply: 115 V or 230 V, selected by jumper - Converter cooling fan: 230V 1-ph at A5 (armature), C1 + C2 (field); 400 V / 690 V 3-ph. at A6/A7 (armature); see Technical Data - Motor cooling fan: depending on motor manufacturer / local demands - Relay logic: depending on local demands This configuration is basically identical to the one shown at figure 3.1/1. The converters in use here are much bigger than before. They are equipped with fuses in the legs of the power part. That´s the reason F1 is drawn within the square of the power part. If additional fuses are needed between supply transformer or not, has to be decided case by case. The field supply transformer T3 cannot be used for this configuration! See also power supply fig. 3.4/1 (fully-controlled field). In case the power for A, B, D and E should be taken from the source, used for C, a decision must be made, whether the fuses F1 can be used for two reasons (protection of the power part + auxiliary power supply) or not. In addition it has to be checked, if the consumers can be supplied with this voltage wave form (see chapter Line Chokes) before connecting to C. II D 3-8 3ADW000066R0901_DCS500_System_description_e_i Voltage levels see description C L1 L2 L3 F1.2 1 1 1 F5.2 F8.2 2 2 2 X96:1 K10.2 X96:2 X2:4 X2:5 K8.2 K8.2 1 3 2 4 1 3 5 2 4 6 U1 V1 K1.2 L1.2 K1.2 3 IN3 V5 OUT3 V6 IN1 V1 OUT1 V2 X96: 1 Communication board (COM-x) 2 X99: 1 AITAC _ + 2 3 4 AI1 _ + 5 5 X2: 1 AI2 _ + 5 6 AI3 _ + 6 7 8 9 2 3 W1 PE M ~ Power supply (POW-1) DCF 506 depending on the unit type an other configuration is possible Overvoltage protection Converter module AI4 _ + +10V -10V 0V X3: 1 X2: 4 DO8 S4 X33 2 Control board (CON-2) 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 X6: 1 2 3 4 5 6 7 8 9 X4:1 DO1 DO2 DO3 DO4 DO5 DO6 DO7 0V 0V 10 X7: 1 2 3 4 5 6 7 8 X4:2 X16: X5: 1...10 1 2 3 C1 + D1 _ X11 + X12 _ K1.2 K10.2 K8.2 X16: 1 2 3 Figure 3.5/2: Typical configuration for high power drives (field unit DCF 500B) • Control The relay logic can be split into three parts. Basically the logic shown at figure 3.2/1 could be used for this configuration. Because of the size of the drive and it´s value the logic shown is recommended: a: Generation of the ON/OFF and START/STOP command: same as figure 3.1/1 b: Generation of control and monitoring signals: same as figure 3.1/1 Each converter is monitoring his main contactor and his fan supply by himself. c: Stop mode beside ON/OFF and START/STOP: same as figure 3.1/1 It is recommended to use the additional safety provided by the use of the ELECTRICAL DISCONNECT function at such type of drives. • Sequencing It is basically the same than the one described for figure 3.1/1. The 3-phase field exciter is equipped with much more detailed service functionallity compared to the single phase types (SDCS-FEX-2A or DCF 503A/4A). Nevertheless from the control point of view (binary signals given to the armature converter) it will act in exactly the same way as a single phase one! When the ON command is given to the armature converter and there is no error signal active, the converter transfers this command via the serial link to the field converter. Afterwards, each converter closes the fan and main contactor, checks the supply voltage and the status of the contactors and without any error messages, releases the regulators. Then the same actions take place described at fig. 3.1/1. In case the field unit records an error a common error signal is send to the armature converter. In parallel an error indication is displayed on the field unit´s 7-segment display and at its binary output, if programmed. The armature converter will indicate the field unit´s error message with F39 on its display. The drive will be switched off by itself if it was running. The control system should then send a Reset command to the armature converter after having removed the ON/OFF and RUN commands. The error message should no longer be shown. With a new start command the armature converter will at first send a Reset command to the field converter. The field unit will then reset its error message, if the reason for it is no longer present. After that the field unit receives the start command from the armature converter and will switch on its main contactor. It's not necessary to exchange information like commands, actual values or error message within field converter and control system based on a serial link like PROFIBUS or others. In case the more comfortable servicing capabilities of a 3-phase field unit should be used it´s no problem to do so either via hardware (terminal row) or via a serial link. II D 3-9 3ADW000066R0901_DCS500_System_description_e_i 3.6 Typical configuration for high power drives connected in 12-pulse parallel Master-Follower application This wiring diagram can be used for 12-pulse parallel systems. It´s is based on the configuration shown at firgure 3.1/1, too. Such a configuration can be done with two 25 A converters as well as with two 5200 A types. Most often this configuration is selected because of the total power. That´s the reason why the wiring is already adapted to A5 (converter fan 1-phase) or A7 type converters. For the field supply, please take the field wiring at figure 3.5/2. If a smaller type is used, pick up the part of interest shown at one of the figures before. A B L1 N L1 Voltage levels see description C L2 L3 L1 L2 L3 E L1 L2 L3 T2 230V 1 690V 660V 600V 575V F2 525V 500V 450V 415V 400V 380V 1 F7 F5 115V 2 2 K15 OFF 1 3 2 4 F8 1 5 F6 13 1 3 5 14 X96:1 STOP 3 14 I> I> I> K10 2 4 6 1 3 5 2 4 6 13 I> I> I> 2 4 6 1 3 5 2 4 6 U M 3~ X96:2 START ON 1 X2:TK 13 F6 14 K21 K1 2 X2:TK 3 1 EMER. STOP K20 K8 S1 1 3 5 2 4 6 U1 V1 K6 K1 2 K20 K21 IN3 V5 OUT3 V6 IN1 V1 OUT1 V2 K6 K8 K1 K15 X96: 1 Communication board (COM-x) 2 X99: 1 AITAC _ + 2 3 4 AI1 _ + 5 X2: U1 V1 W1 PE AI2 _ + Power supply (POW-1) 5 6 AI3 _ + 6 7 8 9 10 X4: 1 2 depending on the unit type and supply voltage an other configuration is possible X18: AI4 _ + +10V -10V 3 AO1 AO2 IACT 0V 4 5 6 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 10 W1 PE F1 DO8 0V X3: 1 X2: TK TK M ~ S4 X33 2 Control board (CON-2) 0V 0V X6: 1 e.g. Pressure switch at C4 module 2 3 K6 4 5 6 1 7 8 X16: X7: 1 2 3 4 5 6 7 8 X5: 1...10 1 2 3 + C1 _ D1 K10 2 K1 10 K20 S1 K8 9 Converter module DO1 DO2 DO3 DO4 DO5 DO6 DO7 K21 the polarities are shown for motor operation T M + T 1 2 3 X16: if there are intermediate terminals V W to field converter DCF 500B X16: _ Figure 3.6/1: Typical configuration for high power drives connected in 12-pulse parallel (MASTER) • Selection of components See remarks above. • Power supply There are several components, which need a power supply: - Armature converter´s power part: 200 V to 1000 V, depending on converter type; see chapter 2 - Converters electronics power supply: 115 V or 230 V, selected by jumper - Converter cooling fan: 230V 1-ph at C1 + C2, A5; 400 V / 690 V 3-ph. at A6/A7; see Technical Data - Motor field supply: see fig. 3.5/2 - Motor cooling fan: depending on motor manufacturer / local demands - Relay logic: depending on local demands This configuration is basically identical to the one shown at figure 3.5/1. The drive system is supplied by a 12-pulse transformer, which has got two secondary windings with a phase shift of 30 degrees. In this case a decision has to be made, how the auxiliary voltage levels A, B, C, D=field and E are generated. Attention has to be paid to the auxiliary voltage A: - is the power of transformer T2 sufficient to supply all consumers? Consumers are electronics of all the converters, possibly fans of the two 12pulse converters and the field supply unit, main contactors, monitoring circuits, etc. - is redundancy required, and/or flexibility to be able to operate master and follower independent of one another? If necessary several auxiliary voltage levels (A, A', A'' etc.) should be constructed. • Power supply (continuation) Afterwards it has to be decided how the different consumers will be protected against any type of failure. If circuit breakers are used, take their interruption capacity into account. Take the hints given before as a rough idea. See also power supply fig. 3.4/1 (fully-controlled field). II D 3-10 3ADW000066R0901_DCS500_System_description_e_i ∆ ∆ Y Voltage levels see description C L1 L2 L3 B L1 L2 L3 1 1 F5.3 2 F8.3 1 3 5 13 14 2 X96:1 I> I> I> K10.3 2 4 6 1 3 5 2 4 6 X96:2 X2:TK X2:TK 1 3 5 2 4 6 K8.3 K1.3 K8.3 K1.3 3 U1 V1 X96: 1 W1 PE F1 2 X99: 1 2 X2: TK TK X2: U1 V1 W1 PE Control board (CON-2) DO8 AITAC _ + X18: _ D1 Power supply (POW-1) S4 Converter module AI1 _ + AI2 _ + 5 6 AI3 _ + AI4 _ + +10V -10V 0V + C1 X3: 1 2 3 4 5 6 7 8 9 10 X4: 1 2 3 AO1 AO2 IACT 0V 4 5 6 depending on the unit type and supply voltage an other configuration is possible DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 +48V 0V 7 8 9 Communication board (COM-x) M ~ 10 2 3 4 5 6 7 8 9 10 IN3 V6 OUT3 V1 IN1 V2 OUT1 X33 DO1 DO2 DO3 DO4 DO5 DO6 DO7 0V 0V X6: 1 V5 X16: X7: 1 2 3 4 5 6 7 8 X5: 1...10 1 2 K20 Pressure switch K10.3 K8.3 Figure 3.6/2: K1.3 Typical configuration for high power drives connected in 12-pulse parallel (FOLLOWER) • Control The relay logic can be split into three parts. Basically the logic shown at figure 3.2/1 could be used for this configuration. Because of the size of the drive and it´s value the logic shown is recommended: a: Generation of the ON/OFF and START/STOP command: same as figure 3.1/1 b: Generation of control and monitoring signals: same as figure 3.1/1 Each converter is monitoring his main contactor and his fan supply by himself. c: Stop mode beside ON/OFF and START/STOP: same as figure 3.1/1 It is recommended to use the additional safety provided by the use of the ELECTRICAL DISCONNECT function at such type of drives. • Sequencing The circuit diagram is based on a permanent 12-pulse mode without any adaptation concerning redundancy and on one converter working as a Master and taking care for the field control. All remarks given in chapter 3.5 can be applied to this configuration too. The converters exchange binary signals for bridge reversal and for fast monitoring via the flat cable connection X18:. Analogue signals like current reference and actual current are exchanged via terminal row X3: / X4:. Parameters at group 36 have to be set within Master and Slave converter to get the data exchange via flat cable connection X18: and connected inputs / outputs working. Parameters to be set at group 1 and 2 within Master and Slave make sure the data exchange of current values analogue inputs and outputs will take place. Additional information and a detailed parameter list are available within the manual Planning and Start-up for 12-pulse Power Converters. • Engineering hint If the drive system has to be available in case of a failure redundancy is needed and basically possible! Basically errors and failures can happen to all components any time, depending on the single component affected the result will have a different severity. Because of that errors and faults resulting in a redundancy mode have to be specified at first. Errors and faults causing severe break down are found at the power supply / 12-pulse transformer, at the two converters, supplying the armature, at the field supply unit, at the 12-pulse interphase reactor or at the motor. Precautions can be made to increase the availability of the drive in case the load condition and the motor data allow to use the system with reduced power. This can be made for example by using two transformers instead of one single 12-pulse transformer, by enabling 6-pulse mode at the converters (only one converter is switched on; the other is still kept switched off), by a second installed field supply unit in case of hardware failures there or by enabling the field control done by either the one or the other converter and by a possibility to bypass the 12-pulse interphase choke. II D 3-11 3ADW000066R0901_DCS500_System_description_e_i II D 3-12 3ADW000066R0901_DCS500_System_description_e_i 4 Overview of