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DCS800Technical Presentation

DCS800built on DCS technology

NURUL

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DCS800 - Contents

Overview

Simplicity, basic package

Scalability

Programmability

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The best of four worlds

Control performance

of DCS 600Simplicity

of DCS 400

Programming capability

of DCS 500B

Synergies withAC drives

DCS800 - The next generation

DCS800

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20 A to 5200 A in single modules20 A to 5200 A in single modules

D1: 20 A - 140 AD2: 180 A - 260 AD3: 315 A - 520 AD4: 610 A - 1000 A

DCS800 - Complete range of power stacks

D5: 900 A - 2000 A

D6: 1900 A- 3000 A

D7: 2050 A - 5200 A

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DCS800 - EZ2Use during its whole lifecycle Sales:

Presentations, flyers and DC catalogue

Single phase demo case Ordering:

Engineering with DriveSize

Same options and plus code as AC

Ordering via internet Transportation:

New package for D1-D4 is save and easy to open Installation and commissioning:

Easy transport due to grips or lifting lugs Each package contains a 1:1 drilling template Fast commissioning by means of

Modular Startup Assistant,Macros andAdaptive program (AP)

D1: 20 A - 140 A

D2: 180 A - 260 A

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DCS800 - EZ2Use during its whole lifecycle Operation:

Same drive tools as AC (DriveWindow Light, DriveWindow, control panel)

The connectors are vibration proof It is possible to generate user defined events

Maintenance and service: Automatic detection of option modules and field exciters The DCS800 provides online help Remote diagnostics (via Ethernet, DriveWindow, …) Ladenburg provides DC support world wide spare part support (parts online)

Recycling: ABB offers revamps and upgrades

D4: 610 A - 1000 A

D3: 315 A - 520 A

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DCS800 - Contents

Overview

Simplicity, basic package

Scalability

Programmability

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DCS800 - Basic package The basic package contains:

Standard firmware comes including macros and Adaptive Program (AP)

Startup Assistant Approvals CE, cULus, C-tick All printed circuit boards are coated

Modules up to 1000 A include

Mains voltage up to 525 VAC

OnBoard field exciter DCS800 panel Standard I/O with 16 bit analog inputs

Including connections for analog tacho,

pulse encoder and PTC

Same terminal layout as DCS500/600 DriveWindow Light

7 + 1 DO

8 DI

PulseEncoder

3 A0

Analogtacho

plus 4 AI

Field exciter is located in the drive module

RS232 cable

DriveWindow Light

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DCS800 - DCS800 panel Characteristics

Panel is also used for AC drives

Large display

Door mounting kit available

Functions Two soft keys

Help function

Multilingual

Startup Assistant

Adaptive Program (AP)

Plain text for fault logger, faults and alarms

Shows actual values in physical units

Copy and compare function for parameters

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DCS800 - Adaptive Program (AP) Drive programming done in a few minutes!

No additional software, hardware or tools needed Adaptive Programs can be created by setting parameters with panel or PC Adaptive Programs are easy to understand Each drive contains 16 function blocks The library contains 31 different basic functions (e.g. AND, OR, ADD, …) Create and modify e.g I/O signals, speed or torque references Visualization Tool for graphical display (DWL AP) Used in ACS800

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DCS800 - Startup Assistant Modular Startup Assistant Fast commissioning!

Available in DCS800 panel and DriveWindow Light

Intelligent filter for 1000 parameters

Correct commissioning sequence

Online help

Autotunings

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OnBoard field - The exciting solution! 3 wires in, 4 wires out up to 2000 A due to

OnBoard- and internal field exciter

Less hardware, wiring and testing

Simple ordering

Optimal control of armature voltage

Higher armature voltage for 4-Q drives

Smooth field voltage due to 3-phase field

Maximum field current:

OnBoard field exciter can be disabled

DCS800 - Field exciter

D1 D2 D3 D4 D5

If 6 A 15 A 20 A 25 A 25 A

Ia 20 -140 A

180 - 260 A

315 - 520 A

610 - 1000 A

900 - 2000 A

3 in

4 out~~

DCS800

~~

DCS600

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DCS800 - Technique of field exciters Technique:

Thyristor based half controlled 3-phase bridge up to 25 A and 525 VAC +10% supply

