DCS800

Hardware Manual
DCS800-E Panel Solution

DCS800-E draw_3d.dsf
DCS800 Drive Manuals
Language
Public. number E D I ES F CN
DCS800 Quick Guide 3ADW000191 x p p p p
DCS800 Tools & Documentation CD 3ADW000211 x
DCS800 Converter module
Flyer DCS800 3ADW000190 x x p x p p
Technical Catalogue DCS800 3ADW000192 x x x x p x
Hardware Manual DCS800 3ADW000194 x x p p p p
Firmware Manual DCS800 3ADW000193 x p p p p p
Installation according to EMC 3ADW000032 x
Technical Guide 3ADW000163 x
Service Manual DCS800 3ADW000195 x p
Planning and Start-up for12-Pulse converters 3ADW000196 p
CMA-2 Board 3ADW000136 p
Flyer Hard - Parallel 3ADW000153 p

Drive Tools
DriveWindow 2.x - User's Manual 3BFE64560981 x
DriveOPC 2.x - User's Manual 3BFE00073846 x
Optical DDCS Communication Link 3AFE63988235 x
DDCS Branching Units - User´s Manual 3BFE64285513 x

DCS800 Applications
PLC Programming with CoDeSys CoDeSys_V23 x x x
61131 DCS800 target +tool description - Application Program 3ADW000199 x
Winding with the DCS 800XXXXX 3ADW000058
Winder application description 3ADW000253 x
Flyer magnetic application
Magnetic application description

DCS800-E Panel Solution

Flyer DCS800-E Panel solution 3ADW000210 x
Hardware Manual DCS800-E 3ADW000224 x

DCS800-A Enclosed Converters

Flyer DCS800-A 3ADW000213 x
System description DCS800-A 3ADW000198 x p
Installation of DCS800-A 3ADW000091 p p

DCS800-R Rebuild System

Flyer DCS800-R 3ADW000007 x x
DCS800-R Manual 3ADW000197 x
DCS500/DCS600 upgrade manual

Extension Modules
RAIO-01 Analogue IO Extension 3AFE64484567 x
RDIO-01 Digital IO Extension 3AFE64485733 x
AIMA R-slot extension 3AFE64661442 x

Serial Communication
Drive specific serial communication
NETA Remote diagnostic interface 3AFE64605062 x

Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) 3AFE64504215 x

Fieldbus Adapter with DC Drives RCAN-02 (CANopen)

Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3AFE64506005 x

Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x

Fieldbus Adapter with DC Drives RMBA (MODBUS) 3AFE64498851 x

Fieldbus Adapter with DC Drives RETA (Ethernet) 3AFE64539736 x

x -> existing p -> planned
Status 01.2007
DCS800 Drive Manuals-List_d.doc
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Safety instructions

What this chapter contains

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

To which products this chapter applies

This chapter applies to the DCS800... Size D1 to D7 and field exciter units
DCF80x.

Use of warnings and notes

There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment. They also tell you how to avoid the
danger. Notes draw attention to a particular condition or fact, or give information on
a subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high

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

Safety instructions

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Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death.

Only qualified electricians are allowed to install and maintain the drive.
• Never work on the drive, motor cable or motor when main power is
applied.
Always ensure by measuring with a multimeter (impedance at least
1 Mohm) that:
1. Voltage between drive input phases U1, V1 and W1 and
the frame is close to 0 V.
2. Voltage between terminals C+ and D- and the frame is
close to 0 V.
• Do not work on the control cables when power is applied to the
drive or to the external control circuits. Externally supplied control
circuits may cause dangerous voltages inside the drive even when
the main power on the drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive
or drive modules.
• When reconnecting the motor cable, always check that the C+ and
D- cables are connected with the proper terminal.
Note:
• The motor cable terminals on the drive are at a dangerously high
voltage when the input power is on, regardless of whether the
motor is running or not.
• Depending on the external wiring, dangerous voltages (115 V,
220 V or 230 V) may be present on the terminals of relay outputs
SDCS-IOB-2 and RDIO.
• DCS800 with enclosure extension: Before working on the drive,
isolate the whole drive from the supply.

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WARNING! The printed circuit boards contain components sensitive to

electrostatic discharge. Wear a grounding wrist band when handling
the boards. Do not touch the boards unnecessarily.