software (Version 21.2xx) 4.1 GAD Engineering-Program The standard diagram of the DCS500 Software Structure is added to this chapter as folder. In addition to all the function blocks presented there (called "Standard Function Blocks") additional blocks (called "Application blocks") are available, like ABSolute value, ADDer with 2 and 4 inputs, AND gates with 2 and 4 inputs, COMParators, CONVersion blocks, COUNTer, DIVider, FILTer, FUNG (x-y function generator, LIMiter, MULiplier, OR gates with 2 and 4 inputs, PARameter function block, PI controller, SR memory, SUBtraction, XOR gates and others. Both types are stored in the converter and delivered with every converter. The application function blocks as well as the standard function blocks are available as a library in file format. This library serves as a basis for your customized modifications. As a library is always a copy of the one available within the converter former libraries are automatically included in the latest one. Commissioning and Maintenance Tools for DCS500 (Panel or DDC/CMT Tool) are able to connect or disconnect function blocks and therefore can produce customized software applications. Both these tools however are not able to produce a documentation of the Standard function block changes in software other than in a table. Therefore ABB offers another special tool to develop extended software structures as drawings and deliver a data file with these informations to be transferred into the drive control section via the CMT Tool. This tool is called GAD ( Graphical Application Designer). The GAD is for off-line use only and needs a CMT tool to transfer the changed software structure into the drive. The GAD PC program features the following functions: • application design and programming • graphics editor for drawing and altering program diagrams • user-controlled document depiction • compilation of the application file to be downloaded into the converter by using CMT tool • compilation of the diagram file to be loaded into the CMT tool window to see actual values on-line System requirements / recommendation: • min. 486 PC, 4 MB RAM, 40MB free hard disk space • operating system: Windows 3.x, 95, 98, NT, 2000 or XP Application block Fig. 4.1/1 Standard and Applications function blocks utilized with GAD Please note: For more information of the GAD PC program and the library there are manuals available describing the possibilities and the handling of the program. II D 4-1 3ADW000066R0901_DCS500_System_description_e_i 4.2 Introduction to the structure and handling The entire software is made up of connected function blocks. Each of these individual function 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: When you want to alter connections between function blocks, proceed as follows: • first select the input • and then connect to output All those connections possessing one dot each at their beginning and end can be altered. Parameters for setting values (such as ramp-up time / ramp-down time, controller gain, reference values and others) RAMP GENERATOR P2 Value P4 Value P6 Value Default setting 10713 Output 901 1709 1710 Parameter For input / parameter selection, the following applies: • Ignore the two right-hand digits; the remaining digits are the group and to be selected • The two right-hand digits are the element and to be selected Inputs for designating connections DI7 1708 DI7 10713 Group 107 element 13 DRIVE LOGIC Input The selection can be done with the control panel CDP312, using the (double-up-down) for the group and the (single-up-down) for the element or a PC-based tool program CMT/DCS500B. The following pages correspond to what you get printed from the GAD tool with additional explanations based on software 21.233 which is identical with software 21.234. Please note: The following pages describe the as-delivered wired functionality. If a desired signal or a certain function seems to be missing, it can in most cases be implemented very easily: • 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. • 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. • The values of the parameters are displayed in GADTool format. II D 4-2 3ADW000066R0901_DCS500_System_description_e_i Terminals SDCS-CON-2 Speed reference SP -20 SP -90 6 5 X3: P1 1 P2 20000 AI1 10104 AI1:OUT+ 10105 AI1:OUT10106 AI1:ERR 104 AI1 CONV MODE 105 AI1 HIGH VALUE P3 -20000 106 AI1 LOW VALUE + -- REF SEL 1910 IN1 1911 SEL1 DI8 (10715) OUT 11903 1912 IN2 1913 SEL2 1914 IN3 1915 SEL3 0 1916 ADD 1917 REV ST5 ST5 SP -77 CONST REF 1901 ACT1 1902 ACT2 1 1903 ACT3 ACT 11902 DRIVE LOGIC (903) 1904 ACT4 P2 1500 P3 0 P4 1906 REF1 1907 REF2 Speed reference handling OUT 11901 1908 REF3 1909 REF4 0 P5 0 P1 1000 1905 DEF ST5 SP -15 SOFTPOT1 SOFTPOT 1918 INCR OUT 11904 1919 DECR ACT 11905 1920 FOLLOW 1923 ENABLE DRIVE LOGIC (10903) P1 5000 P2 -5000 1921 OHL 1922 OLL (10903) RUNNING T20 SP -11 Incremental encoder SPEED MEASUREMENT X5: 10 CH A 1 Tacho 4 3 X3: SP -84 15000 P2 2048 AITAC 10101 AITAC:OUT+ 10102 AITAC:OUT10103 AITAC:ERR + 2 1 -8...-30V -30...-90V -90...-270V P1 P1 0 P2 30000 P3 -30000 101 102 103 2103 2101 SPEED SCALING PULSE TACHO 0 1 2 3 4 TACHOPULS NR AITAC:OUT+ (10505) (501) 12104 TACHO PULSES CH B EMF TO SPEED CALC U ARM ACT U MOTN V 12102 SPEED ACT T DATA LOGGER (601) 5 AITAC CONV MODE AITAC HIGH VALUE P3 5 AITAC LOW VALUE ST5 P4 0 P5 500 2102 2104 2105 SPEED MEAS MODE SPEED ACT FTR SPEED ACT FILT SPEED ACT FLT FTR 12103 T SPEED ACT EMF MAINTENANCE (1210) 12101 T5 Speed feedback calculation SP -89 Torque reference 8 7 X3: AI2 AI2:OUT+ 10107 AI2:OUT- 10108 + -- AI2:ERR 10109 P1 0 P2 2000 P3 -2000 107 AI2 CONV MODE AI3 X3: 10 9 + -- 0 P2 0 P3 0 P4 0 P5 0 P7 500 AI3:OUT+ 10110 AI3:OUT- 10111 AI3:ERR 10112 P1 0 P2 2000 -2000 110 111 112 AI3 CONV MODE AI3 HIGH VALUE AI3 LOW VALUE ST5 P8 10 P9 30 P10 30 P11 0 P13 500 P14 2 501 502 503 504 AI4:OUT+ 2 1 X4: AI4:OUTAI4:ERR P1 0 P2 2000 -2000 113 114 115 AI4 CONV MODE 10113 P12 0 10114 P16 4 10115 P17 1024 P18 0 P6 10 AI4 HIGH VALUE AI4 LOW VALUE ST5 Line I MOTN A I MOT1 FIELDN A I MOT2 FIELDN A 507 506 Supply Data U SUPPLY U NET ACT U NET DC NOM V PHASE SEQ CW LINE FREQUENCY Control Adjust. AI4 + -- Motor Data U MOTN V 505 FEXC SEL SP -87 Not used P3 P1 SP -88 Not used SETTGS_3 SETTINGS Conv. settings C4 Conv. values 10510 517 SET I COMV A I TRIP A 518 10509 SET U CONV V I CONV A 519 10511 SET MAX BR TEMP U CONV V 10512 520 SET CONV TYPE MAX BR TEMP 521 10513 SET QUADR TYPE CONV TYPE 10514 QUADR TYPE 10507 BRIDGE TEMP SP -1 108 AI2 HIGH VALUE 109 AI2 LOW VALUE ST5 P3 12PULSE LOGIC (3604) 523 CURR ACT FILT TC 524 PLL CONTROL 528 PLL DEV LIM UDC 526 OFFSET UDC 513 EMF FILT TC CONV CUR ACT ARM CUR ACT TORQUE ACT + - CALC Iact 10504 DATA LOGGER (604) 10508 10515 10501 10502 DATA LOGGER (602) MAINTENANCE (1211) 10503 II D 4-3 U ARM ACT 10505 EMF ACT 10506 525 UNI FILT TC 3ADW000066R0901_DCS500_System_description_e_i P19 10 (only for Cur. Controlling) P15 0 522 LANGUAGE ST20 1/8 DATA LOGGER (603) MAINTENANCE (1212) 3ADW000066R0901_DCS500_System_description_e_i 2/8 RAMP_3 SP -18 1720 SPEED SET 1701 IN (11803) P10 RAMP GENERATOR LOC REF (10906) LOCAL 0 1702 RES IN 1717 STARTSEL 0 1703 HOLD P1 200 P2 200 P3 100 P4 200 P5 100 P6 0 P7 0 P8 20000 P9 -20000 1711 1709 1712 1710 OUT 11701 S 0 2021 2005 0 P1 SP -17 REFSUM_2 IN1 OUT 11802 1802 IN2 2003 1801 2004 0 P2 FREE SIGNALS (12517) H 1707 T1/T2 1714 EMESTOP RAMP 1708 SP -13 2001 SPEED 11801 REFERENCE 11703 SIGN 2002 SPEED ERROR IN OUT 12001 SPEED ACT FRS WIN MODE OUT OF WIN WIN SIZE STEP RESP 12002 12003 STEP ST5 ST5 E- ACCEL1 T+ ACCEL2 DECEL1 T- DECEL2 Speed controller SMOOTH1 1713 SMOOTH2 1715 SPEEDMAX 1716 SPEEDMIN 1704 FOLLOW IN 1705 FOLL ACT 1706 RES OUT P11 0 P12 0 (10903) RUNNING (11205) BC SET ALL RAMP VALUES TO ZERO 1718 ACC COMP.MODE (OUT) 1719 ACC COMP.TRMIN ST5 SP -12 ACCELCOMP 50 P2 5000 P3 10000 P4 23000 P5 0 P6 50 P7 3000 P8 10 P9 200 P10 50 2201 2202 2203 2204 2205 2206 2207 2208 2209 2210 MIN SPEED MIN SPEED L SPEED L1 SPEED GT L1 SPEED L2 SPEED GT L2 OVERSPEEDLIMIT OVERSPEED 12201 12202 12203 201 P3 20000 203 204 CONSTANTS (12511) CONSTANTS (12510) 2302 2303 2304 TORQUE/CURRENT LIMITATION SPC TORQ MAX Min SPC TORQ MIN Max TREF TORQ MAX Min TREF TORQ MIN Max SPC TORQMAX1 12301 SPC TORQMIN1 12302 TREF TORQMAX112303 TREF TORQMIN1 12304 TORQ MAX2 12305 TORQ MIN2 12306 P1 4000 P2 -4000 P3 16000 P4 100 2305 TORQ MAX Min STALL.TORQUE STALL.TIME 2306 TORQ MIN Max MON.MEAS LEV MON.EMF V P5 200 Terminals P6 4095 AO1 IN AO1 NOMINAL V SDCS-CON-2 P7 0V AO1 AO1 OFFSET V X4: 0 BRAKE CONTROL (303) 2301 12204 STALL.SPEED 10 7 P2 202 CONSTANTS (12510) STALL.SEL SP -81 10000 DRIVE LOGIC CONSTANTS (12511) ST20 P1 TORQ REF HANDLING SP -10 SPMONI_2 SPEED MONITOR SPEED ACT P1 11702 AO1 NOMINAL VALUE P8 P9 ST5 P10 P11 P12 P13 2315 2316 2317 2307 2308 -4095 (12102) 2309 20000 2310 16383 2311 16383 2312 16383 2313 16383 2314 16383 (11001) GEAR.START TORQ GEAR.TORQ TIME T t GEAR.TORQ RAMP ARM CURR LIM P CURR LIM P Min ARM CURR LIM N Max x x y y 4192 SPEED ACT CURR LIM N 12308 x x y y 4192 MAX CURR LIM SPD ARM CURR LIM N1 12307 I ARM CURR LIM N2 ARM CURR LIM N3 ARM CURR LIM N4 n ARM CURR LIM N5 FLUX REF1 ST5 DCS 500B Software structure Software version: Schematics: Library: S21.233 S21V2_0 DCS500_1.5 and motor data 5000 0 P3 4095 208 AO2 NOMINAL VALUE 0V AO2 X4: P2 II D 4-4 10 8 P1 SP -80 AO2 205 IN 206 AO2 NOMINAL V 207 AO2 OFFSET V 3ADW000066R0901_DCS500_System_description_e_i ST5 1/8 2/8 3ADW000066R0901_DCS500_System_description_e_i 3/8 SP -9 SP -14 2006 TORQ REF HANDLING KP DROOPING 2008 TORQ REF HANDLING (12403) TORQ REF HANDLING (12402) 2009 2010 2011 2012 2007 OUT BAL SET1 BALREF VAL1 BAL2 SET2 BAL2REF VAL2 HOLD HOLD RINT CLEAR IN LIM 2407 12004 12005 2408 P1 P2 P3 P4 P5 P6 P7 P8 0 12403 SEL2:TORQ/SPEED 1 SEL2:OUT 2 SEL2.TREF EXT Max (12001) SP ERR SEL2:IN_LIM 12402 SPEED CONTROL (2010) 12404 3 4 5 (11702) FREE SIGNALS (12520) P1 1 SPC TORQMIN1 (11205) 2014 500 2015 0 2016 0 2017 500 2018 5000 2013 0 2019 0 2020 50 0 SEL2.TREF SPC Min SPC TORQMAX1 (10903) TREFHND2 SPEED CONTROL IN ACCELCOMP 2409 2406 SEL2.TORQ STEP SEL2.TREF SEL TORQ MAX2 RUNNING TORQ MIN2 SET OUT TO ZERO BC (10903) KP RUNNING ST5 -1 SET OUTPUTS TO ZERO KPSMIN KPSPOINT KPSWEAKFILT KI Torque ref DROOPING TD TF ST5 SP -8 TORQ REF SELECTION 2401 FREE SIGNALS (12521) FREE SIGNALS (12519) P1 0 P2 0 2403 2404 2402 2405 TREF A SEL1:OUT LOAD SHARE 12401 TREF B TREF A FTC TREF B SLOPE TREF TORQMAX1 TREF TORQMIN1 (10903) RUNNING ST5 SETS SEL1:OUT TO ZERO -1 Torque/current limitation EMFCONT2 SP -34 EMF CONTROL P11 0 1001 FIELD MODE 1001=1,3,5 (10907) EMESTOP ACT 1004 FLUX REF SEL 1002 CONSTANTS (12512) FLUX REF (12102) SPEED ACT P2 P13 P14 20000 23100 0 100% FLUX REF 1 100% 1012 FIELD WEAK POINT 1017 GENER.WEAK POINT 1018 FIELD WEAK DELAY FLUX REF SUM P1 P12 P3 P4 1006 100 1016 160 (10506) 1007 150 1008 4905 50 P5 P6 410 P7 -4095 P8 P9 1187 P10 3255 2190 11002 cal generatoric DRIVE MODE (1201) EMESTOP ACT (10907) 1005 EMF REF SEL 1003 EMF REF CONSTANTS (12509) 11001 F CURR REF 1201=10 TRef2 11003 0 40 70 90 & LOCAL EMF REF GENER.EMF REF EMF ACT EMF KP EMF KI 1011 EMF REL LEV 1009 EMF REG LIM P 1010 EMF REG LIM N 1013 FIELD CONST 1 Motor voltage controller 1014 FIELD CONST 2 1015 FIELD CONST 3 II D 4-5 ST10 3ADW000066R0901_DCS500_System_description_e_i 2/8 1/8 3/8 3ADW000066R0901_DCS500_System_description_e_i 4/8 C_CNTR_3 SP -75 CURRENT CONTROL ARM CURR REF FLUX N 401 SPEED CONTROL (2011) CONSTANTS (12526) CONSTANTS (12527) 0 P2 1366 P3 300 P4 3200 P5 2050 P6 150 P7 15 P8 0 P9 0 P10 0 P11 40 TORQ REF 12-PULS [1209] 1,2 FLUX REF1 402 403 404 P1 ARM CUR ACT 405 CURR REF IN LIM CURR DER IN LIM ARM DIR CURR REF CURR STEP ARM ALPHA BLOCK 10405 10403 10404 10402 10401 DATA LOGGER (606) t REF TYPE SEL 406 ARM CURR REF SLOPE 415 ARM CURR LIM P 416 ARM CURR LIM N 407 408 409 ARM CURR PI KP ARM CURR PI KI ARM CONT CURR LIM 412 ARM ALPHA LIM MAX 413 ARM ALPHA LIM MIN 414 DXN 410 ARM L 411 ARM R 417 ARM CURR CLAMP Armature current controller STSYN DCFMOD SP -105 C_MONIT SP -104 DCF FIELDMODE P1 0 1215 DCF MODE : 0 1 2 1 2 2 DI2 (10703) P2 0 : : : 3 : 4 : 5 : 6 : 45 6 45 6 1216 DI/OVP 1217 CURRENT MONITOR Disabled DCF Current Control Stand Alone Reserved Fexlink Node 1 Fexlink Node 2 MG Set P1 P2 7 Cur.Controller for high inductive load ... 