Incoming voltage is taken from armature circuit up to 525 VAC +10%

Advantages: Lower voltage stress for the motor

Higher current available compared to IGBT and single phase solution

Easy connection (3 wires in, 4 wires out)

No external wiring needed

Reduced amount of external hardware like autotransformer, breakers, line chokes, fuses and wiring

Field

OnBoard / internal

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DCS800 - High precision and speed Speed control:

Min. speed resolution with pulse encoder: 0.005 % of nominal speed

Min. speed resolution with analog tacho: 16 bit

Speed controller cycle time: 3.3 ms / 2.77 ms (synchronized with mains frequency)

Current control: Current controller 3.3 ms / 2.77 ms (synchronized with mains frequency)

Current response to step load: 5 ms

Reference handling: Resolution of analogue inputs: 16 bit

Update time AI = 3.3 ms / 2.77 ms (synchronized with mains frequency)

Update time AO = 5 ms

Fastest update time to overriding control system: 2 ms

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Main functions: Speed reference selection

Speed ramp

Speed actual selection

EMF, analog tacho, pulse encoder

Speed controller

Window control, droop, acceleration compensation

Torque handling

Torque reference, -selection, -limitation

Armature current control

EMF and flux control

Field current control

DCS800 - Firmware (armature)

Adaptive program (AP)

Motor protection

Overvoltage and overcurrent

Stall protection

Motor temperature calculation and measurement

DC breaker control

Autotunings

E-stop logic

Remote local control

Drive-to-drive communication

4 mail boxes with a total of 16 values

Master-follower

12-pulse operation

New

New

New

New

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Main functions: EMF and flux control

EMF controller

Flux linearization

Field current control

Field reversal

OPTI-torque

Field heating

Dual field control

Dynamic brake logic

Stand alone capability

DCS800 - Firmware (excitation / macros) Macros:

DCS400 macros are used (except field reversal)

2 user macros are available (like DCS600 MultiDrive and ACS800)

2 motor parameter sets available (e.g. shared motion)

New

New

New

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Hardware (D1-D4) Power stack

Power interface board (SDCS-PIN-4) includes OnBoard field exciter, power supply and firing unit

Electronic tray

Control board (SDCS-CON-4)

Converter fan

Intermediate cover

Plug in options and DCS800 panel

Click on design cover

DCS800 - Hardware

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DCS800 - Synergies with ABB AC drives Synergies with AC - Same 'look and feel' as ABB AC drives!

DCS800 and ACS550 panels are identical

Identical drive tools (DriveSize, DriveWindow, DriveWindow Light, CoDeSys, …)

Same extension I/O modules (analog- and digital I/O)

Same serial communication modules (Profibus, Ethernet, …)

Same fast communication to ABB PLC’s (AC 800M, AC 80, …)

Adaptive Program (AP)

Similar macros, parameter structures and command words

Same ordering code DriveWindow Light

DriveWindow

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DCS800 - Backward compatibility (1)

Compatibility - We make it easy to upgrade Your old DCS500/600! Firmware:

The DCS800 firmware contains all feature of DCS500/600 drive

Old parameter sets can be updated to DCS800 (cross reference lists)

Hardware:

The SDCS-CON-4 has the same connection configuration as SDCS-CON-2

Same Isolated I/O (SDCS-IOB-2x and SDCS-IOB-3)

Since D1-D4 is smaller than C1-C2b the whole converter should be changed

A special upgrade kit for the electronics will be available (D5-D7)

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DCS800 - Backward compatibility (2)

Compatibility - We make it easy to upgrade Your old DCS500/600! HMI:

CDP312xx panels can be connected via SDCS-COM-8

DriveWindow Light is now standard

DriveWindow via SDCS-COM-8

Overriding control system:

The former Nxxx fieldbus modules for serial communication can be reused

No changes in the control- and status words

ABB overriding control system AC 800M and AC80 are supported

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Adaptive program: Usable by PC and

panel

Comes with every DCS800

Adaptive program: Usable by PC and

panel

Comes with every DCS800

DCS800 - Benefits

DCS800 panel: Intuitive user guidance

Comes with every DCS800

DCS800 panel: Intuitive user guidance

Comes with every DCS800

Startup Assistant: Fast commissioning

Reduced training

Startup Assistant: Fast commissioning

Reduced training

Field exciter: 3 wires in, 4 wires out

Less hardware

Field exciter: 3 wires in, 4 wires out

Less hardware

Hardware: Only 2 printed circuit

boards

Proven power stack

Hardware: Only 2 printed circuit

boards

Proven power stack

Synergies: Less training

Look & feel like ABB AC drives

Synergies: Less training

Look & feel like ABB AC drives

Savings

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DCS800 - Contents

Overview

Simplicity, basic package

Scalability

Programmability

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DCS800 - Scalability

External Field exciter

Extension I/O

Serial communication

Isolated I/O

Interface to the ABB fiber optic world: SDCS-COM-8

The basic package can be scaled to a wide variety of applicationsFast monitoring of different drives

IEC 61131 Programming

Basic package

Master-follower,drive-to-drive,

12 pulse & ‘hard parallel’

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Type code: DCS800 - S01 - 0680 - 04 - +K454

Product seriesDCS800

TypeS0 = converter module IP00R0 = Rebuild systemA0 = Enclosed converterE0 = Panel solution

Bridge type1 = Single bridge (2-Q)2 = Double bridge (4-Q)

Rated DC current0680 = 680 ADC (IP 00)

DCS800 - Type code

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Type code: DCS800 - S01 - 0680 - 04 - +K454

Rated AC voltage04 = 230 ... 400 VAC05 = 230 ... 500 VAC06 = 270 ... 600 VAC07 = 315 ... 690 VAC08 = 360 ... 800 VAC10 = 450 ... 990 VAC12 = 540 ... 1200 VAC

Power connection- = Standard D1 ... D6L = Left side D7R = Right side D7

Plug-in optionsSee next slide

DCS800 - Type code

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DCS800 - Plus code (plug-in options)Plus code

No control panel + 0J400 Internal field exciter (only D5) + S163 Fieldbus module Profibus DP + K454 Fieldbus module Modbus + K458 Analog I/O extension module RAIO-01 + L500 Digital I/O extension module RDIO-01 + L501 Interface board SDCS-COM-81 + L508 Interface board SDCS-COM-82 + L509 DCSLink board SDCS-DSL-4 + S199

The plus code represents a modification of the drive module e.g. to build in a RAIO-01 into the module is +L500.

A RAIO-01 on an AIMA board is not a modification of the drive module and thus has to be ordered by means of the ID code.

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DCS800 - Scalability

I/O configuration …

Overriding control …

Human Machine Interface (HMI) …

1. Excitation …

Remote diagnostics …

2. Master-follower …

3. Drive-to-drive …

4. 12-pulse …

External field exciters …

Versatile DCSLink used for:

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DCS800 - I/O configuration Standard I/O:

Including connections for analog tacho, pulse encoder and PTC

Same terminal layout as DCS500/600 Extension I/O:

RDIO and RAIO

Max: 8 AI, 7 AO, 14 DI, 12 DO

Isolated I/O: SDCS-IOB-2x with 8 DI and 8 DO

SDCS-IOB-3 with 4 AI, 2 AO and 1 encoder input

Scalability …

Flatcables 7 + 1 DO

8 DI

PulseEncoder

3 A0

Analogtacho

plus 4 AI

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DCS800 - HMI DCS800 panel:

Shows actual values in physical units

Multilingual

Help functions

Startup Assistant

DriveWindow Light: Basic tool for commissioning and

maintenance (Startup Assistant, DWL AP)

Free of charge

DriveWindow (via SDCS-COM-8): ABB drives PC tool for commissioning

and maintenance

Up to 2000 DC and AC drives can be connected

Scalability …

RS232 cable

DriveWindow Light

Optical link, up to 200 m

DriveWindow

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Optical link, up to 10 m

PLCOptical link, up to 200 m

DCS800 - Overriding control Serial communication with Rxxx

fieldbus interfaces: Profibus-DP, DeviceNet, CANopen,

ControlNet, Modbus, Ethernet

Serial communication with former Nxxx fieldbus modules possible via SDCS-COM-8

DDCS communication to ABB overriding control (e.g. AC 800M) possible via SDCS-COM-8

