ABB DC Drives DCS800 The next Generation nde Flying Shears · Centrifuges · Battery Charging · Winders · Casting Cranes · Mud Pumps · Roller Tables · Filling machines · Test Rigs · Cutters · Printing machines · Extruders · Mixers · DCS800 – The key Advantages n Unique power spectrum 20 A … 20,000 A, up to 5,200 A in one module n Supply voltage 230 … 1,200 V AC (0 … 1,500 V ) DC n Intuitive, easy programming and commissioning n Modular expandable in hardware and software n Adaptive programming n PLC integrated (IEC 61131-3) n Backwards compatible with DCS500/600 n Same tools and options as ABB AC drives n Compact - highest power/size ratio in its class DCS800 – the next Generation nde Flying Shears · Centrifuges · Battery Charging · Winders · Casting Cranes · Mud Pumps · Roller Tables · Filling machines · Test Rigs · Cutters · Printing machines · Extruders · Mixers · The practical requirements for modern DC drives are extremely diverse. On the one hand opera- tion and handling should be easy while on the other hand almost perfect functionality and per- formance for all different applications is expec- ted. The challenge is to find an innovative soluti- on which copes with both of them - the solution is DCS800. The combination of best-in-class user friend- liness, high performance and almost unlimited scalability allows You to configure Your drives to get flexible, cost effective solutions. Thus the DCS800 helps You to save Your investment for the future. Decision makers ask themselves: n Which DC drive manufacturer today invests millions of Euros in a new DC product series? n Which DC drive manufacturer today still offers complete support for old DC installations as well as for new customer requirements? n Which DC drive manufacturer delivers DC drives with the latest state of the art technol- ogy, even in the future? ABB – The reliable partner Saving money with DCS800 n Highest reliability and availability n Fast installation and commissioning n Less components, thus less spare parts needed n PC Tool included in the standard scope of delivery n PLC included in the drive without additional hard- ware n Remote maintenance and diagnosis via internet n Field supply, encoder and tacho interfaces always included n Reduced installation work due to integrated field supply ABB DC drive technology - Innovation driven by tradition Propulsion Drives · Material transport · Electrolysis · Cranes · Lifts · Open Pit Mining · Galvanization · Rolling Mills · Oil Rigs · Conveyor belts · Drilling Drives · Kilns · Tube mills · Mine Hoists A DC drive from ABB is more than just a With the innovative DCS800 technology our cus- drive. tomers are well armed for the challenges of the Due to… future. And with ABB they have the certainty of a • our advanced technical Know How, reliable and fair partner- especially in the field of • our experience over decades in every imaginable DC drives. application, • highest quality and reliability of our products, as well as, • our worldwide presence ...we can help you to be more competitive within the global marketplace of the future. During the deve- lopment of the DCS800 we focused on the user’s needs. By means of innovations, which save money. By means of functions, which make DC technology easier than ever before. One world - one drive n Standard supply voltage up to 525 V n Applicable for 50/60 Hz networks n Multi-lingual control panel and PC tool n Documentation available in 8 lan- guages, even Russian and Chinese DCS800 – designed to ease n Support by ABB’s worldwide drive Your life network in more than 140 countries n Approvals: n Intuitive assistants make the commissioning a mere child‘s play n Context sensitive user guidance and help functions n High resolution control panel included in the standard delivery n Simplified fault diagnosis by means of fault assistants n Predefined macros for most ap- plications n Optimized auto tuning for all internal controllers n Automatic phase sequence detection n Automatic tacho adjustment DCS800 – Simplicity as a principle Many users -like machine builders- have more Extremely flexible important issues to do than wasting much time Adaptive programming allows simple adaptation with drives in their applications. Therefore, the of every drive without using additional hard- drives must work well and be simple to operate ware or other options. Preconfigured function – just like the DCS800. The innovative DC drive blocks (e.g. free PI controller, filters, logic blocks) from ABB sets all new standards in simple