407 x8 ARM_CURR_PI_KP ARM_CURR_PI_KI ... 408 x8 ARM_CONT_CUR_LIM 0 409 3601 REV_DELAY 15 3602 REV_GAP 15 3603 FREV_DELAY 15 P3 0 P4 0 419 CUR RIPPLE LIM 0 1 2 3 A137 F34 A137 F34 CUR RIPPLE MONIT ZERO CUR DETECT INTERNAL 0 1 CURRENT ZERO SIGNAL STSYN BC A121 F 21 as FEX 1 (Receiver) as FEX 2 (Receiver) 6 RUN DCF RESET DCF F1 CURR GT MIN L F1 CURR MIN TD F1 OVERCURR L F1 CURR TC F1 KP F1 KI F1 U LIM N F1 U LIM P 10916 10917 11303 Fexlink as Transmitter for FEX1 and FEX2 SP -30 MOTOR 1 FIELD FANS ON (10908) DRIVE MODE 1201=7 (1201) 1313 F1 RED.SEL 0 FIELD MODE 1001=1,3,5 (1001) 1301 F1 REF 100% 1314 F1 SEL.REF 1228 TEST REF2 1302 F1 FORCE FWD 0% 1303 F1 FORCE REV 1304 F1 ACK 1305 1321 1306 1307 1308 1309 1311 1312 420 Monit. 1 method 2 EXTERNAL via Options REF DCF 2047 200 4710 0 1 20 -4096 4096 421 Input for external Overvoltg.Protection from ext. FEXLINK P3 P10 P4 P5 P6 P7 P8 P9 F03 DriveLogic Iact 0 1 5 P2 CURRENT RISE MAX OVP SELECT 4 P1 32767 418 SDCS-FEX-2 or DCF503/504 or P1 (10908) FANS ON (1201) DRIVE MODE 1201=7 1510 F2 RED.SEL 0 CONSTANTS (12512) F1 CURR REF M2FIELD2 SP -28 M1FIELD2 11301 P2 1228 1501 F2 REF 1511 F2 SEL.REF MOTOR 2 FIELD 100% TEST REF2 F1 CURR ACT 11302 DATA LOGGER (605) DCF501/502 P3 P4 P5 P6 P7 P8 P9 2047 4710 0 1 20 -4096 4096 1502 1503 1504 1505 1506 1508 1509 F2 CURR GT MIN L F2 OVERCURR L F2 CURR TC F2 KP F2 KI F2 U LIM N F2 U LIM P F2 CURR REF 11501 0% SDCS-FEX-2 or DCF503/504 or DCF501/502 F2 CURR ACT 11502 ST20 ST20 SP -24 SP -26 MOTOR 2 FIELD OPTIONS MOTOR 1 FIELD OPTIONS P1 10 P4 100 P5 614 P6 200 P7 80 P8 80 P9 0 1310 F1 U AC DIFF MAX FREE WHEELING P1 10 1507 F2 U AC DIFF MAX FREE WHEELING ST20 1315 1316 1317 1318 1319 1320 OPTI.REF GAIN OPTI.REF MIN L OPTITORQUE II D 4-6 OPTI.REF MIN TD REV.REV HYST REV.REF HYST REV.FLUX TD FIELD REVERSAL Field current controller 1 and 2 3ADW000066R0901_DCS500_System_description_e_i ST20 3/8 1/8 4/8 3ADW000066R0901_DCS500_System_description_e_i 5/8 Terminals SDCS-CON-2 SP -63 DI7 7 X6: O1 ON/OFF O2 Binary in and outputs (standard) 10713 10714 ST5 SP-36 901 SP -62 DI8 8 X6: O1 RUN O2 902 10715 10716 REF SEL (1911) BRAKE CONTROL (302) ST5 904 905 SP -65 DI5 5 X6: O1 EM STOP O2 906 10709 SP -64 DI6 6 X6: O2 10711 908 10712 909 910 911 SP -69 DI1 1 X6: O1 O2 912 10701 913 10702 ST5 SP -68 DI2 2 X6: O1 O2 10703 10704 DCF FIELDMODE (1216) ST5 SP -67 DI3 3 X6: O1 MAIN CONT RUNNING 10903 FAULT 10904 COAST STOP ALARM 10905 RAMP GENERATOR TORQ REF SELECTION TORQ REF HANDLING EMESTOP ACT 10907 LOCAL 10906 EME STOP MAINTENANCE MIN SPEED (12201) BC (BLOCK.) (11205) 907 ST5 MOTOR FAN 1 RUN3 RUN2 RESET O1 CONV FAN RDY ON 10901 RDY RUNNING 10902 RUN1 LOCAL 10710 ST5 RESET 903 CONST REF (11902) DRLOGI_2 DRIVE LOGIC ON/OFF O2 10705 P1 0 P2 1 P3 0 P4 0 P5 0 P6 0 P7 0 P8 2 914 915 916 917 918 919 920 921 10706 START INHIBIT DISABLE LOCAL FAN ON 10908 ACK CONV FAN MOTOR 1/2 FIELD FIELD ON 10909 ACK MOTOR FAN MAIN CONT ON 10910 MOTOR ACT 10913 ACK MAIN CONT MOTOR2 TRIP DC BREAKER 10911 FIELD HEAT SEL DYN BRAKE ON 10912 MAIN CONT MODE STOP MODE EME STOP MODE PANEL DISC MODE PWR LOSS MODE AUTO-RECLOSING 10914 COMFAULT MODE COMM FAULT 10915 COMFLT. TIMEOUT T20 ST5 SP -66 DI4 4 X6: O1 O2 10707 Must be connected, when no fan acknowledges (DI1, DI2) 10708 ST5 Additional binary inputs Terminals SDCS-IOE-1 1 X1: not used SP-61 DI9 O1 O2 2 X1: not used ST5 SP-60 DI10 Inputs and outputs for fieldbus SP -91 DATASET 1 10717 10122 OUT1 10123 OUT2 10124 OUT3 10718 IN ST5 O1 O2 10719 10720 ST5 SP-59 3 X1: DI11 not used O1 O2 10721 10722 ST5 SP-58 SP -93 DATASET 3 4 X1: DI12 not used O1 O2 IN 10724 ST5 ST5 ST5 SP-57 6 X1: DI13 not used 10125 OUT1 10126 OUT2 10127 OUT3 10723 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 SP-95 FLBSET_2 FIELDBUS 4001 FIELDBUS PAR.1 4002 (MODULE TYPE) 4003 4004 4005 4006 4007 4008 4009 4010 Parameters 4011 depends of modul type 4012 4013 4014 4015 O1 O2 10725 10726 ST5 SP-56 7 X1: DI14 not used O1 O2 10727 Inputs and outputs for 12 pulse 10728 ST5 SP-55 8 X1: O1 O2 12-PULSE LOGIC BRIDGE REVERSAL LOGIC active, if [1209]= 1 or 2 INPUT X18 10729 13617 X18:13 13618 X18:14 13619 X18:15 13620 X18:16 10730 ST5 SP -86 AI5 AI5:OUT+ 2 1 X2: AI5:OUT- + -- AI5:ERR 0 116 AI5 CONV MODE P2 2000 117 AI5 HIGH VALUE P3 -2000 118 AI5 LOW VALUE P1 P1 P2 P3 10116 10117 1 10 10 10118 3610 Revers.Logic 3601 REV DELAY 3602 REV GAP 3603 FREV DELAY ON/OFF LOGIC 3607 INHIB Logic not used 5 4 X2: + -- AI6:ERR 10121 119 AI6 CONV MODE 0 P2 2000 120 AI6 HIGH VALUE P3 -2000 121 AI6 LOW VALUE P4 P5 10 150 3605 DIFF CURRENT 3606 DIFF CURR DELAY 13616 13621 13601 Conv.Curr.Slave 13602 Arm.Curr.Slave 13603 Conv.Curr.Both 13604 Arm.CURR.Both 13615 Fault Current CURRENT REFERENCE 3615 ADJ REF1 3604 IACT SLAVE AI2 (10107) 3ADW000066R0901_DCS500_System_description_e_iMASTER 6-PULSE P6 ST5 4/8 BC not Zero CURRENT ANALYSIS active, if [1209] = 1 AI6:OUT+ 10119 AI6:OUT- 10120 P1 Logic f. INHIBIT (11205) BC 3616 BC Logic ST5 SP -85 AI6 13611 Bridge 13606 IREF1-Polarity 13609 IREF2-Polarity 13607 IREF1-Pol.Master 13610 IREF2-Pol.Broth 13612 Bridge of Slave 13613 Indicat.Revers 13614 Fault Reversion 3608 IREF0 Logic 3609 Bridge Logic STSYN not used 12PULS_2 SP -99 SP -97 DI15 not used 2048 II D [1209] 4-7 Curr.Ref.2 13608 * 2048 Curr.Ref.1 Res. f.Commun 13605 13622 STSYN 5/8 3ADW000066R0901_DCS500_System_description_e_i 6/8 Terminals SDCS-CON-2 808 INV IN SP -100 RDY RUNNING (11208) 4 SP -46 DO4 IN X7: 807 T20 INV IN T20 1000 P3 0 P4 100 1 FAN CONT (10906) LOCAL 1201 DRIVEMODE (11209) P2 X7: SP -49 DO1 801 IN 802 INV IN RUNNING 0 5 810 SP -45 DO5 IN X7: 809 P1 SP -48 DO2 803 IN 804 INV IN P6 1 P7 358 2 250 X7: P5 0 SP -47 DO3 805 IN 806 INV IN T20 P10 6 INV IN X7: MAIN CONT Relay output SDCS-POW-1 SP -44 DO6 IN 812 SPEED MESUREMENT (12103) SETTINGS (10505) 1 2 811 P11 1206 0 1202 1203 1207 1208 1209 1213 1210 1211 1212 1214 & I1=I2 RELEASE OF ARM. CONTROLLING TEST REF SEL 0 4 ARM. CONTROLLER POT1 VALUE 1 7 FIRST FIELD EXCITER POT2 VALUE 2 8 SECOND FIELD EXCITER PERIOD t BTW.POT1/2 3 9 4 10 0 SPEED LOOP EMF CONTROLLER TEST REF SQUARE WAVE DRIVE ID WRITE ENABLE KEY WRITE ENABLE PIN SELECT OPER.SYST DRIVE LOGIC RAMP GENERATOR 12 PULSE LOGIC 11203 FEXC STATUS 11210 FEXC1 CODE 11220 FEXC1 SW VERSION 11211 FEXC1 COM STATUS FEXC1 COM ERRORS 11212 11213 FEXC2 CODE 11221 FEXC2 SW VERSION FEXC2 COM STATUS 11214 11215 FEXC2 COM ERRORS FIELDBUS NODE ADDR ACTUAL VALUE 1 ACTUAL VALUE 2 11206 11204 TC STATUS 11201 COMMIS STAT 11205 BC 11202 BACKUPSTOREMODE 11222 PROGRAM LOAD 11216 11218 CNT SW VERSION CMT COM ERRORS 11217 11219 CNT BOOT SW VER CDI300 BAD CHAR CMT DCS500 ADDR CDP312 ACTUAL VALUE 3 MACRO SELECT Maintenance 7 SP -43 DO7 IN X7: 814 1205 4 T5 T20 813 1 SETTINGS (10501) X96: SP -42 DO8 815 IN 816 INV IN T20 3 358 P9 X7: P8 T20 MAIN CONT 1204 (11207) T20 EXC CONT MANTUN_3 MAINTENANCE TEST RELEASE INV IN T20 SP -92 DATASET 2 209 IN1 210 IN2 211 IN3 ST5 OUT Monitoring SP -94 DATASET 4 212 IN1 213 IN2 214 IN3 ST5 SP -76 OUT P1 110 P2 230 P3 80 P4 60 P5 5000 P6 0 P7 4 P8 P9 10 0 511 512 508 509 510 514 515 516 527 CONPROT2 CONVERTER PROTECTION ARM OVERVOLT LEV ARM OVERCURR LEV U NET MIN1 U NET MIN2 PWR DOWN TIME EARTH.CURR SEL EARTH.FLT LEV EARTH.FLT DLY CONV TEMP DELAY ST20 SP -22 SP -98 OUTPUT X18 3611 3612 3613 3614 P1 0 X18:09 X18:10 X18:11 X18:12 P2 0 P3 0 STSYN P4 4096 P5 120 P6 130 P7 240 M1PROT_2 MOTOR 1 PROTECTION 1401 MOT1.TEMP IN 1402 11401 MOT1.TEMP ALARM L MOT1 MEAS TEMP 1403 MOT1.TEMP FAULT L 1404 KLIXON IN 1405 11402 MODEL1.SEL MOT1 CALC TEMP 1406 MODEL1.CURR 1407 MODEL1.ALARM L 1408 MODEL1.TRIP L 1409 MODEL1.TC ST20 SP -21 II D 4-8 P1 0 P2 0 P3 0 P4 4096 P5 120 P6 130 P7 240 3ADW000066R0901_DCS500_System_description_e_i M2PROT_2 MOTOR 2 PROTECTION 1601 MOT2.TEMP IN 11601 1602 MOT2.TEMP ALARM L MOT2 MEAS TEMP 1603 MOT2.TEMP FAULT L 1604 11602 MODEL2.SEL MOT2 CALC TEMP 1605 MODEL2.CURR 1606 MODEL2.ALARM L 1607 MODEL2.TRIP L 1608 MODEL2.TC ST20 5/8 6/8 3ADW000066R0901_DCS500_System_description_e_i 7/8 SP -7 P1 0 "EXT. IND. 1" P3 0 SP-102 1101 IN USER EVENT 1 1102 TYPE 1103 TEXT 1104 SPEED MEASUREMENT (12102) DLY ST20 SP -6 P1 0 "EXT. IND. 2" P3 0 1107 TEXT 1108 DLY 602 SETTINGS (10505) 603 SETTINGS (10504) 604 MOTOR 1 FIELD (11302) 605 P1 1 P2 20000 P3 200 P4 3 "EXT. IND. 3" P3 0 606 607 608 609 610 611 SP -5 0 601 SETTINGS (10501) CURRENT CONTROL (10401) 1105 IN USER EVENT 2 1106 TYPE ST20 P1 DATALOG DATA LOGGER 612 1109 IN USER EVENT 3 1110 TYPE 1111 TEXT 613 IN1 Ch.1 IN2 Ch.2 IN3 Ch.3 IN4 Ch.4 IN5 Ch.5 IN6 Ch.6 DLOG.TRIGG COND DLOG STATUS 10601 DLOG.TRIGG VALUE CMT-TOOL DLOG.TRIGG DELAY TRIG STOP RESTART DLOG.SAMPL INT DLOG.TRIG 0 DLOG.STOP 0 DLOG.RESTART 0 TRIG STOP RESTART T1ms 1112 DLY ST20 SP -4 1113 IN P1 0 "EXT. IND. 4" P3 0 1114 USER EVENT 4 Data logger TYPE 1115 TEXT 1116 DLY ST20 SP -3 1117 IN P1 0 "EXT. IND. 5" P3 0 1118 USER EVENT 5 TYPE 1119 TEXT 1120 DLY ST20 Additional signals SP -2 1121 IN P1 0 "EXT. IND. 6" P3 0 USER EVENT 6 1122 TYPE 1123 TEXT 1124 DLY SP -73 ST20 CONSTANTS 0 -1 1 User events 2 10 100 1000 31416 EMF:100% TORQ:100% TORQ:-100% CUR,FLX,VLT: 100% CUR,FLX,VLT:-100% Brake control SPEED: 100% SPEED:-100% 12501 CONST_0 12502 CONST_M1_TRUE 12503 CONST_1 12504 CONST_2 12505 CONST_10 12506 CONST_100 12507 CONST_1000 12508 CONST_31416 12509 EMF_MAX 12510 TORQ_MAX 12511 TORQ_MAX_N 12512 CONST_4095 12513 CONST_M4095 12514 CONST_20000 12515 CONST_M20000 ST SP -74 FREE SIGNALS 12516 SIG1(SPEED REF) 12517 SIG2(SPEED STEP) 12518 SIG3(TORQ. REF A) 12519 SIG4(TORQ. REF B) 12520 SIG5(TORQUE STEP) 12521 SIG6(LOAD SHARE) 12522 SIG7(FLUX REF) 12523 SIG8(EMF REF) 12524 SIG9(FORCE_FWD) 12525 SIG10(FORCE REV) 12526 SIG11(CURR. REF) 12527 SIG12(CURR._STEP) SP -32 (10902) (10503) BRAKE CONTROL RESET TORQUE ACT 301 HOLD REF DI8 (10715) SPEED MONITOR (12201) P1 0 P2 0 P3 0 P4 0 TREF OUT 10301 LOCAL 302 BR RELEASE TREF ENABLE 10302 303 MIN SP IND DECEL CMND 10303 10304 304 ACT BRAKE LIFT BRAKE 10305 305 START DELAY BRAKE RUN 306 STOP DELAY 307 HOLD TORQ 308 EMESTOP BRAKE ST20 SPEED_STEP TORQ_REF_B TORQ_STEP LOAD_SHARE CUR_REF CUR_STEP ST FLTHNDL SP-103 FAULT HANDLING FAULT WORD 1 FAULT WORD 2 FAULT WORD 3 LATEST FAULT ALARM WORD 1 ALARM WORD 2 ALARM WORD 3 LATEST ALARM OPERATING HOURS 11101 11102 11103 11107 11104 11105 11106 11108 11109 T20 II D 4-9 3ADW000066R0901_DCS500_System_description_e_i 6/8 7/8 3ADW000066R0901_DCS500_System_description_e_i 8/8 Speed reference handling Field current controller 1 and 2 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). 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 REF SUM block enables the output of the ramp function generator and a user-definable signal to be added. 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 buildup. Speed feedback calculation 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 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. Speed controller 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 drive’s 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 drive’s actual speed back into the window. The SPEED CONTROL block contains the speed controller with P, I and DT1 contents. For adaptation it receives a variable P-amplification. Binary in and outputs (standard) 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 converter’s line contactor, the field-circuit contactor or contactors for various fans, or for outputting status messages. Additional binary inputs 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. Inputs and outputs for fieldbus 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. Torque / current limitation 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 AI2 block (analogue input 2) is used for reading in an analogue signal. 