IEC 61131 drive programming is possible with the ABB Memory Card

Scalability …

PLC

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Full controlled 3-phase field exciter 20 A to 520 A

Overvoltage protection

Second external field exciter 0.3 A - 35 A,or 0.3 A - 50 A

DCS800 - DCSLink (excitation) Excitation:

Max. 2 field exciter per armature converter

Scalability …

First external field exciter 0.3 A - 35 A,or 0.3 A - 50 A

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DCS800 - DCSLink (master-follower) Master-follower:

One master can control up to 10 followers

Scalability …

…

Follower 10Follower 1

Master

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DCS800 - DCSLink (drive-to-drive) Drive-to-drive (multiple master) communication with up to 3 DCS800

Scalability …

Main drive

RecoilerUncoiler

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DCS800 - DCSLink (12-pulse) 12-pulse configurations

Parallel / serial / sequential

Scalability …

12-pulse follower12-pulse master

External field exciter

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DCS800 - Remote diagnostics DriveWindow:

via OPC and Ethernet

NETA-01 via Ethernet and browser

Tixi modem via phone line and DriveWindow

Light

Scalability …

Optical link

up to 2000 drives

Ethernet

Remote location

Optical link

up to 9 drives

Ethernet

Remote location

RS232 cablePhone line

Remote location

Tixi modem

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Type designation

Current range

Max. supply voltage Type of field exciter

DCF803-0035 5 A - 35 A

respectively

0.3 A - 5 A

525 VAC / 600 VAC*,

single phase or 3-phase

Half controlled,

1-Q

DCF803-0050

DCF803-0060

0.3 A - 50 A

0.3 A - 60 A

500 VAC / 690 VAC*,

single phase,

500 VAC / 690 VAC*

Half controlled,

1-Q

DCF804-0050

DCF804-0060

0.3 A - 50 A

0.3 A - 60 A

500 VAC / 690 VAC*,

single phase,

500 VAC / 690 VAC*

Full controlled,

4-Q

DCS800-S0x 20 A - 520 A 525 VAC,

3-phase

Full controlled,

2-Q or 4-Q

DCS800 - External field exciter

* with auto transformer

Scalability …

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DCS800 - Benefits

DCSLink: One link fits all (4 in 1)

DCSLink: One link fits all (4 in 1)

HMI: Open to OPC, DW,

DWL, panel

HMI: Open to OPC, DW,

DWL, panel

Overriding control: Open to all

communication

Fits all control structures

Overriding control: Open to all

communication

Fits all control structures

I/O configuration: Same terminal layout

as DCS500/600

Same isolated I/O as DCS500/600

I/O configuration: Same terminal layout

as DCS500/600

Same isolated I/O as DCS500/600

Savings

Remote diagnostics: Remote service

possible

Connection via internet or phone line

Remote diagnostics: Remote service

possible

Connection via internet or phone line

External field exciter: Vast variety for all

customer needs

Up to 520 A

External field exciter: Vast variety for all

customer needs

Up to 520 A

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DCS800 - Contents

Overview

Simplicity, basic package

Scalability

Programmability

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For the Adaptive Program (AP), you can use DWL AP as visualization tool

Small PLC-function integrated Program your drive even faster

during commissioning Easier as setting parameters DWL AP is integrated into

DriveWindow Light and comes with every DCS800 for free

There is no additional hardware or software necessary

Define your own I/O-signals, modify the speed or torque references

DCS800 - DWL AP

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Free application programming - Your PLC integrated into the DCS800! Firmware and application programs are separate

Standard tool (CoDeSys)

IEC 61131 programming

No user limitation (everyone can use the tool)

Source code can be

Saved on drive

Protected by password

Size and performance is suitable for cranes and winders

The application and parameter are located on the ABB Memory Card

Visualizations can be build by CoDeSys and used on a PC

DCS800 - Free application programming

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DCS800 - Benefits

DWL AP: Visualization is based

on parameters

Visualization for even more easy commissioning

DWL AP: Visualization is based

on parameters

Visualization for even more easy commissioning

Application programming: PLC integrated into

DCS800

Less training due to common standards (IEC 61131, CoDeSys)

Application programming: PLC integrated into

DCS800

Less training due to common standards (IEC 61131, CoDeSys)

Savings

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DCS800

Thank You for Your attention!