opera- are included off-the-shelf in every drive. The tion and smooth handling. DCS800 control panel or the commissioning tool DriveWindow Light serve as programming tools. Hence, unexpected changes on site are easy to handle. DCSLink – the direct connection n Simple and cost-efficient connection of several devices n Peer-to-Peer communication directly from drive to drive n Cycle times < 1.5 ms n Standard support of demanding drive configurations, e.g. Master Follower, drives with multiple field exciters, winder / unwinder, roller tables and 12-pulse operation. DCS800 - PLC included n Programming environment ControlBuil- der, based on the common standard tool CoDeSys n Support for all IEC 61131 programming languages n Numerous preconfigured functions e.g.: n Free PID controller n Winder for diverse applications n Ramp and function generator n Direct configuration in the drive without any needs for additional hardware like techno- logy boards n Memory Card for saving the source code in the drive n Wide and comfortable standard function block library DCS800 – Due to scalability open to all Due to its large function range, the DCS800 is the first DC drive which increases its functionality according to the requirements of the user. Hard- ware extensions are quickly plugged on without using tools. Due to the standard integrated PLC and the Peer-to-Peer communication, even com- plex control tasks are realised directly in the drive. DCS800 – one drive fits all The DCS800 allows cost-efficient drive systems, which are accurately adjusted to the respective application. Thus it is the first choice in various applications – in metals, in pulp and paper as well as in cranes, in mine hoist or in non-motoric applications like battery chargers or magnets. DCS800 – powerful PC tools DriveWindow Light n Free of charge n Standard connection to PC and laptop n Assistants for fast commissioning, diagno- sis and maintenance n Adaptive Programming DriveWindow n Fast optical connection with up to 2000 drives at the same time n Real time monitoring DriveSize n Fast and individual dimensioning of DC drives and motors n Load cycles freely definable n Configuration from individual modules to complex line-ups DCS800 – Far away and still at Your fingertips The DCS800 is „Internet enabled“. Remote service from every internet PC guarantees the reliable use of the DCS800 in an easy and cost effective way - if necessary from thousands of miles away. In addition, our intuitive PC tools provide easy access to all DCS800 functions. Thanks to guided commissioning, adaptive programming and intel- ligent diagnostics its operation will be like a mere child‘s play. ControlBuilder Trending Commissioning assistant DriveSize DCS800 – powerful PC tools DriveWindow Light n Free of charge n Standard connection to PC and laptop n Assistants for fast commissioning, diagno- sis and maintenance n Adaptive Programming DriveWindow n Fast optical connection with up to 2000 drives at the same time n Real time monitoring DriveSize n Fast and individual dimensioning of DC drives and motors n Load cycles freely definable n Configuration from individual modules to complex line-ups DCS800 – Technical Data Technical data DCS800 Digital outputs 8 standard Maintenance / Diagnosis DCSLink Peer-to-Peer Mains supply voltage 230...1,200 V +/–10 %, 3~ up to 12 optional Remote diagnosis with any Internet-PC worldwide • up to 800 kBaud, < 2.5 ms Analog inputs 4 standard Frequency 50...60 Hz +/–5 Hz • with internet browser / internet explorer • Master-Follower Electronics supply 115...230 V +/–10 V; 0/2…10 V up to 6 optional • or with DriveWindow full drive control via OPC • Armature-fieldconverter –15 % / +10 %, 1~ +/–2 0mA; 0/4…20 mA • Free selectable data Analog outputs 3 standard (1x I ) DC Output current 20...5,200 A act Approvals Overload capability 200 % +/-10 V; 0/2…10 V up to 5 optional High Current Solutions (+/–20 mA; 0/4…20 mA, with RAIO optional) Adaptive Programming • 12-pulse up to 20,000 A, serial and parallel Ambient conditions Accuracy pre-defined drive-specific function blocks, e.g. Ambient temperature 0° ... +40° C • Hard parallel and sequential Speed resolution • Free process controller (PI-Controller) 40° ... 55°C with reduction • up to 1,500 V with encoder 0.005 %, • I/O- and digital Operations Storage temperature –40° ... +55° C of nominal Speed With control panel or PC-Tool, no need for additional Transport temperature –40° ... +70° C Protections with analog tacho 0.1 % (16 Bit) hardware Relative humidity 5 ... 