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 signal’s evaluation can be dynamically altered using a multiplier. The TORQ REF HANDLING block determines the drive's 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". Armature current controller 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. At applications with high inductive load and high dynamic performance a different hardware is used to generate the signal current equal to zero. This hardware is selected by the CURRENT MONITOR block. The functions monitoring the current can now be adapted to the needs of the application. This gives easier handling and a higher degree of safety at high performance drives, like test rigs. The DCF mode can be activated via the block DCF FIELDMODE. The functionality within this mode can be specified. If one of these functions is selected the current controller gets a different characteristic, the overvoltage protection DCF 506 is monitored and the field current reference via the X16: terminals is routed. Line and motor data The SETTINGS block serves for scaling all important signals, such as line voltage, motor voltage, motor current and field current. Parameters are available to adjust the control to special conditions like weak networks or interactions with harmonic filter systems. The language, in which you want to read your information on the panel, can be selected. The AO2 block represents a scalable analogue output. Motor voltage controller 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. To enable the drive to utilize a higher motor voltage even with a 4 quadrant system two different field weakening points can be set by parameter. Inputs and outputs for 12 pulse 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. Maintenance The MAINTENANCE 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. Monitoring 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". Adaptations are made for rebuild applications, which keep the power part and the fan, to sense overload conditions or fan failures. 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. User event By using the block USER EVENT1 to USER EVENT6 six different messages are created, which are displayed as faults or alarms on the panel CDP312 as well as on the 7 segment display of the converter. Brake control The BRAKE CONTROL block generates all signals needed for controlling a mechanical brake. Data logger 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. Additional signals By using the block FAULT HANDLING the faults and alarms of the drive are regrouped as 16bit information. The CONSTANTS and FREE SIGNALS blocks can be used for setting limitations or special test conditions. II D 4-10 3ADW000066R0901_DCS500_System_description_e_i 7/8 8/8 3ADW000066R0901_DCS500_System_description_e_i List of parameters (with column for customer-specific values) No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 201 202 203 204 205 206 207 208 209 210 211 212 213 214 301 302 303 304 305 306 307 308 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 501 502 503 504 505 506 Parameter name AITAC_CONV_MODE AITAC_HIGH_VALUE AITAC_LOW_VALUE AI1_CONV_MODE AI1_HIGH_VALUE AI1_LOW_VALUE AI2_CONV_MODE AI2_HIGH_VALUE AI2_LOW_VALUE AI3_CONV_MODE AI3_HIGH_VALUE AI3_LOW_VALUE AI4_CONV_MODE AI4_HIGH_VALUE AI4_LOW_VALUE AI5_CONV_MODE AI5_HIGH_VALUE AI5_LOW_VALUE AI6_CONV_MODE AI6_HIGH_VALUE AI6_LOW_VALUE AO1.[IN] AO1_NOMINAL_V AO1_OFFSET_V AO1_NOMINAL_VAL AO2.[IN] AO2_NOMINAL_V AO2_OFFSET_V AO2_NOMINAL_VAL DATASET2.[IN1] DATASET2.[IN2] DATASET2.[IN3] DATASET4.[IN1] DATASET4.[IN2] DATASET4.[IN3] [HOLD_REF] [BR_RELEASE] [MIN_SP_IND] [ACT_BRAKE] START_DELAY STOP_DELAY HOLD_TORQ EMESTOP_BRAKE [TORQ_REF] [CURR_REF] [CURR_STEP] [BLOCK] REF_TYPE_SEL ARM_CURR_REF_SLOPE ARM_CURR_PI_KP ARM_CURR_PI_KI ARM_CONT_CURR_LIM ARM_L ARM_R ARM_ALPHA_LIM_MAX ARM_ALPHA_LIM_MIN DXN [ARM_CURR_LIM_P] [ARM_CURR_LIM_N] ARM_CURR_CLAMP CURRENT_RISE_MAX ZERO_CUR_DETECT CUR_RIPPLE_MONIT CUR_RIPPLE_LIM U_MOTN_V I_MOTN_A I_MOT1_FIELDN_A I_MOT2_FIELDN_A FEXC_SEL PHASE_SEQ_CW No. Parameter name No. Parameter name 507 U_SUPPLY 920 COMFAULT_MODE 508 U_NET_MIN1 921 COMFAULT_TIMEOUT 509 U_NET_MIN2 1001 FIELD_MODE 510 PWR_DOWN_TIME 1002 [FLUX_REF] 511 ARM_OVERVOLT_LEV 1003 [EMF_REF] 512 ARM_OVERCURR_LEV 1004 [FLUX_REF_SEL] 513 EMF_FILT_TC 1005 [EMF_REF_SEL] 514 EARTH.CURR_SEL 1006 LOCAL_EMF_REF 515 EARTH.FLT_LEV 1007 EMF_KP 516 EARTH.FLT_DLY 1008 EMF_KI 517 SET_I_CONV_A 1009 EMF_REG_LIM_P 518 SET_U_CONV_V 1010 EMF_REG_LIM_N 519 SET_MAX_BR_TEMP 1011 EMF_REL_LEV 520 SET_CONV_TYPE 1012 FIELD_WEAK_POINT 521 SET_QUADR_TYPE 1013 FIELD_CONST_1 522 LANGUAGE 1014 FIELD_CONST_2 523 CURR_ACT_FILT_TC 1015 FIELD_CONST_3 524 PLL_CONTROL 1016 GENER.EMF_REF 525 UNI_FILT_TC 1017 GENER.WEAK_POINT 526 OFFSET_UDC 1018 FIELD_WEAK_DELAY 527 CONV_TEMP_DELAY 1101 USER_EVENT1.[IN] 528 PLL_DEV_LIM 1102 USER_EVENT1.TYPE 601 DLOG.[IN1] 1103 USER_EVENT1.TEXT 602 DLOG.[IN2] 1104 USER_EVENT1.DLY 603 DLOG.[IN3] 1105 USER_EVENT2.[IN] 604 DLOG.[IN4] 1106 USER_EVENT2.TYPE 605 DLOG.[IN5] 1107 USER_EVENT2.TEXT 606 DLOG.[IN6] 1108 USER_EVENT2.DLY 607 DLOG.TRIGG_COND 1109 USER_EVENT3.[IN] 608 DLOG.TRIGG_VALUE 1110 USER_EVENT3.TYPE 609 DLOG.TRIGG_DELAY 1111 USER_EVENT3.TEXT 610 DLOG.SAMPL_INT 1112 USER_EVENT3.DLY 611 DLOG.TRIG 1113 USER_EVENT4.[IN] 612 DLOG.STOP 1114 USER_EVENT4.TYPE 613 DLOG.RESTART 1115 USER_EVENT4.TEXT 801 DO1.[IN] 1116 USER_EVENT4.DLY 802 DO1.[INV_IN] 1117 USER_EVENT5.[IN] 803 DO2.[IN] 1118 USER_EVENT5.TYPE 804 DO2.[INV_IN] 1119 USER_EVENT5.TEXT 805 DO3.[IN] 1120 USER_EVENT5.DLY 806 DO3.[INV_IN] 1121 USER_EVENT6.[IN] 807 DO4.[IN] 1122 USER_EVENT6.TYPE 808 DO4.[INV_IN] 1123 USER_EVENT6.TEXT 809 DO5.[IN] 1124 USER_EVENT6.DLY 810 DO5.[INV_IN] 1201 DRIVEMODE 811 DO6.[IN] 1202 CMT_DCS500_ADDR 812 DO6.[INV_IN] 1203 DRIVE_ID 813 DO7.[IN] 1204 POT1_VALUE 814 DO7.[INV_IN] 1205 POT2_VALUE 815 DO8.[IN] 1206 PERIOD_BTW.POT1/2 816 DO8.[INV_IN] 1207 WRITE_ENABLE_KEY 901 [ON/OFF] 1208 WRITE_ENABLE_PIN 902 [RUN1] 1209 SELECT_OPER.SYST. 903 [RUN2] 1210 ACTUAL VALUE 1 904 [RUN3] 1211 ACTUAL VALUE 2 905 [COAST_STOP] 1212 ACTUAL VALUE 3 906 [EME_STOP] 1213 FIELDBUS NODE ADDR 907 [RESET] 1214 MACRO_SELECT 908 [START_INHIBIT] 1215 DCF MODE 909 [DISABLE_LOCAL] 1216 DI/OVP 910 [ACK_CONV_FAN] 1217 OVP_SELECT 911 [ACK_MOTOR_FAN] 1301 [F1_REF] 912 [ACK_MAIN_CONT] 1302 [F1_FORCE_FWD] 913 [MOTOR 2] 1303 [F1_FORCE_REV] 914 FIELD_HEAT_SEL 1304 [F1_ACK] 915 MAIN_CONT_MODE 1305 F1_CURR_GT_MIN_L 916 STOP_MODE 1306 F1_OVERCURR_L II D 4-11 917 EME_STOP_MODE 1307 F1_CURR_TC 3ADW000066R0901_DCS500_System_description_e_i 918 PANEL_DISC_MODE 1308 F1_KP 919 PWR_LOSS_MODE 1309 F1_KI 3ADW000066R0901_DCS500_System_description_e_i List of parameters (with column for customer-specific values) No. Parameter name 1310 F1_U_AC_DIFF_MAX 1311 F1_U_LIM_N 1312 F1_U_LIM_P 1313 F1_RED.SEL 1314 F1_RED.REF 1315 OPTI.REF_GAIN 1316 OPTI.REF_MIN_L 1317 OPTI.REF_MIN_TD 1318 REV.REV_HYST 1319 REV.REF_HYST 1320 REV.FLUX_TD 1321 F1_CURR_MIN_TD 1401 MOT1.[TEMP_IN] 1402 MOT1.TEMP_ALARM_L 1403 MOT1.TEMP_FAULT_L 1404 [KLIXON_IN] 1405 MODEL1.SEL 1406 MODEL1.CURR 1407 MODEL1.ALARM_L 1408 MODEL1.TRIP_L 1409 MODEL1.TC 1501 [F2_REF] 1502 F2_CURR_GT_MIN_L 1503 F2_OVERCURR_L 1504 F2_CURR_TC 1505 F2_KP 1506 F2_KI 1507 F2_U_AC_DIFF_MAX 1508 F2_U_LIM_N 1509 F2_U_LIM_P 1510 F2_RED.SEL 1511 F2_RED.REF 1601 MOT2.[TEMP_IN] 1602 MOT2.TEMP_ALARM_L 1603 MOT2.TEMP_FAULT_L 1604 MODEL2.SEL 1605 MODEL2.CURR 1606 MODEL2.ALARM_L 1607 MODEL2.TRIP_L 1608 MODEL2.TC 1701 RAMP.[IN] 1702 RAMP.[RES_IN] 1703 RAMP.[HOLD] 1704 RAMP.[FOLLOW_IN] 1705 RAMP.[FOLL_ACT] 1706 RAMP.[RES_OUT] 1707 RAMP.[T1/T2] 1708 ACCEL1 1709 DECEL1 1710 SMOOTH1 1711 ACCEL2 1712 DECEL2 1713 SMOOTH2 1714 EMESTOP_RAMP 1715 SPEEDMAX 1716 SPEEDMIN 1717 STARTSEL 1718 ACC_COMP.MODE 1719 ACC_COMP.TRMIN 1720 RAMP.[SPEED_SET] 1801 REF_SUM.[IN1] 1802 REF_SUM.[IN2] 1901 CONST_REF.[ACT1] 1902 CONST_REF.[ACT2] 1903 CONST_REF.[ACT3] 1904 CONST_REF.[ACT4] 1905 CONST_REF.DEF II D 4-12 1906 CONST_REF.REF1 1907 CONST_REF.REF2 1908 CONST_REF.REF3 No. Parameter name 1909 CONST_REF.REF4 1910 REFSEL.[IN1] 1911 REFSEL.[SEL1] 1912 REFSEL.[IN2] 1913 REFSEL.[SEL2] 1914 REFSEL.[IN3] 1915 REFSEL.[SEL3] 1916 REFSEL.[ADD] 1917 REFSEL.[REV] 1918 SOFTPOT.[INCR] 1919 SOFTPOT.[DECR] 1920 SOFTPOT.[FOLLOW] 1921 SOFTPOT.OHL 1922 SOFTPOT.OLL 1923 SOFTPOT.[ENABLE] 2001 ERR.[IN] 2002 ERR.[STEP] 2003 ERR.[WIN_MODE] 2004 ERR.WIN_SIZE 2005 ERR.FRS 2006 SPC.[IN] 2007 SPC.[RINT] 2008 SPC.[BAL] 2009 SPC.[BALREF] 2010 SPC.[BAL2] 2011 SPC.[BAL2REF] 2012 SPC.[HOLD] 2013 SPC.DROOPING 2014 SPC.KP 2015 SPC.KPSMIN 2016 SPC.KPSPOINT 2017 SPC.KPSWEAKFILT 2018 SPC.KI 2019 SPC.TD 2020 SPC.TF 2021 ERR. [SPEED_ACT] 2101 TACHOPULS_NR 2102 SPEED_MEAS_MODE 2103 SPEED_SCALING 2104 SPEED_ACT_FTR 2105 SPEED_ACT_FLT_FTR 2201 MIN_SPEED_L 2202 SPEED_L1 2203 SPEED_L2 2204 OVERSPEEDLIMIT 2205 STALL.SEL 2206 STALL.SPEED 2207 STALL.TORQUE 2208 STALL.TIME 2209 MON.MEAS_LEV 2210 MON.EMF_V 2301 [SPC_TORQ_MAX] 2302 [SPC_TORQ_MIN] 2303 [TREF_TORQ_MAX] 2304 [TREF_TORQ_MIN] 2305 TORQ_MAX 2306 TORQ_MIN 2307 ARM_CURR_LIM_P 2308 ARM_CURR_LIM_N 2309 MAX_CURR_LIM_SPD 2310 MAX_CURR_LIM_N1 2311 MAX_CURR_LIM_N2 2312 MAX_CURR_LIM_N3 2313 MAX_CURR_LIM_N4 2314 MAX_CURR_LIM_N5 2315 GEAR.START_TORQ 2316 GEAR.TORQ_TIME 2317 GEAR.TORQ_RAMP 3ADW000066R0901_DCS500_System_description_e_i 2401 SEL1.[TREF_A] 2402 SEL1.TREF_A_FTC 3ADW000066R0901_DCS500_System_description_e_i No. Parameter name 2403 SEL1.[LOAD_SHARE] 2404 SEL1.[TREF_B] 2405 SEL1.TREF_B_SLOPE 2406 SEL2.TREF_SEL 2407 SEL2.[TREF_SPC] 2408 SEL2.[TREF_EXT] 2409 SEL2.[TORQ_STEP] 2501 TASK1_EXEC_ORDER 2502 TASK2_EXEC_ORDER 2503 TASK3_EXEC_ORDER 2504 FB_APPL_ENABLE 2505 FB_TASK_LOCK 2601-Par. f. appl. func. blocks 2701-Par. f. appl. func. blocks 2801-Par. f. appl. func. blocks 2901-Par. f. appl. func. blocks 3001-Par. f. appl. func. blocks 3101-Par. f. appl. func. blocks 3201-Par. f. appl. func. blocks 3301-Par. f. appl. func. blocks 3401-Par. f. appl. func. blocks 3601 REV_DELAY 3602 REV_GAP 3603 FREV_DELAY 3604 IACT_SLAVE 3605 DIFF_CURRENT 3606 DIFF_CURR_DELAY 3607 INHIB_Logic 3608 IREF0_Logic 3609 Bridge_Logic 3610 Reverse.Logic 3611 [X18:09] 3612 [X18:10] 3613 [X18:11] 3614 [X18:12] 3615 ADJ_REF1 3616 BC-Logic 3701-Par. f. appl. func. blocks 3801-Par. f. appl. func. blocks 3901-Par. f. appl. func. blocks 4001 FIELDBUS_PAR.1 4002 FIELDBUS_PAR.2 4003 FIELDBUS_PAR.3 4004 FIELDBUS_PAR.4 4005 FIELDBUS_PAR.5 4006 FIELDBUS_PAR.6 4007 FIELDBUS_PAR.7 4008 FIELDBUS_PAR.8 4009 FIELDBUS_PAR.9 4010 FIELDBUS_PAR.10 4011 FIELDBUS_PAR.11 4012 FIELDBUS_PAR.12 4013 FIELDBUS_PAR.13 4014 FIELDBUS_PAR.14 4015 FIELDBUS_PAR.15 List of signals No. 10101 10102 10103 10104 10105 10106 10107 10108 10109 10110 10111 10112 10113 10114 10115 10116 10117 10118 10119 10120 10121 10122 10123 10124 10125 10126 10127 10301 10302 10303 10304 10305 10401 10402 10403 10404 10405 10501 10502 10503 10504 10505 10506 10507 10508 10509 10510 10511 10512 10513 10514 10515 10601 10701 10702 10703 10704 10705 10706 10707 10708 10709 10710 10711 10712 10713 10714 10715 10716 10717 10718 10719 10720 10721 10722 10723 10724 10725 10726 10727 10728 10729 Parameter name AITAC:OUT+ AITAC:OUTAITAC:ERR AI1:OUT+ AI1:OUTAI1:ERR AI2:OUT+ AI2:OUTAI2:ERR AI3:OUT+ AI3:OUTAI3:ERR AI4:OUT+ AI4:OUTAI4:ERR AI5:OUT+ AI5:OUTAI5:ERR AI6:OUT+ AI6:OUTAI6:ERR DATASET1:OUT1 DATASET1:OUT2 DATASET1:OUT3 DATASET3:OUT1 DATASET3:OUT2 DATASET3:OUT3 TREF_OUT TREF_ENABLE DECEL_CMND LIFT_BRAKE BRAKE_RUN ARM_ALPHA ARM_DIR CURR_REF_IN_LIM CURR_DER_IN_LIM ARM_CURR_REF CONV_CURR_ACT ARM_CURR_ACT TORQUE_ACT U_NET_ACT U_ARM_ACT EMF_ACT BRIDGE_TEMP U_NET_DC_NOM_V I_CONV_A I_TRIP_A U_CONV_V MAX_BR_TEMP CONV_TYPE QUADR_TYPE LINE_FREQUENCY DLOG_STATUS DI1:O1 DI1:O2 DI2:O1 DI2:O2 DI3:O1 DI3:O2 DI4:O1 DI4:O2 DI5:O1 DI5:O2 DI6:O1 DI6:O2 DI7:O1 DI7:O2 DI8:O1 DI8:O2 DI9:O1 DI9:O2 DI10:O1 DI10:O2 DI11:O1 DI11:O2 DI12:O1 DI12:O2 DI13:O1 DI13:O2 DI14:O1 DI14:O2 DI15:O1 No. Parameter name 10730 DI15:O2 10901 RDY_ON 10902 RDY_RUNNING 10903 RUNNING 10904 FAULT 10905 ALARM 10906 LOCAL 10907 EMESTOP_ACT 10908 FAN_ON 10909 FIELD_ON 10910 MAIN_CONT_ON 10911 TRIP_DC_BREAKER 10912 DYN_BRAKE_ON 10913 MOTOR_ACT 10914 AUTO-RECLOSING 10915 COMM_FAULT 10916 RUN_DCF 10917 RESET_DCF 11001 FLUX_REF1 11002 FLUX_REF_SUM 11003 F_CURR_REF 11101 FAULT_WORD_1 11102 FAULT_WORD_2 11103 FAULT_WORD_3 11104 ALARM_WORD_1 11105 ALARM_WORD_2 11106 ALARM_WORD_3 11107 LATEST_FAULT 11108 LATEST_ALARM 11109 OPERATING_HOURS 11201 COMMIS_STAT 11202 BACKUPSTOREMODE 11203 FEXC_STATUS 11204 TC_STATUS 11205 BC 11206 SQUARE_WAVE 11207 TEST_REF 11208 TEST_RELEASE 11209 TEST_REF_SEL 11210 FEXC1_CODE 11211 FEXC1_COM_STATUS 11212 FEXC1_COM_ERRORS 11213 FEXC2_CODE 11214 FEXC2_COM_STATUS 11215 FEXC2_COM_ERRORS 11216 CMT_COM_ERRORS 11217 CDI300_BAD_CHAR 11218 CNT_SW_VERSION 11219 CNT_BOOT_SW_VERSION 11220 FEXC1_SW_VERSION 11221 FEXC2_SW_VERSION 11222 PROGRAM_LOAD 11301 F1_CURR_REF 11302 F1_CURR_ACT 11303 REF_DCF 11401 MOT1_MEAS_TEMP 11402 MOT1_CALC_TEMP 11501 F2_CURR_REF 11502 F2_CURR_ACT 11601 MOT2_MEAS_TEMP 11602 MOT2_CALC_TEMP 11701 RAMP:OUT 11702 ACCELCOMP:OUT 11703 RAMP:SIGN 11801 SPEED_REFERENCE 11802 REF_SUM:OUT 11803 LOCAL_SPEED_REF 11901 CONST_REF:OUT 11902 CONST_REF:ACT 11903 REF_SEL:OUT 11904 SOFT_POT:OUT 11905 SOFT_POT:ACT 12001 ERR:OUT 12002 ERR:OUT_OF_WIN 12003 ERR:STEP_RESP 12004 SPC:OUT 12005 SPC:IN_LIM 12101 SPEED_ACT_EMF 12102 SPEED_ACT 12103 SPEED_ACT_FILT 3ADW000066R0901_DCS500_System_description_e_i 12104 TACHO_PULSES 12201 MIN_SPEED 3ADW000066R0901_DCS500_System_description_e_i No. 12202 12203 12204 12301 12302 12303 12304 12305 12306 12307 12308 12401 12402 12403 12404 12501 12502 12503 12504 12505 12506 12507 12508 12509 12510 12511 12512 12513 12514 12515 12516 12517 12518 12519 12520 12521 12522 12523 12524 12525 12526 12527 1260112699 1270112799 1280112899 1290112999 1300113013 13501 13502 13503 13601 13602 13603 13604 13605 13606 13607 13608 13609 13610 13611 13612 13613 13614 13615 13616 13617 13618 13619 13620 13621 13622 1380113819 1390113912 Parameter name SPEED_GT_L1 SPEED_GT_L2 OVERSPEED SPC_TORQMAX1 SPC_TORQMIN1 TREF_TORQMAX1 TREF_TORQMIN1 TORQMAX2 TORQMIN2 CURR_LIM_P CURR_LIM_N SEL1:OUT SEL2:OUT SEL2:TORQ/SPEED SEL2:IN_LIM CONSTANT 0 CONSTANT -1 CONSTANT 1 CONSTANT 2 CONSTANT 10 CONSTANT 100 CONSTANT 1000 CONSTANT 31416 EMF: 100% TORQ: 100% TORQ -100% CUR,FLX,VLT 100% CUR,FLX,VLT -100% SPEED: 100% SPEED: -100% SIG1(SPEED REF) SIG2(SPEED STEP) SIG3(TORQ. REF A) SIG4(TORQ. REF B) SIG5(TORQUE STEP) SIG6(LOAD SHARE) SIG7(FLUX REF) SIG8(EMF REF) SIG9(FORCE FWD) SIG10(FORCE REV) SIG11(CURR. REF) SIG12(CURR. STEP) Signals for application function blocks Signals for application function blocks Signals for application function blocks Signals for application function blocks Signals for application function blocks STATUS_WORD LTIME LDATE Conv.Curr.Slave Arm.Curr.Slave Conv.Curr.Both Arm.CURR.Both Curr.-Ref.1 IREF1-Polarity IREF1-Pol.Master Curr.-Ref.2 IREF2-Polarity IREF2-Pol.Broth. Bridge Bridge of Slave Indicat.Revers. Fault Reversion Fault Current Logik f.INHIBIT Input X18:13 Input X18:14 Input X18:15 Input X18:16 BC not Zero Reserved f.Commun Function for application winder II D 4-13 Function for application winder DCS 400 The drive module for standard applications ● Integrated field supply (max. 20 A) ● Accurate speed and torque control ● Extremely small and compact design ● Very easy installation and commissioning ● Express delivery ● Power range: 10...500 kW (13...670 HP) DCS 500B / DCS 600 The drive module for demanding applications ● Free programming of software ● 6- and 12-pulse configuration up to 10 MW/ 13,000 HP and more ● Plain text display ● Power range: 10...5000 kW (13...6700 HP) DCE 500 / DCE 600 Highly integrated panel ● Excellent upgrade or revamp solution ● Contains: ● DCS 500B / DCS 600 module ● AC fuses ● Auxiliary transformer ● Motor fan starter with protection ● Main contactor ● Power range: 10...130 kW (26...300 HP) DCS 400 / DCS 500 Easy Drive The complete standard cabinet solution ● Pre-engineered ● Easy installation and commissioning ● Protection class: IP 21 ● Plain text display ● Short delivery time ● Power range: 50...1350 kW (65...1800 HP) DCA 500 / DCA 600 For complex, completely engineered Drive System in common cabinet design ● Flexible and modular hardware structure ● 6- and 12-pulse configuration up to 18 MW/ 23,000 HP and more ● Pre-programmed applications: Metals, Cranes, P&P application, Mining ● Power range: 10...18000 kW (13...23000 HP) ABB Automation Products GmbH Postfach 1180 68619 Lampertheim • GERMANY Telefon +49(0) 62 06 5 03-0 Telefax +49(0) 62 06 5 03-6 09 www.abb.com/dc II D 4-14 Since we aim to always meet the latest state-of-the-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. 3ADW 000 066 R0901 REV I 09_2005 DC Drives Product Portfolio *066R0901A5360000* 3ADW000066R0901_DCS500_System_description_e_i *066R0901A5360000* Terminals SDCS-CON-2 Speed reference SP -20 SP -90 6 5 X3: P1 1 P2 20000 AI1 10104 AI1:OUT+ 10105 AI1:OUT10106 AI1:ERR 104 AI1 CONV MODE 105 AI1 HIGH VALUE -20000 106 AI1 LOW VALUE + -- P3 DI8 (10715) OUT 11903 (11803) 1912 IN2 1913 SEL2 1914 IN3 1915 SEL3 0 P10 1916 ADD 1917 REV ST5 ST5 SP -77 CONST REF 1901 ACT1 1902 ACT2 1 1903 ACT3 ACT 11902 DRIVE LOGIC (903) 1904 ACT4 P2 1500 P3 0 P4 0 1906 REF1 1907 REF2 Speed reference handling OUT 11901 1908 REF3 1909 REF4 P5 0 P1 1000 1905 DEF P1 200 P2 200 P3 100 P4 200 P5 100 P6 0 P7 0 P8 20000 P9 -20000 P1 5000 P2 -5000 X5: 10 1 4 3 X3: 2 1 0 P3 -30000 101 102 103 P11 0 P12 0 (10903) RUNNING (11205) BC P1 15000 P2 2048 AITAC 10101 AITAC:OUT+ 10102 AITAC:OUT10103 AITAC:ERR 2103 2101 SPEED SCALING PULSE TACHO 0 1 2 3 4 TACHOPULS NR AITAC:OUT+ (10505) (501) EMF TO SPEED CALC U ARM ACT U MOTN V AITAC CONV MODE AITAC HIGH VALUE P3 AITAC LOW VALUE ST5 P4 0 P5 500 5 2102 2104 2105 12104 TACHO PULSES 12102 SPEED ACT T DATA LOGGER (601) 5 SPEED MEAS MODE SPEED ACT FTR SPEED ACT FLT FTR T SPEED ACT FILT 12103 P1 50 P2 5000 P3 10000 P4 23000 P5 0 P6 50 P7 3000 P8 10 P9 200 P10 50 2201 2202 2203 2204 2205 2206 2207 2208 2209 2210 SPEED ACT T- ACCELCOMP MIN SPEED SPEED L1 SPEED GT L1 SPEED L2 SPEED GT L2 OVERSPEEDLIMIT OVERSPEED 11702 AI2 AI2:OUT+ 10107 AI2:OUT- 10108 12201 12202 12203 201 P1 10000 P2 0 P3 20000 202 203 204 DRIVE LOGIC CONSTANTS (12510) BRAKE CONTROL (303) CONSTANTS (12511) CONSTANTS (12510) CONSTANTS (12511) 2302 2303 2304 4000 P2 -4000 P3 16000 P4 100 P5 Terminals 200 P6 SDCS-CON-2 4095 P7 STALL.TORQUE STALL.TIME X3: 10 9 + -- AI3:OUT+ 10110 AI3:OUT- 10111 AI3:ERR 10112 P1 0 P2 2000 P3 -2000 110 111 112 AI3 CONV MODE AI3 HIGH VALUE AI3 LOW VALUE ST5 2305 2306 MON.EMF V AO1 IN AO1 NOMINAL V AO1 OFFSET V 0V AO1 AO1 NOMINAL VALUE P8 P9 P10 2315 2316 2317 2307 2308 -4095 (12102) 2309 20000 2310 16383 2311 16383 2312 16383 2313 16383 2314 16383 (11001) AI4:OUT+ 2 1 X4: AI4:OUT- + -0 -2000 114 115 AI4 HIGH VALUE AI4 LOW VALUE ST5 TREF TORQ MIN Max SPC TORQMIN1 12302 TREF TORQMAX112303 TREF TORQMIN1 12304 TORQ MAX2 12305 TORQ MAX Min TORQ MIN Max GEAR.START TORQ GEAR.TORQ TIME T t GEAR.TORQ RAMP ARM CURR LIM P CURR LIM P Min ARM CURR LIM N Max SPEED ACT CURR LIM N 12308 x x y y 4192 MAX CURR LIM SPD ARM CURR LIM N1 12307 x x y y 4192 I ARM CURR LIM N2 ARM CURR LIM N3 ARM CURR LIM N4 ARM CURR LIM N5 n FLUX REF1 P1 0 P2 0 P3 0 P4 0 P5 0 P7 500 P8 10 P9 30 P10 30 P11 0 P13 500 P14 2 517 518 519 520 521 SETTINGS Conv. settings C4 SET I COMV A Conv. values 10510 I TRIP A 10509 I CONV A 10511 U CONV V 10512 MAX BR TEMP 10513 CONV TYPE 10514 QUADR TYPE 10507 BRIDGE TEMP SET U CONV V SET MAX BR TEMP SET CONV TYPE SET QUADR TYPE 501 502 503 504 10113 P12 0 10114 P16 4 10115 P17 1024 P18 0 P6 10 P19 10 P15 0 Software version: Schematics: Library: Motor Data U MOTN V Line I MOTN A I MOT1 FIELDN A S21.233 S21V2_0 DCS500_1.5 and motor data I MOT2 FIELDN A 505 FEXC SEL 507 506 Supply Data U SUPPLY U NET ACT PHASE SEQ CW U NET DC NOM V LINE FREQUENCY 523 CURR ACT FILT TC 524 PLL CONTROL 528 PLL DEV LIM UDC 526 OFFSET UDC 513 + - CALC Iact EMF FILT TC 525 UNI FILT TC (only for Cur. Controlling) 522 LANGUAGE ST20 1/8 DCS 500B Software structure CONV CUR ACT ARM CUR ACT TORQUE ACT 10504 DATA LOGGER (604) 10508 10515 10501 10502 DATA LOGGER (602) MAINTENANCE (1211) 10503 U ARM ACT 10505 EMF ACT 10506 P1 5000 P2 0 P3 4095 DATA LOGGER (603) MAINTENANCE (1212) SP -80 AO2 205 IN 206 AO2 NOMINAL V 207 AO2 OFFSET V 208 AO2 NOMINAL VALUE 0V AO2 X4: 2000 P3 AI4:ERR AI4 CONV MODE Min 10 8 P2 113 TREF TORQ MAX SPC TORQMAX1 12301 SETTGS_3 Control Adjust. AI4 Max ST5 SP -87 Not used Min SPC TORQ MIN MON.MEAS LEV P13 SP -88 AI3 TORQUE/CURRENT LIMITATION SPC TORQ MAX TORQ MIN2 12306 P1 P12 SP -1 ST5 P1 2301 12204 STALL.SPEED 12PULSE LOGIC (3604) AI2 CONV MODE 108 AI2 HIGH VALUE 109 AI2 LOW VALUE Not used ST5 TORQ REF HANDLING STALL.SEL X4: -2000 12003 STEP SP -10 SPMONI_2 SPEED MONITOR 10 7 8 7 X3: 2000 P3 12002 Speed controller AI2:ERR 10109 P2 STEP RESP T+ P11 SP -89 107 OUT OF WIN WIN SIZE E- ST5 0 2002 WIN MODE SET ALL RAMP VALUES TO ZERO MIN SPEED L SP -81 12101 Speed feedback calculation P1 FREE SIGNALS (12517) FRS ST5 ST20 MAINTENANCE (1210) T5 + -- 0 P2 H 1718 ACC COMP.MODE (OUT) 1719 ACC COMP.TRMIN ST5 SP -12 SPEED ACT EMF Torque reference 2004 12001 1715 SPEEDMAX 1716 SPEEDMIN 1704 FOLLOW IN SPEED MEASUREMENT CH B 30000 0 1707 T1/T2 1714 EMESTOP RAMP 1708 ACCEL1 1711 ACCEL2 1709 DECEL1 1712 DECEL2 1710 SMOOTH1 1713 SMOOTH2 SP -11 CH A P2 S 2003 OUT SPEED ACT RUNNING T20 Incremental encoder -8...-30V -30...-90V -90...-270V OUT 11701 2005 0 P1 SP -17 REFSUM_2 1801 IN1 OUT 11802 1802 IN2 SPEED ERROR IN 1921 OHL 1922 OLL (10903) P1 LOC REF 2021 1920 FOLLOW 1923 ENABLE DRIVE LOGIC (10903) SP -84 SP -13 2001 SPEED 11801 REFERENCE 11703 SIGN 1705 FOLL ACT 1706 RES OUT SP -15 SOFTPOT1 SOFTPOT 1918 INCR OUT 11904 1919 DECR ACT 11905 + RAMP GENERATOR (10906) LOCAL 0 1702 RES IN 1717 STARTSEL 0 1703 HOLD ST5 Tacho RAMP_3 SP -18 1720 SPEED SET 1701 IN REF SEL 1910 IN1 1911 SEL1 ST5 2/8 1/8 2/8 3/8 SP -9 SP -14 2006 IN TORQ REF HANDLING (12403) TORQ REF HANDLING (12402) 2009 2010 2011 2012 2007 OUT IN LIM SET1 BAL 12004 2407 12005 2408 BAL2 SET2 BAL2REF VAL2 HOLD HOLD RINT CLEAR P1 P2 P3 P4 P5 P6 P7 P8 Max (12001) SP ERR CURRENT CONTROL SEL2:TORQ/SPEED SEL2:OUT SEL2:IN_LIM 12403 12402 SPEED CONTROL (2010) 12404 401 SPEED CONTROL (2011) 3 CONSTANTS (12526) CONSTANTS (12527) 4 (11702) FREE SIGNALS (12520) P1 1 2409 2406 ACCELCOMP SEL2.TORQ STEP SEL2.TREF SEL P1 0 P2 1366 TORQ MAX2 RUNNING TORQ MIN2 SET OUT TO ZERO P3 300 P4 3200 KPSMIN P5 2050 KPSPOINT P6 150 KPSWEAKFILT P7 15 P8 0 P9 0 TD P10 0 TF P11 40 BC FLUX N ARM CUR ACT TORQ REF 12-PULS [1209] 1,2 FLUX REF1 402 403 404 (10903) KP KI RUNNING ST5 -1 SET OUTPUTS TO ZERO Torque ref DROOPING 405 ARM CURR REF CURR REF IN LIM CURR DER IN LIM ARM DIR CURR REF CURR STEP ARM ALPHA BLOCK 10405 10403 10404 10402 10401 DATA LOGGER (606) t 5 SPC TORQMIN1 (11205) 2014 500 2015 0 2016 0 2017 500 2018 5000 2013 0 2019 0 2020 50 SEL2.TREF EXT 2 VAL1 BALREF 0 1 Min SPC TORQMAX1 (10903) 0 SEL2.TREF SPC C_CNTR_3 SP -75 TORQ REF HANDLING KP DROOPING 2008 TREFHND2 SPEED CONTROL REF TYPE SEL 406 ARM CURR REF SLOPE 415 ARM CURR LIM P 416 ARM CURR LIM N 407 408 409 ARM CURR PI KP ARM CURR PI KI ARM CONT CURR LIM 412 ARM ALPHA LIM MAX 413 ARM ALPHA LIM MIN 414 DXN 410 ARM L 411 ARM R 417 ARM CURR CLAMP Armature current controller STSYN ST5 DCFMOD SP -105 C_MONIT SP -104 DCF FIELDMODE P1 0 1215 DCF MODE : 0 1 SP -8 TORQ REF SELECTION 2401 FREE SIGNALS (12521) FREE SIGNALS (12519) P1 0 P2 0 2403 2404 2402 2405 1 2 TREF A SEL1:OUT LOAD SHARE : : 2 : 3 : 4 : 5 : 6 : 45 6 12401 Disabled DCF Current Control Stand Alone Reserved Fexlink Node 1 Fexlink Node 2 MG Set P1 P2 7 Cur.Controller for high inductive load ... 407 x8 ARM_CURR_PI_KP ARM_CURR_PI_KI ... 