95 %, not condensing Speed feedback monitoring Temperature Cycle time speed controller 3.3 / 2.77 ms (50 / 60 Hz), (max. 50 % betw. 0°...5° C) Speed Feedback synchronous with mains Overload Over speed Pollution degree Class 2 EMF frequency Motor stalled Motor over current Protection class IP 00 Analogue tacho Step response curr. contr. 5 ms Motor over voltage Field over current finger protection I < 1,000 A nom Encoder Cycle time curr. contr. 3.3 / 2.77 ms (50 / 60 Hz), Altitude < 1,000 m height above sea Field over voltage Minimum field current synchr. with mains frequency 2nd Encoder possible (RTAC) level: nominal Current Zero speed Armature current ripple Analog inputs 16 Bit > 1,000 m height above sea Communication Mains over- and under voltage level: with reduction PC-Tools Serial communication DriveWindow Light free of charge with every Field current • Ethernet • Modbus Plus converter Integrated IEC 61131-PLC Up to 25A integrated (not D6 / D7) • Profibus • CS31 (Procontic) Standard RS232 PC- • Open standard programming tool ControlBuilder Up to 60 A, external 1~ • CANopen • Masterpiece (Asea) connection • Support of all five IEC-languages Up to 520 A, external 3~ • DeviceNet • Selma2 (Strömberg) DriveWindow Real-time optical connection • Drive-specific function blocks I/O ControlBuilder IEC61131 programming tool • ControlNet • DDCS (AC800 M) • Saving of program and source in Memory Card Digital inputs 8 standard DriveSize Converter- and motor • Modbus © up to 14 optional dimensioning Industrial IT enabled • Online debugging and forcing Unit 2-Q 4-Q Supply voltage max. field Dimensions size rated Current rated Current [V ] current AC DCS800-01 DCS800-02 internal I [A] I [A] 400 525 600 690 800 990 1200 [A ] h x w x d [mm] h x w x d [inch] DC DC DC D1 20 25 6 310 x 270 x 200 12.50 x 10.75 x 8.00 45 50 65 75 90 100 125 140 D2 180 200 15 310 x 270 x 270 13.75 x 10.75 x 10.75 230 260 3) D3 315 350 20 400 x 270 x 310 15,75 x 10,75 x 12,50 405 450 470 520 3) D4 610 680 25 580 x 270 x 345 23.00 x 10.75 x 13.75 740 820 900 1000 D5 900 900 25 1050 x 510 x 410 41.50 x 20.25 x 16.25 1200 1200 1500 1500 1) 1) 2000 2000 D6 1900 1900 external 1750 x 460 x 410 69.00 x 18.25 x 16.25 2050 2050 field 2500 2500 35/60A, 1~ 3000 3000 520A, 3~ D7 2050 2050 external 1750 x 760 x 570 69.00 x 30.00 x 22.50 2) 2600 2600 field 2) 3300 3300 35/60A, 1~ 4000 4000 520A, 3~ 4800 4800 5200 5200 1) 2) 3) only available as 2-Q drive on request 600V 2-Q -> 290 A / 590 A 4-Q -> 320 A / 650 A DCS800 family DCS800-S Modules n Compact The versatile drive for any n Highest power ability application n Simple operation n Comfortable assistants, e.g. for commissioning or fault Propulsion Drives · Material transport · Electrolysis · Cranes · Lifts · Open Pit Mining · Galvanization · Rolling Mills · Oil Rigs · Conveyor belts · Drilling Drives · Kilns · Tube mills · Mine Hoists 20 … 5,200 A tracing DC 0 … 1,160 V n Scalable to all applications DC 230 … 1,000 V n Free programmable by means of integrated IEC61131- AC IP00 PLC DCS800-A Enclosed n Individually adaptable to customer requirements Converters n User-defined accessories like external PLC or automati- Complete drive solutions on systems can be included n High power solutions in 6- und 12-pulse up to 20,000 A, 20 … 20,000 A 1,500 V DC 0 … 1,500 V n In accordance to usual standards DC 230 … 1,200 V n Individually factory load tested AC IP21 – IP54 n Detailed documentation DCS800-E Series n DCS800 Module with all necessary accessories moun- Pre-assembled drive-kits ted and fully cabled on a panel n Very fast installation and commissioning 20 … 2,000 A n Squeezes shut-down-times in revamp projects to a DC 0 … 700 V minimum DC 230 … 600 V n Fits into Rittal cabinets AC IP00 n Compact Version up to 450 A and Vario Version up to 2,000 A DCS800-R Rebuild Kit n Proven long life components are re-used, such as Digital control-kit for existing power stacks, (main) contactors, cabinets and cabling / powerstacks busbars, cooling systems n Use of up-to-date communication facilities 20 … 20,000 A n Increase of production and quality DC 0 … 1,160 V n Very cost-effective solution DC 230 … 1,200 V n Open Rebuild Kits for nearly all existing DC-drives AC IP00 n tailor-made solutions for… n BBC PxD n BBC SZxD n ASEA Tyrak n other manufacturers ABB Automation Products Wallstadter Straße 59 68526 Ladenburg • Germany Phone +49(0)6203-71-0 Fax +49(0)6203-71-7609 www.abb.com/motors&drives dc-drives@de.abb.com 3ADW000190R0201 Subject to changes without prior notice