408 x8 P3 0 TREF B TREF A FTC 2 TREF TORQMAX1 DI2 (10703) 45 6 1216 DI/OVP RUNNING ST5 SETS SEL1:OUT TO ZERO -1 P2 0 1217 EMFCONT2 SP -34 EMF CONTROL P11 0 FIELD MODE (10907) EMESTOP ACT 1004 FLUX REF SEL 1002 CONSTANTS (12512) FLUX REF (12102) SPEED ACT P2 P13 P14 20000 23100 0 1001=1,3,5 P1 100% FLUX REF 1 100% 1012 FIELD WEAK POINT 1017 GENER.WEAK POINT 1018 FIELD WEAK DELAY FLUX REF SUM cal generatoric DRIVE MODE 1201=10 (1201) EMESTOP ACT TRef2 (10907) 1005 EMF REF SEL & 1003 EMF REF CONSTANTS (12509) P1 P12 P3 P4 1006 100 1016 160 (10506) 1007 150 1008 4905 P5 P6 410 50 P7 -4095 P8 P9 1187 P10 3255 2190 F CURR REF 11001 P2 11002 11003 P3 P10 P4 P5 P6 P7 P8 P9 0 40 70 90 LOCAL EMF REF GENER.EMF REF EMF ACT EMF KP EMF KI 1011 EMF REL LEV 1009 EMF REG LIM P 1010 EMF REG LIM N 1013 FIELD CONST 1 1305 1321 1306 1307 1308 1309 1311 1312 F1 CURR GT MIN L F1 CURR MIN TD F1 OVERCURR L F1 CURR TC F1 KP F1 KI F1 U LIM N F1 U LIM P CUR RIPPLE MONIT ZERO CUR DETECT INTERNAL 0 1 A137 F34 A137 F34 CURRENT ZERO SIGNAL RUN DCF RESET DCF 10916 10917 11303 Fexlink as Transmitter for FEX1 and FEX2 SP -30 MOTOR 1 FIELD FANS ON (10908) DRIVE MODE 1201=7 (1201) 1313 F1 RED.SEL 0 FIELD MODE 1001=1,3,5 (1001) 1301 F1 REF 100% 1314 F1 SEL.REF 1228 TEST REF2 1302 F1 FORCE FWD 0% 1303 F1 FORCE REV 1304 F1 ACK 2047 200 4710 0 1 20 -4096 4096 419 0 1 2 3 BC A121 F 21 REF DCF 1001 0 420 Monit. 1 method 2 CUR RIPPLE LIM STSYN from ext. FEXLINK Torque/current limitation F03 DriveLogic EXTERNAL via Options as FEX 1 (Receiver) as FEX 2 (Receiver) 6 CURRENT RISE MAX Input for external Overvoltg.Protection 0 1 5 P4 421 REV_DELAY REV_GAP FREV_DELAY OVP SELECT 4 418 Iact TREF TORQMIN1 (10903) 32767 ARM_CONT_CUR_LIM 409 3601 15 3602 15 3603 15 0 TREF B SLOPE CURRENT MONITOR SDCS-FEX-2 or DCF503/504 or P1 F1 CURR REF M2FIELD2 SP -28 M1FIELD2 (10908) FANS ON (1201) DRIVE MODE 1201=7 1510 F2 RED.SEL 0 CONSTANTS (12512) 11301 P2 1228 1501 F2 REF 1511 F2 SEL.REF MOTOR 2 FIELD 100% TEST REF2 F1 CURR ACT 11302 DATA LOGGER (605) DCF501/502 P3 P4 P5 P6 P7 P8 P9 2047 4710 0 1 20 -4096 4096 1502 1503 1504 1505 1506 1508 1509 F2 CURR GT MIN L F2 OVERCURR L F2 CURR TC F2 KP F2 KI F2 U LIM N F2 U LIM P F2 CURR REF 11501 0% SDCS-FEX-2 or DCF503/504 or DCF501/502 F2 CURR ACT 11502 ST20 ST20 SP -26 SP -24 MOTOR 1 FIELD OPTIONS Motor voltage controller P1 10 P4 100 P5 614 P6 200 P7 80 P8 80 P9 0 MOTOR 2 FIELD OPTIONS 1310 F1 U AC DIFF MAX FREE WHEELING P1 10 1507 F2 U AC DIFF MAX FREE WHEELING ST20 1014 FIELD CONST 2 1015 FIELD CONST 3 ST10 1315 1316 1317 1318 1319 1320 OPTI.REF GAIN OPTI.REF MIN L OPTITORQUE OPTI.REF MIN TD REV.REV HYST REV.REF HYST Field current controller 1 and 2 FIELD REVERSAL REV.FLUX TD ST20 2/8 1/8 3/8 4/8 3/8 1/8 4/8 5/8 Terminals Terminals SDCS-CON-2 SDCS-CON-2 SP -63 DI7 SP-36 10716 REF SEL (1911) BRAKE CONTROL (302) ST5 905 5 O1 O2 906 10709 10710 (12201) (11205) 907 ST5 SP -64 DI6 6 O2 10712 909 910 ST5 1 O2 912 10701 913 10702 ST5 2 O2 10703 10704 DCF FIELDMODE (1216) ST5 SP -67 DI3 10706 P3 0 P4 0 P5 0 P6 0 P7 0 P8 2 915 916 917 918 919 920 921 LOCAL MIN SPEED BC (BLOCK.) MAINTENANCE RESET START INHIBIT 803 DISABLE LOCAL 804 FAN ON 10908 ACK CONV FAN MAIN CONT ON 10910 ACK MAIN CONT MOTOR ACT 10913 MOTOR2 TRIP DC BREAKER 10911 FIELD HEAT SEL DYN BRAKE ON 10912 MAIN CONT MODE STOP MODE PWR LOSS MODE AUTO-RECLOSING 10914 COMFAULT MODE COMM FAULT 10915 10707 X1: SP-61 DI9 1 O1 O2 X1: ST5 SP-60 DI10 1 814 10708 SP -91 DATASET 1 10717 10122 OUT1 10123 OUT2 10124 OUT3 10718 IN 2 O1 DI11 3 X1: O1 O2 10719 10720 10721 10722 ST5 SP-58 SP -93 DATASET 3 DI12 4 X1: O1 O2 10125 OUT1 10126 OUT2 10127 OUT3 10723 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 ST5 SP-59 INV IN T20 SETTINGS (10501) SETTINGS (10505) MAIN CONT Relay output SDCS-POW-1 SP -44 DO6 IN INV IN 6 X1: O1 O2 0 1207 1208 1209 1213 1210 1211 1212 1214 0 4 ARM. CONTROLLER POT1 VALUE 1 7 FIRST FIELD EXCITER POT2 VALUE 2 8 SECOND FIELD EXCITER PERIOD t BTW.POT1/2 3 9 4 10 0 TEST REF SQUARE WAVE DRIVE ID WRITE ENABLE KEY WRITE ENABLE PIN SELECT OPER.SYST ACTUAL VALUE 1 7 X1: not used O1 O2 MACRO SELECT T5 INV IN T20 SP-95 FLBSET_2 FIELDBUS 4001 FIELDBUS PAR.1 4002 (MODULE TYPE) 4003 4004 4005 4006 4007 4008 4009 4010 Parameters 4011 depends of 4012 modul type 4013 4014 4015 SP -92 DATASET 2 209 IN1 210 IN2 211 IN3 ST5 OUT Monitoring SP -94 DATASET 4 212 IN1 213 IN2 214 IN3 ST5 ST5 SP -76 P2 230 P3 80 P4 60 10725 P5 5000 10726 P6 0 P7 4 P8 10 P9 0 IN OUT Inputs and outputs for 12 pulse 10727 10728 DI15 8 X1: O1 13617 X18:13 13618 X18:14 13619 X18:15 13620 X18:16 10730 ST5 AI5 AI5:OUT+ 3610 Revers.Logic 2 1 X2: AI5:OUT- + -- AI5:ERR 0 116 AI5 CONV MODE P2 2000 117 AI5 HIGH VALUE P3 -2000 118 AI5 LOW VALUE P1 P1 P2 P3 10116 10117 1 10 10 10118 3601 REV DELAY 3602 REV GAP 3603 FREV DELAY ON/OFF LOGIC 3607 INHIB Logic not used 5 4 X2: + -- SP -85 AI6 P4 P5 0 119 AI6 CONV MODE 2000 120 AI6 HIGH VALUE P3 -2000 121 AI6 LOW VALUE 3605 DIFF CURRENT 3606 DIFF CURR DELAY CURRENT REFERENCE P6 2048 AI2 (10107) ST5 4/8 10 150 AI6:ERR 10121 P2 BC not Zero CURRENT ANALYSIS active, if [1209] = 1 AI6:OUT+ 10119 AI6:OUT- 10120 P1 Logic f. INHIBIT (11205) BC 3616 BC Logic ST5 3615 ADJ REF1 3604 IACT SLAVE MASTER 6-PULSE 3611 3612 3613 3614 13611 Bridge 13606 IREF1-Polarity 13609 IREF2-Polarity 13607 IREF1-Pol.Master 13610 IREF2-Pol.Broth 13612 Bridge of Slave 13613 Indicat.Revers 13614 Fault Reversion 3608 IREF0 Logic 3609 Bridge Logic STSYN SP -86 SP -98 OUTPUT X18 12-PULSE LOGIC BRIDGE REVERSAL LOGIC active, if [1209]= 1 or 2 INPUT X18 10729 12PULS_2 SP -99 SP -97 O2 not used 511 512 508 509 510 514 515 516 527 CONPROT2 CONVERTER PROTECTION ARM OVERVOLT LEV ARM OVERCURR LEV U NET MIN1 U NET MIN2 PWR DOWN TIME EARTH.CURR SEL EARTH.FLT LEV EARTH.FLT DLY CONV TEMP DELAY ST20 SP -22 ST5 SP-55 not used CDP312 ACTUAL VALUE 3 ST5 SP-56 DI14 DRIVE LOGIC RAMP GENERATOR 12 PULSE LOGIC 11203 FEXC STATUS 11210 FEXC1 CODE 11220 FEXC1 SW VERSION 11211 FEXC1 COM STATUS FEXC1 COM ERRORS 11212 11213 FEXC2 CODE 11221 FEXC2 SW VERSION FEXC2 COM STATUS 11214 11215 FEXC2 COM ERRORS FIELDBUS NODE ADDR ACTUAL VALUE 2 11206 11204 TC STATUS 11201 COMMIS STAT 11205 BC 11202 BACKUPSTOREMODE 11222 PROGRAM LOAD 11216 11218 CNT SW VERSION CMT COM ERRORS 11217 11219 CNT BOOT SW VER CDI300 BAD CHAR CMT DCS500 ADDR 110 10724 SPEED LOOP EMF CONTROLLER Maintenance SP -43 DO7 IN ST5 DI13 P11 1203 TEST REF SEL P1 ST5 SP-57 not used SP -42 DO8 IN SPEED MESUREMENT (12103) 1202 RELEASE OF ARM. CONTROLLING Inputs and outputs for fieldbus ST5 O2 not used 358 P10 813 Must be connected, when no fan acknowledges (DI1, DI2) Additional binary inputs not used P7 MAIN CONT 1206 & I1=I2 7 O2 not used 1 INV IN 1205 4 X7: 4 X6: O1 ST5 not used 250 P6 T20 SP -66 DI4 Terminals P5 SP -48 DO2 IN SP -47 DO3 805 IN 806 INV IN T20 ST5 SDCS-IOE-1 T20 EXC CONT 1204 (11207) 0 812 T20 100 358 811 COMFLT. TIMEOUT 0 P4 P9 816 PANEL DISC MODE P3 P8 815 EME STOP MODE FAN CONT 1000 T20 MOTOR 1/2 FIELD FIELD ON 10909 ACK MOTOR FAN (10906) LOCAL 1201 DRIVEMODE 6 3 O2 10705 1 EME STOP SP -49 DO1 801 IN 802 INV IN MANTUN_3 MAINTENANCE TEST RELEASE X7: X6: MAIN CONT O1 P2 914 RAMP GENERATOR TORQ REF SELECTION TORQ REF HANDLING EMESTOP ACT 10907 LOCAL 10906 0 (11209) P2 1 2 X6: MOTOR FAN O1 0 RUN3 COAST STOP RUNNING X96: SP -68 DI2 P1 FAULT 10904 ALARM 10905 INV IN T20 3 X6: CONV FAN O1 810 X7: SP -69 DI1 911 RUNNING 10903 1 SP -45 DO5 IN 2 O1 908 809 X7: X6: RESET 10711 RUN2 RDY ON 10901 RDY RUNNING 10902 P1 1 X6: EM STOP 904 RUN1 RDY RUNNING T20 DRLOGI_2 X7: SP -65 DI5 903 CONST REF (11902) DRIVE LOGIC ON/OFF INV IN SP -100 (11208) 5 8 O2 902 10715 SP -46 DO4 IN X7: X6: RUN 901 O1 808 10714 ST5 SP -62 DI8 807 4 7 O2 Binary in and outputs (standard) 10713 X7: X6: ON/OFF O1 * 2048 P1 0 X18:09 X18:10 X18:11 X18:12 P2 0 P3 0 STSYN P4 4096 P5 120 P6 130 P7 240 13616 ST20 13621 SP -21 13601 Conv.Curr.Slave 13602 Arm.Curr.Slave 13603 Conv.Curr.Both 13604 Arm.CURR.Both 13615 Fault Current [1209] Curr.Ref.2 Curr.Ref.1 Res. f.Commun 13608 13605 13622 P1 0 P2 0 P3 0 P4 4096 P5 120 P6 130 P7 240 M2PROT_2 MOTOR 2 PROTECTION 1601 MOT2.TEMP IN 11601 1602 MOT2.TEMP ALARM L MOT2 MEAS TEMP 1603 MOT2.TEMP FAULT L 1604 11602 MODEL2.SEL MOT2 CALC TEMP 1605 MODEL2.CURR 1606 MODEL2.ALARM L 1607 MODEL2.TRIP L 1608 MODEL2.TC ST20 STSYN 5/8 M1PROT_2 MOTOR 1 PROTECTION 1401 MOT1.TEMP IN 1402 11401 MOT1.TEMP ALARM L MOT1 MEAS TEMP 1403 MOT1.TEMP FAULT L 1404 KLIXON IN 1405 11402 MODEL1.SEL MOT1 CALC TEMP 1406 MODEL1.CURR 1407 MODEL1.ALARM L 1408 MODEL1.TRIP L 1409 MODEL1.TC 6/8 5/8 6/8 7/8 SP -7 P1 0 "EXT. IND. 1" P3 0 SP-102 1101 IN USER EVENT 1 1102 TYPE 1103 TEXT 1104 DLY ST20 SP -6 P1 0 "EXT. IND. 2" P3 0 1105 IN USER EVENT 2 1106 TYPE 1107 TEXT 1108 DLY ST20 DATA LOGGER SPEED MEASUREMENT (12102) 0 "EXT. IND. 3" P3 0 601 SETTINGS (10501) 602 SETTINGS (10505) 603 SETTINGS (10504) 604 MOTOR 1 FIELD (11302) 605 CURRENT CONTROL (10401) P1 1 P2 20000 P3 200 P4 3 606 607 608 609 610 611 SP -5 P1 DATALOG 612 1109 IN USER EVENT 3 1110 TYPE 1111 TEXT 613 IN1 Ch.1 IN2 Ch.2 IN3 Ch.3 IN4 Ch.4 IN5 Ch.5 IN6 Ch.6 DLOG.TRIGG COND DLOG STATUS DLOG.TRIGG VALUE 10601 CMT-TOOL DLOG.TRIGG DELAY TRIG DLOG.SAMPL INT DLOG.TRIG 0 DLOG.STOP 0 DLOG.RESTART 0 STOP TRIG STOP RESTART ST20 1113 IN 0 "EXT. IND. 4" P3 0 1114 USER EVENT 4 Data logger TYPE 1115 TEXT 1116 Speed controller DLY 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 drive’s 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 drive’s actual speed back into the window. The SPEED CONTROL block contains the speed controller with P, I and DT1 contents. For adaptation it receives a variable P-amplification. ST20 SP -3 1117 IN P1 0 "EXT. IND. 5" P3 0 1118 USER EVENT 5 TYPE 1119 TEXT 1120 DLY ST20 Additional signals SP -2 1121 IN P1 0 "EXT. IND. 6" P3 0 USER EVENT 6 1122 DLY 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 AI2 block (analogue input 2) is used for reading in an analogue signal. 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 signal’s evaluation can be dynamically altered using a multiplier. The TORQ REF HANDLING block determines the drive's 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". SP -73 ST20 CONSTANTS 0 -1 User events 1 2 10 100 1000 31416 EMF:100% TORQ:100% TORQ:-100% CUR,FLX,VLT: 100% CUR,FLX,VLT:-100% Brake control SPEED: 100% SPEED:-100% 12501 CONST_0 12502 CONST_M1_TRUE 12503 CONST_1 12504 CONST_2 12505 CONST_10 12506 CONST_100 12507 CONST_1000 12508 CONST_31416 12509 EMF_MAX 12510 TORQ_MAX 12511 TORQ_MAX_N 12512 CONST_4095 12513 CONST_M4095 12514 CONST_20000 12515 CONST_M20000 ST SP -74 FREE SIGNALS 12516 SIG1(SPEED REF) 12517 SIG2(SPEED STEP) 12518 SIG3(TORQ. REF A) 12519 SIG4(TORQ. REF B) 12520 SIG5(TORQUE STEP) 12521 SIG6(LOAD SHARE) 12522 SIG7(FLUX REF) 12523 SIG8(EMF REF) 12524 SIG9(FORCE_FWD) 12525 SIG10(FORCE REV) 12526 SIG11(CURR. REF) 12527 SIG12(CURR._STEP) SP -32 (10902) (10503) BRAKE CONTROL RESET TORQUE ACT 301 HOLD REF DI8 (10715) SPEED MONITOR (12201) P1 0 P2 0 P3 0 P4 0 Binary in and outputs (standard) 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 converter’s line contactor, the field-circuit contactor or contactors for various fans, or for outputting status messages. Additional binary inputs 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. Inputs and outputs for fieldbus 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. Torque / current limitation TYPE 1123 TEXT 1124 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 buildup. 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 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. SP -4 P1 Field current controller 1 and 2 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). 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 REF SUM block enables the output of the ramp function generator and a user-definable signal to be added. Speed feedback calculation RESTART T1ms 1112 DLY Speed reference handling 10301 TREF OUT LOCAL 302 BR RELEASE TREF ENABLE 10302 303 MIN SP IND DECEL CMND 10303 10304 304 ACT BRAKE LIFT BRAKE 10305 305 START DELAY BRAKE RUN 306 STOP DELAY 307 HOLD TORQ 308 EMESTOP BRAKE ST20 Armature current controller 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. At applications with high inductive load and high dynamic performance a different hardware is used to generate the signal current equal to zero. This hardware is selected by the CURRENT MONITOR block. The functions monitoring the current can now be adapted to the needs of the application. This gives easier handling and a higher degree of safety at high performance drives, like test rigs. The DCF mode can be activated via the block DCF FIELDMODE. The functionality within this mode can be specified. If one of these functions is selected the current controller gets a different characteristic, the overvoltage protection DCF 506 is monitored and the field current reference via the X16: terminals is routed. SPEED_STEP TORQ_REF_B TORQ_STEP LOAD_SHARE CUR_REF CUR_STEP ST FLTHNDL SP-103 FAULT HANDLING FAULT WORD 1 FAULT WORD 2 FAULT WORD 3 LATEST FAULT ALARM WORD 1 ALARM WORD 2 ALARM WORD 3 LATEST ALARM OPERATING HOURS Line and motor data The SETTINGS block serves for scaling all important signals, such as line voltage, motor voltage, motor current and field current. Parameters are available to adjust the control to special conditions like weak networks or interactions with harmonic filter systems. The language, in which you want to read your information on the panel, can be selected. The AO2 block represents a scalable analogue output. 11101 11102 11103 11107 Motor voltage controller 11104 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. To enable the drive to utilize a higher motor voltage even with a 4 quadrant system two different field weakening points can be set by parameter. 11105 11106 11108 11109 Inputs and outputs for 12 pulse 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. Maintenance The MAINTENANCE 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. Monitoring 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". Adaptations are made for rebuild applications, which keep the power part and the fan, to sense overload conditions or fan failures. 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. User event By using the block USER EVENT1 to USER EVENT6 six different messages are created, which are displayed as faults or alarms on the panel CDP312 as well as on the 7 segment display of the converter. Brake control The BRAKE CONTROL block generates all signals needed for controlling a mechanical brake. Data logger 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. Additional signals By using the block FAULT HANDLING the faults and alarms of the drive are regrouped as 16bit information. The CONSTANTS and FREE SIGNALS blocks can be used for setting limitations or special test conditions. T20 6/8 7/8 8/8 7/8 8/8 Terminals SDCS-CON-2 Speed reference SP -20 SP -90 6 5 X3: P1 1 P2 20000 AI1 10104 AI1:OUT+ 10105 AI1:OUT10106 AI1:ERR 104 AI1 CONV MODE 105 AI1 HIGH VALUE P3 -20000 106 AI1 LOW VALUE + -- DI8 (10715) OUT 11903 (11803) 1912 IN2 1913 SEL2 1914 IN3 1915 SEL3 0 P10 ST5 SP -77 CONST REF 1901 ACT1 1902 ACT2 1 1903 ACT3 ACT 11902 DRIVE LOGIC (903) 1904 ACT4 P2 1500 P3 0 P4 1906 REF1 1907 REF2 Speed reference handling OUT 11901 1908 REF3 1909 REF4 0 P5 0 P1 1000 1905 DEF P1 200 P2 200 P3 100 P4 200 P5 100 P6 0 P7 0 P8 20000 P9 -20000 SP -15 SOFTPOT1 SOFTPOT 1918 INCR OUT 11904 1919 DECR ACT 11905 1920 FOLLOW P2 -5000 S 0 0 P2 2002 FREE SIGNALS (12517) FRS WIN MODE OUT OF WIN WIN SIZE STEP RESP 12003 STEP ST5 P11 0 P12 0 2008 TORQ REF HANDLING (12403) TORQ REF HANDLING (12402) (10903) T- DECEL2 Speed controller SMOOTH1 P1 P2 P3 1716 SPEEDMIN 1704 FOLLOW IN 1705 FOLL ACT (10903) RUNNING (11205) BC (11205) 2014 500 2015 0 2016 0 2017 500 2018 5000 2013 0 2019 0 2020 50 P4 P5 P6 P7 SET ALL RAMP VALUES TO ZERO 1718 ACC COMP.MODE (OUT) 1719 ACC COMP.TRMIN ST5 P8 ACCELCOMP X5: 10 1 4 3 X3: 2 1 P2 30000 P3 -30000 SP -12 P2 15000 2048 AITAC 10101 AITAC:OUT+ 10102 AITAC:OUT10103 AITAC:ERR 2103 2101 PULSE TACHO SPEED SCALING 0 1 2 3 4 TACHOPULS NR AITAC:OUT+ (10505) (501) AITAC HIGH VALUE P3 5 AITAC LOW VALUE ST5 P4 0 P5 500 2102 2104 2105 12104 TACHO PULSES EMF TO SPEED CALC U ARM ACT U MOTN V AITAC CONV MODE 103 P1 DATA LOGGER (601) 5 SPEED MEAS MODE SPEED ACT FTR SPEED ACT FLT FTR T SPEED ACT FILT 12103 50 P2 5000 P3 10000 P4 12102 SPEED ACT T SPEED ACT EMF 23000 P5 0 P6 50 P7 3000 P8 10 P9 200 P10 50 2201 2202 2203 2204 2205 2206 2207 2208 2209 2210 SPEED ACT MIN SPEED SPEED L1 SPEED GT L1 SPEED L2 SPEED GT L2 OVERSPEEDLIMIT OVERSPEED 12201 12202 DRIVE LOGIC CONSTANTS (12510) BRAKE CONTROL (303) CONSTANTS (12511) CONSTANTS (12510) 12203 CONSTANTS (12511) STALL.SPEED P1 STALL.TIME P2 P2 0 P3 20000 -4000 MON.EMF V P3 16000 P4 100 P5 Terminals 200 AO1 P6 SDCS-CON-2 4095 IN 202 AO1 NOMINAL V P7 203 0V AO1 AO1 OFFSET V 204 X4: SP -89 2301 2302 2303 2304 2305 2306 AO1 NOMINAL VALUE 2315 2316 2317 2307 2308 -4095 (12102) 2309 20000 2310 16383 2311 16383 2312 16383 2313 16383 2314 16383 P8 P9 P10 P12 12PULSE LOGIC (3604) 8 7 X3: AI2 AI2:OUT+ 10107 AI2:OUT- 10108 P13 (11001) AI2:ERR 10109 P2 2000 P3 -2000 107 ST5 P1 0 P2 0 P3 0 P4 0 P5 0 SP -88 X3: 10 9 + -- AI3:OUT+ 10110 AI3:OUT- 10111 0 P2 2000 P3 -2000 110 111 112 P8 10 P9 30 P10 30 P11 0 P13 500 P14 2 10113 P12 0 10114 P16 4 P17 1024 P18 0 P6 10 P19 10 P15 0 AI3 CONV MODE AI3 HIGH VALUE AI3 LOW VALUE SP -87 AI4 AI4:OUT+ 2 1 X4: AI4:OUT- + -P1 113 0 P2 2000 P3 -2000 114 115 AI4:ERR 10115 AI4 CONV MODE AI4 HIGH VALUE AI4 LOW VALUE ST5 SETTINGS Conv. settings C4 Conv. values 10510 517 SET I COMV A I TRIP A 518 10509 SET U CONV V I CONV A 519 10511 SET MAX BR TEMP U CONV V 10512 520 SET CONV TYPE MAX BR TEMP 521 10513 SET QUADR TYPE CONV TYPE 10514 QUADR TYPE 10507 BRIDGE TEMP Motor Data 501 U MOTN V 502 I MOTN A 503 I MOT1 FIELDN A 504 I MOT2 FIELDN A 505 FEXC SEL 507 506 Line Supply Data U SUPPLY U NET ACT U NET DC NOM V PHASE SEQ CW LINE FREQUENCY UDC 526 OFFSET UDC 513 CONV CUR ACT TORQUE ACT 10501 P1 5000 P2 0 P3 4095 SP -80 AO2 205 IN 206 AO2 NOMINAL V 207 AO2 OFFSET V 0V AO2 REF SEL (1911) BRAKE CONTROL (302) CONST REF (11902) 908 10712 909 910 912 10701 10703 10704 DCF FIELDMODE (1216) ST5 SP -67 DI3 3 O2 RAMP GENERATOR TORQ REF SELECTION TORQ REF HANDLING EMESTOP ACT 10907 EME STOP LOCAL 10906 MAINTENANCE 10705 10706 P1 0 P2 1 P3 0 P4 0 P5 0 P6 0 P7 0 P8 2 914 915 916 917 918 919 920 921 SP -49 DO1 801 IN 802 INV IN FAN CONT T20 RESET START INHIBIT 803 DISABLE LOCAL 804 FAN ON 10908 ACK CONV FAN MOTOR 1/2 FIELD FIELD ON 10909 ACK MOTOR FAN MOTOR ACT 10913 TRIP DC BREAKER 10911 FIELD HEAT SEL DYN BRAKE ON 10912 MAIN CONT MODE SP -42 DO8 815 IN 816 INV IN T20 STOP MODE EME STOP MODE PANEL DISC MODE AUTO-RECLOSING 10914 PWR LOSS MODE COMFAULT MODE INV IN SP -47 DO3 805 IN 806 INV IN T20 MAIN CONT ON 10910 ACK MAIN CONT MOTOR2 SP -48 DO2 IN EXC CONT MAIN CONT COMM FAULT 10915 T20 813 300 KPSMIN P5 2050 KPSPOINT P6 150 KPSWEAKFILT P7 15 KI P8 0 P9 0 TD P10 0 TF P11 40 2402 2405 (10903) TORQ MIN 814 MAIN CONT Relay output SDCS-POW-1 SEL1:OUT LOAD SHARE X1: 1 O1 O2 X1: 2 not used ST5 SP-60 DI10 10717 10122 OUT1 10123 OUT2 10124 OUT3 10718 IN ST5 O1 O2 10719 10720 ST5 SP-59 DI11 3 X1: not used O1 O2 10721 10722 ST5 SP-58 SP -93 DATASET 3 DI12 4 X1: not used O1 O2 IN 10724 DI13 6 X1: O1 O2 7 X1: not used O1 O2 GEAR.TORQ TIME T t GEAR.TORQ RAMP CURR LIM P ARM CURR LIM P Min ARM CURR LIM N 8 X1: not used Max O2 CURR LIM N ARM CURR LIM N1 I ARM CURR LIM N4 SETS SEL1:OUT TO ZERO -1 RUNNING ST5 P2 P13 S21.233 S21V2_0 DCS500_1.5 0 1001 P14 20000 23100 0 1001=1,3,5 P1 100% 1018 FIELD WEAK DELAY DRIVE MODE (1201) EMESTOP ACT (10907) 1005 EMF REF SEL 1003 EMF REF CONSTANTS (12509) 1006 100 1016 160 (10506) 1007 150 1008 4905 P5 P6 410 P7 -4095 P8 P9 1187 P10 3255 50 2190 0 P4 100 1204 1205 1206 (11207) 250 P6 1 P7 358 P8 358 P9 0 P10 1 SPEED MESUREMENT (12103) P11 0 1202 1203 1207 1208 1209 1213 1210 1211 1212 1214 RELEASE OF ARM. CONTROLLING & I1=I2 1201=10 2 1 X2: AI5:ERR 116 AI5 CONV MODE P1 0 P2 2000 117 AI5 HIGH VALUE -2000 118 AI5 LOW VALUE P3 3610 Revers.Logic P1 P2 P3 1 10 10 10118 3601 REV DELAY 3602 REV GAP 3603 FREV DELAY ON/OFF LOGIC 3607 INHIB Logic 5 4 X2: + -- SP -85 AI6 AI6:OUT+ 10119 AI6:OUT- 10120 AI6:ERR 10121 119 AI6 CONV MODE P1 0 P2 2000 120 AI6 HIGH VALUE -2000 121 AI6 LOW VALUE P3 ST5 Logic f. INHIBIT (11205) BC 3616 BC Logic BC not Zero CURRENT ANALYSIS active, if [1209] = 1 ST5 not used Bridge IREF1-Polarity IREF2-Polarity IREF1-Pol.Master IREF2-Pol.Broth Bridge of Slave Indicat.Revers Fault Reversion P4 P5 10 150 3605 DIFF CURRENT 3606 DIFF CURR DELAY CURRENT REFERENCE P6 2048 AI2 (10107) 3615 ADJ REF1 3604 IACT SLAVE MASTER 6-PULSE STSYN * 2048 P3 P10 P4 P5 P6 P7 P8 P9 0 TRef2 40 70 90 & EMF ACT EMF KP EMF KI 1011 EMF REL LEV 1009 EMF REG LIM P 1 1010 EMF REG LIM N 1013 FIELD CONST 1 4 POT1 VALUE 1 7 FIRST FIELD EXCITER POT2 VALUE 2 8 SECOND FIELD EXCITER PERIOD t BTW.POT1/2 3 9 4 10 TEST REF P1 0 "EXT. IND. 1" 0 1101 IN USER EVENT 1 1102 TYPE 1103 TEXT 1104 DLY DRIVE ID WRITE ENABLE KEY WRITE ENABLE PIN SELECT OPER.SYST FIELDBUS NODE ADDR FEXC STATUS P1 CDP312 ACTUAL VALUE 3 MACRO SELECT 0 "EXT. IND. 2" 11206 11203 11210 FEXC1 CODE 11220 FEXC1 SW VERSION 11211 FEXC1 COM STATUS FEXC1 COM ERRORS 11212 11213 FEXC2 CODE 11221 FEXC2 SW VERSION FEXC2 COM STATUS 11214 11215 FEXC2 COM ERRORS ACTUAL VALUE 1 ACTUAL VALUE 2 SP -6 11204 TC STATUS 11201 COMMIS STAT 11205 BC 11202 BACKUPSTOREMODE 11222 PROGRAM LOAD 11216 11218 CNT SW VERSION CMT COM ERRORS 11217 11219 CNT BOOT SW VER CDI300 BAD CHAR CMT DCS500 ADDR SP-102 ST20 SPEED LOOP EMF CONTROLLER SQUARE WAVE P3 0 1105 IN USER EVENT 2 1106 TYPE 1107 TEXT 1108 DLY ST20 P1 0 "EXT. IND. 3" P3 0 1109 IN USER EVENT 3 1110 TYPE 1111 TEXT T5 [1209] Curr.Ref.2 Curr.Ref.1 Res. f.Commun DATALOG DATA LOGGER SPEED MEASUREMENT (12102) 601 SETTINGS (10501) 602 SETTINGS (10505) 603 SETTINGS (10504) 604 MOTOR 1 FIELD (11302) 605 CURRENT CONTROL (10401) P1 1 P2 20000 P3 200 P4 3 606 607 608 609 610 611 SP -5 DRIVE LOGIC RAMP GENERATOR 12 PULSE LOGIC 612 613 IN1 Ch.1 IN2 Ch.2 IN3 Ch.3 IN4 Ch.4 IN5 Ch.5 IN6 Ch.6 DLOG.TRIGG COND DLOG STATUS DLOG.TRIGG VALUE CMT-TOOL DLOG.TRIGG DELAY TRIG DLOG.SAMPL INT DLOG.TRIG 0 DLOG.STOP 0 DLOG.RESTART 0 1113 IN P1 0 0 1114 STOP RESTART USER EVENT 4 TYPE 1115 TEXT 1116 Data logger Cur.Controller for high inductive load ... 407 x8 ARM_CURR_PI_KP ARM_CURR_PI_KI ... 408 x8 ARM_CONT_CUR_LIM 409 0 3601 REV_DELAY 15 3602 REV_GAP 15 3603 FREV_DELAY 15 P3 0 P4 0 0 1217 421 420 419 Monit. 1 method 2 CUR RIPPLE LIM CUR RIPPLE MONIT ZERO CUR DETECT INTERNAL 0 1 0 1 2 3 A137 F34 A137 F34 CURRENT ZERO SIGNAL STSYN Input for external Overvoltg.Protection BC A121 F 21 0 1 OVP SELECT as FEX 1 (Receiver) as FEX 2 (Receiver) 5 F03 DriveLogic EXTERNAL via Options RUN DCF RESET DCF 10916 10917 11303 Fexlink as Transmitter for FEX1 and FEX2 SP -30 MOTOR 1 FIELD FANS ON (10908) DRIVE MODE 1201=7 (1201) 1313 F1 RED.SEL 0 FIELD MODE 1001=1,3,5 (1001) 1301 F1 REF 100% 1314 F1 SEL.REF 1228 TEST REF2 1302 F1 FORCE FWD 0% 1303 F1 FORCE REV 1304 F1 ACK 2047 200 4710 0 1 20 -4096 4096 1305 1321 1306 1307 1308 1309 1311 1312 F1 CURR GT MIN L F1 CURR MIN TD F1 OVERCURR L F1 CURR TC F1 KP F1 KI F1 U LIM N F1 U LIM P SDCS-FEX-2 or DCF503/504 or (10908) FANS ON (1201) DRIVE MODE 1201=7 1510 F2 RED.SEL 0 P1 F1 CURR REF M2FIELD2 SP -28 M1FIELD2 CONSTANTS (12512) 11301 P2 1228 1501 F2 REF 1511 F2 SEL.REF MOTOR 2 FIELD 100% TEST REF2 F1 CURR ACT 11302 DATA LOGGER (605) DCF501/502 P3 P4 P5 P6 P7 P8 P9 2047 4710 0 1 20 -4096 4096 1502 1503 1504 1505 1506 1508 1509 F2 CURR GT MIN L F2 OVERCURR L F2 CURR TC F2 KP F2 KI F2 U LIM N F2 U LIM P F2 CURR REF 11501 0% SDCS-FEX-2 or DCF503/504 or DCF501/502 F2 CURR ACT 11502 ST20 SP -24 P1 10 P4 100 P5 614 P6 200 MOTOR 2 FIELD OPTIONS 1310 F1 U AC DIFF MAX FREE WHEELING P1 P7 80 P8 80 P9 0 1315 10 1507 F2 U AC DIFF MAX FREE WHEELING 1316 1317 1318 1319 1320 OPTI.REF GAIN OPTI.REF MIN L OPTITORQUE OPTI.REF MIN TD REV.REV HYST REV.REF HYST Field current controller 1 and 2 FIELD REVERSAL REV.FLUX TD ST20 1117 IN P1 0 "EXT. IND. 5" P3 0 1118 USER EVENT 5 TYPE 1119 TEXT 1120 DLY ST20 0 0 USER EVENT 6 Additional signals 1122 DLY SP -73 CONSTANTS User events 0 1 2 10 100 1000 TORQ:100% TORQ:-100% CUR,FLX,VLT:-100% OUT P1 110 P2 230 P3 80 P1 0 X18:09 X18:10 X18:11 X18:12 P2 0 P3 0 STSYN P4 4096 P5 120 P6 130 P7 240 SPEED: 100% SPEED:-100% CONPROT2 CONVERTER PROTECTION 511 ARM OVERVOLT LEV 512 ARM OVERCURR LEV 508 U NET MIN1 509 U NET MIN2 510 PWR DOWN TIME 514 EARTH.CURR SEL 515 EARTH.FLT LEV 516 EARTH.FLT DLY 527 CONV TEMP DELAY ST20 SP -32 (10902) (10503) BRAKE CONTROL RESET TORQUE ACT 301 HOLD REF DI8 (10715) SPEED MONITOR (12201) M1PROT_2 MOTOR 1 PROTECTION 1401 MOT1.TEMP IN 1402 11401 MOT1.TEMP ALARM L MOT1 MEAS TEMP 1403 MOT1.TEMP FAULT L 1404 KLIXON IN 1405 11402 MODEL1.SEL MOT1 CALC TEMP 1406 MODEL1.CURR 1407 MODEL1.ALARM L 1408 MODEL1.TRIP L 1409 MODEL1.TC P1 0 P2 0 P3 0 P4 4096 P5 120 P6 130 P7 240 1602 1603 1604 1605 1606 1607 1608 MOT2.TEMP ALARM L MOT2 MEAS TEMP MOT2.TEMP FAULT L MODEL2.SEL MODEL2.CURR MODEL2.ALARM L MODEL2.TRIP L MODEL2.TC ST20 12502 MOT2 CALC TEMP CONST_M1_TRUE 12503 CONST_1 12504 CONST_2 12505 CONST_10 12506 CONST_100 12507 CONST_1000 12508 CONST_31416 12509 EMF_MAX 12510 TORQ_MAX 12511 TORQ_MAX_N 12512 CONST_4095 12513 CONST_M4095 12514 CONST_20000 12515 P1 0 P2 0 P3 0 P4 0 10301 TREF OUT LOCAL 302 BR RELEASE TREF ENABLE 10302 303 MIN SP IND DECEL CMND 10303 10304 304 ACT BRAKE LIFT BRAKE 10305 305 START DELAY BRAKE RUN 306 STOP DELAY 307 HOLD TORQ 308 EMESTOP BRAKE ST20 CONST_M20000 ST 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 buildup. 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 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. 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 drive’s 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 drive’s actual speed back into the window. The SPEED CONTROL block contains the speed controller with P, I and DT1 contents. For adaptation it receives a variable P-amplification. FAULT HANDLING FAULT WORD 1 FAULT WORD 2 FAULT WORD 3 LATEST FAULT ALARM WORD 2 ALARM WORD 3 11601 LATEST ALARM 11602 OPERATING HOURS T20 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 AI2 block (analogue input 2) is used for reading in an analogue signal. 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 signal’s evaluation can be dynamically altered using a multiplier. The TORQ REF HANDLING block determines the drive's 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". Armature current controller SPEED_STEP TORQ_REF_B TORQ_STEP LOAD_SHARE CUR_REF CUR_STEP 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. At applications with high inductive load and high dynamic performance a different hardware is used to generate the signal current equal to zero. This hardware is selected by the CURRENT MONITOR block. The functions monitoring the current can now be adapted to the needs of the application. This gives easier handling and a higher degree of safety at high performance drives, like test rigs. The DCF mode can be activated via the block DCF FIELDMODE. The functionality within this mode can be specified. If one of these functions is selected the current controller gets a different characteristic, the overvoltage protection DCF 506 is monitored and the field current reference via the X16: terminals is routed. FLTHNDL SP-103 ALARM WORD 1 M2PROT_2 MOTOR 2 PROTECTION MOT2.TEMP IN CONST_0 SP -74 FREE SIGNALS 12516 SIG1(SPEED REF) 12517 SIG2(SPEED STEP) 12518 SIG3(TORQ. REF A) 12519 SIG4(TORQ. REF B) 12520 SIG5(TORQUE STEP) 12521 SIG6(LOAD SHARE) 12522 SIG7(FLUX REF) 12523 SIG8(EMF REF) 12524 SIG9(FORCE_FWD) 12525 SIG10(FORCE REV) 12526 SIG11(CURR. REF) 12527 SIG12(CURR._STEP) ST20 1601 12501 ST SP -76 Field current controller 1 and 2 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). 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 REF SUM block enables the output of the ramp function generator and a user-definable signal to be added. Binary in and outputs (standard) 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 converter’s line contactor, the field-circuit contactor or contactors for various fans, or for outputting status messages. Additional binary inputs 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. Inputs and outputs for fieldbus 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. Torque / current limitation TYPE 1123 TEXT 1124 10601 Speed reference handling Speed controller DLY 13621 13622 TRIG ST20 P3 13616 13605 7 CURRENT RISE MAX Iact Speed feedback calculation RESTART SP -4 31416 SP -98 OUTPUT X18 13608 STOP T1ms 1112 DLY "EXT. IND. 4" SP -94 DATASET 4 13601 13602 13603 13604 13615 1216 DI/OVP P2 418 32767 ST20 1014 FIELD CONST 2 1015 FIELD CONST 3 SP -21 Conv.Curr.Slave Arm.Curr.Slave Conv.Curr.Both Arm.CURR.Both Fault Current 45 6 P1 MOTOR 1 FIELD OPTIONS Motor voltage controller Brake control 13611 13606 13609 13607 13610 13612 13613 13614 45 6 Disabled DCF Current Control Stand Alone Reserved Fexlink Node 1 Fexlink Node 2 MG Set SP -26 CUR,FLX,VLT: 100% 3611 3612 3613 3614 : : : 2 : 3 : 4 : 5 6 : CURRENT MONITOR ST20 Monitoring 12PULS_2 3608 IREF0 Logic 3609 Bridge Logic 11003 OUT Inputs and outputs for 12 pulse 10730 F CURR REF GENER.EMF REF ARM. CONTROLLER 0 0 0 13617 X18:13 13618 X18:14 13619 X18:15 13620 X18:16 cal 11002 LOCAL EMF REF TEST REF SEL 10 12-PULSE LOGIC BRIDGE REVERSAL LOGIC active, if [1209]= 1 or 2 FLUX REF SUM P2 EMF:100% 212 IN1 213 IN2 214 IN3 ST5 SP -99 100% 11001 SP -7 P3 P9 INPUT X18 FLUX REF 1 generatoric 4 P8 AI5:OUT- + -- 0 6 EMFCONT2 1012 FIELD WEAK POINT 1017 GENER.WEAK POINT MANTUN_3 4 10117 DCF MODE : 4 FIELD MODE MAINTENANCE P7 10728 P2 SP -34 P11 0 10727 DI2 (10703) EMF CONTROL P6 10116 1215 2 FLUX REF1 10726 AI5:OUT+ 0 TREF B SLOPE -1 209 IN1 210 IN2 211 IN3 ST5 C_MONIT SP -104 n ARM CURR LIM N5 60 STSYN AI5 DCFMOD 12308 SP -92 DATASET 2 4001 FIELDBUS PAR.1 4002 (MODULE TYPE) 4003 4004 4005 4006 4007 4008 4009 4010 Parameters 4011 depends of modul type 4012 4013 4014 4015 Armature current controller ARM CURR LIM N3 5000 SP -86 410 ARM L 411 ARM R 417 ARM CURR CLAMP ARM CURR LIM N2 P5 ST5 not used ARM CONT CURR LIM ARM ALPHA LIM MAX 413 ARM ALPHA LIM MIN 414 DXN x x y y 4192 MAX CURR LIM SPD P4 10729 ARM CURR PI KI 412 TREF A FTC ST20 ST5 SP -97 O1 409 ARM CURR PI KP 12307 SP -22 DI15 408 x x y y 4192 SPEED ACT 10725 ST5 SP-55 407 12401 SP -2 ST5 SP-56 DI14 ARM CURR REF SLOPE 415 ARM CURR LIM P 416 ARM CURR LIM N Torque/current limitation GEAR.START TORQ Maintenance INV IN T20 ST5 ST5 SP-57 not used 10125 OUT1 10126 OUT2 10127 OUT3 10723 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 DATA LOGGER (606) REF TYPE SEL TREF B SP -3 SP -43 DO7 IN FLBSET_2 FIELDBUS 10401 406 1 2 TREF A Inputs and outputs for fieldbus SP-95 10402 REF DCF P3 SP -91 DATASET 1 10404 STSYN "EXT. IND. 6" Additional binary inputs not used SET OUTPUTS TO ZERO 405 10403 t Max P1 SP-61 DI9 -1 RUNNING ST5 Torque ref DROOPING 1121 IN SDCS-IOE-1 TORQ MIN2 3200 7 Must be connected, when no fan acknowledges (DI1, DI2) 10708 ST5 Terminals 1366 P4 X7: 4 X6: O2 10707 1000 P3 SETTINGS (10505) SP -44 DO6 811 IN 812 INV IN COMFLT. TIMEOUT P2 SETTINGS (10501) T20 O1 ARM ALPHA BLOCK from ext. FEXLINK TEST RELEASE (10906) LOCAL 1201 0 DRIVEMODE (11209) P5 T20 ST5 SP -66 DI4 0 P2 P3 6 O1 P1 TORQ MAX2 (10903) X7: X6: MAIN CONT ALARM 10905 1 2 2 O2 FAULT 10904 COAST STOP X96: X6: MOTOR FAN O1 RUN3 RUNNING 3 1 913 10702 ST5 SP -68 DI2 RUNNING 10903 SP -45 DO5 809 IN 810 INV IN T20 X7: X6: O2 CURR STEP Min (11208) P1 2 6 10711 911 O1 1 RUN2 MIN SPEED (12201) BC (BLOCK.) (11205) 907 ST5 CONV FAN RDY ON 10901 RDY RUNNING 10902 RUN1 LOCAL 10710 T20 DRLOGI_2 X7: X6: O1 O2 SP -69 DI1 904 ON/OFF RDY RUNNING 1 5 RESET 903 906 10709 ST5 SP -64 DI6 TORQ MAX SP -100 X7: X6: O2 SP -46 DO4 807 IN 808 INV IN 5 8 EM STOP CURR REF 10405 ST20 X7: X6: 902 10715 905 O1 404 ST5 4 7 SP -65 DI5 SEL2.TREF SEL ST10 208 AO2 NOMINAL VALUE DATA LOGGER (603) MAINTENANCE (1212) 10714 ST5 TORQ MAX2 12305 P3 P4 10503 Binary in and outputs (standard) 10716 403 ARM DIR TREF TORQMIN1 DATA LOGGER (602) MAINTENANCE (1211) 525 UNI FILT TC (only for Cur. Controlling) 522 LANGUAGE 901 O2 SEL2.TORQ STEP TREF TORQMAX1 10515 EMF ACT 10506 DRIVE LOGIC 2404 TREF TORQMIN1 12304 DATA LOGGER (604) X7: X6: RUN TREF TORQMAX112303 10508 U ARM ACT 10505 + - CALC Iact EMF FILT TC 10504 10502 ARM CUR ACT SP-36 O1 0 P12 Control Adjust. 523 CURR ACT FILT TC 524 PLL CONTROL 528 PLL DEV LIM ST5 SP -62 DI8 Max 0 P2 P1 Terminals O2 Min TREF TORQ MIN P1 SPC TORQMIN1 12302 and motor data SDCS-CON-2 O1 TREF TORQ MAX Software version: Schematics: Library: Terminals ON/OFF Max SPC TORQMAX1 12301 DCS 500B Software structure SDCS-CON-2 10713 1 KP (10907) EMESTOP ACT 1004 FLUX REF SEL 1002 CONSTANTS (12512) FLUX REF (12102) SPEED ACT ST20 SP -63 DI7 2406 ACCELCOMP X4: 500 ST5 Not used 2409 10 8 P7 AI3:ERR 10112 P1 Min SPC TORQ MIN SETTGS_3 SP -1 108 AI2 HIGH VALUE 109 AI2 LOW VALUE AI3 TORQUE/CURRENT LIMITATION SPC TORQ MAX ST5 AI2 CONV MODE Not used (11702) FREE SIGNALS (12520) SET OUT TO ZERO BC 402 CURR REF IN LIM CURR DER IN LIM 5 P1 RUNNING 12-PULS [1209] 1,2 FLUX REF1 MON.MEAS LEV 10 7 10000 4000 STALL.TORQUE 201 P1 2403 TORQ MIN2 12306 STALL.SEL P11 0 CLEAR CONSTANTS (12527) ARM CUR ACT SP -105 12204 ST5 P1 HOLD RINT CONSTANTS (12526) 4 SP ERR SPEED CONTROL (2011) FLUX N TORQ REF SP -10 SPMONI_2 SPEED MONITOR MIN SPEED L SP -81 12101 Speed feedback calculation + -- HOLD 3 Max (12001) SEL2:IN_LIM 12404 401 ARM CURR REF DCF FIELDMODE ST20 MAINTENANCE (1210) T5 Torque reference VAL2 Min SEL2:OUT SPEED CONTROL (2010) TORQ REF HANDLING FREE SIGNALS (12521) CH B 102 SET2 BAL2REF 2 12402 TORQ REF SELECTION SPEED MEASUREMENT 101 BAL2 SEL2.TREF EXT SEL2:TORQ/SPEED ST5 11702 2401 P1 0 VAL1 2408 1 SP -8 CH A P1 BALREF 12005 0 SEL2.TREF SPC CURRENT CONTROL 12403 P1 Incremental encoder -8...-30V -30...-90V -90...-270V 2012 SET1 2407 SPC TORQMIN1 1713 SMOOTH2 1715 SPEEDMAX SP -11 SP -84 2011 BAL IN LIM 12004 SPC TORQMAX1 FREE SIGNALS (12519) + 2010 2007 RUNNING T20 (10903) Tacho 2009 OUT 0 C_CNTR_3 SP -75 TORQ REF HANDLING KP DROOPING 12002 TREFHND2 SPEED CONTROL IN SPEED ACT T+ DECEL1 1710 2004 2006 12001 ST5 ACCEL2 1712 2003 OUT E- ACCEL1 1709 2005 0 P1 SP -17 REFSUM_2 1801 IN1 OUT 11802 1802 IN2 H 1707 T1/T2 1714 EMESTOP RAMP 1711 OUT 11701 2021 SP -9 SP -14 SPEED ERROR IN 1923 ENABLE 1921 OHL 1922 OLL DRIVE LOGIC (10903) 5000 LOC REF 1708 SP -13 2001 SPEED 11801 REFERENCE 11703 SIGN 1706 RES OUT ST5 P1 RAMP GENERATOR (10906) LOCAL 0 1702 RES IN 1717 STARTSEL 0 1703 HOLD 1916 ADD 1917 REV ST5 RAMP_3 SP -18 1720 SPEED SET 1701 IN REF SEL 1910 IN1 1911 SEL1 Line and motor data 11101 11102 11103 11107 11104 11105 11106 11108 11109 The SETTINGS block serves for scaling all important signals, such as line voltage, motor voltage, motor current and field current. Parameters are available to adjust the control to special conditions like weak networks or interactions with harmonic filter systems. The language, in which you want to read your information on the panel, can be selected. The AO2 block represents a scalable analogue output. Motor voltage controller 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. To enable the drive to utilize a higher motor voltage even with a 4 quadrant system two different field weakening points can be set by parameter. Inputs and outputs for 12 pulse 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. Maintenance The MAINTENANCE 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. Monitoring 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". Adaptations are made for rebuild applications, which keep the power part and the fan, to sense overload conditions or fan failures. 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. User event By using the block USER EVENT1 to USER EVENT6 six different messages are created, which are displayed as faults or alarms on the panel CDP312 as well as on the 7 segment display of the converter. Brake control The BRAKE CONTROL block generates all signals needed for controlling a mechanical brake. Data logger 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. Additional signals By using the block FAULT HANDLING the faults and alarms of the drive are regrouped as 16bit information. The CONSTANTS and FREE SIGNALS blocks can be used for setting limitations or special test conditions.
Source Exif Data:
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