Use grounding strip:

PE

ABB order no.: 3ADV050035P0001

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

• Ground the drive, motor and adjoining equipment to ensure

personnel safety in all circumstances, and to reduce
electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized as
required by safety regulations.
• In a multiple-drive installation, connect each drive separately to
protective earth (PE) .
• Minimize EMC emission and make a 360° high frequency
grounding of screened cable entries at the cabinet lead-through.
• Do not install a drive with EMC filter on an ungrounded power
system or a high resistance-grounded (over 30 ohms) power
system.
Note:
• Power cable shields are suitable for equipment grounding
conductors only when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA
AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed protective
earth connection is required.

Safety instructions

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Fibre optic cables

WARNING! Handle the fibre optic cables with care. When unplugging
optic cables, always grab the connector, not the cable itself. Do not
touch the ends of the fibres with bare hands as the fibre is extremely
sensitive to dirt. The minimum allowed bend radius is 35 mm (1.4 in.).

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

• DCS800 sizes D4...D7: The drive is heavy. Do not lift it alone. Do

not lift the unit by the front cover. Place units D4 and D5 only on its
back.

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

Operation
These warnings are intended for all who plan the operation of the drive
or operate the drive. Ignoring the instructions can cause physical injury
or death or damage the equipment.

• Before adjusting the drive and putting it into service, make sure
that the motor and all driven equipment are suitable for operation
throughout the speed range provided by the drive. The drive can
be adjusted to operate the motor at speeds above and below the
base speed.
• Do not activate automatic fault reset functions of the Standard
Application Program if dangerous situations can occur. When
activated, these functions will reset the drive and resume operation
after a fault.
• Do not control the motor with the disconnecting device
(disconnecting means); instead, use the control panel keys
and , or commands via the I/O board of the drive.

Safety instructions

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

If in special cases the electrical machines and devices are in-

tended for use in non-industrial installations - which may require
stricter safety regulations (e.g. protection against contact by
children or similar) -, these additional safety measures for the
installation must be provided by the customer during assembly.

Note:
• When the control location is not set to Local (L not shown in the
status row of the display), the stop key on the control panel will not
stop the drive. To stop the drive using the control panel, press the
LOC/REM key and then the stop key .

Safety instructions

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Table of contents

0 Safety instructions 4 5H3

1HWhat this chapter contains......................................................................................................... 3 4 6H

2HTo which products this chapter applies...................................................................................... 3 4 7H

3HUse of warnings and notes ........................................................................................................ 3 4 8H

Grounding....................................................................................................................... 5
4H 4 9H

5HMechanical installation............................................................................................................... 6 5 0H

6HOperation ................................................................................................................................... 6 5 1H

7H Table of contents 5 2H8

8H Mechanical Installation 5 3H10

9HHow to use this manual ................................................................................................ 10 5 4H

Associated publications................................................................................................ 10
1 0H 5 5H

DCS800-E lifted by crane............................................................................................. 11

1 1H 5 6H

Before installation......................................................................................................... 11
1 2H 5 7H

Cabinet installation....................................................................................................... 12
1 3H 5 8H

Preparations and considerations that can be done before the system shut down ....... 13
1 4H 5 9H

Preparing the cabinet ................................................................................................... 13

1 5H 6 0H

Fixing the mounting supports..................................................................................... 14

1 6H 6 1H

Inserting the sliding rails ............................................................................................ 15

1 7H 6 2H

Push the DCS800-E panel into the cabinet. .............................................................. 16

1 8H 6 3H

Removing the Sliding Rails ........................................................................................ 16

1 9H 6 4H

Mounting of the CDP312 or DCS800 panel on the cabinet door (optional) ............... 17
2 0H 6 5H

2 1H Electrical installation 6 6H18

2 2H What this chapter contains........................................................................................... 18 6 7H

2 3H Checking the insulation of the assembly...................................................................... 18 6 8H

2 4H IT (ungrounded) systems ............................................................................................. 19 6 9H

2 5H Supply voltage.............................................................................................................. 19
7 0H

2 6H Connecting the power cables....................................................................................... 19 7 1H

2 7H Supply transformer T2 for electronics and fan ............................................................. 19 7 2H

2 8H Cross-sectional areas - Tightening torques ................................................................. 20 7 3H

2 9H AC-connection.............................................................................................................. 21
7 4H

3 0H DC-connection ............................................................................................................. 21
7 5H

3 1H Control cable connection.............................................................................................. 22 7 6H

3 2H Commissioning............................................................................................................. 22
7 7H

3 3H Installation Checklist 7 8H23

3 4H Technical Data 7 9H25

3 5H Environmental Conditions ............................................................................................ 25 8 0H

Harmonized Standards .............................................................................................. 26

3 6H 8 1H

3 7H DCS800-E Panel Solution unit types ........................................................................... 27 8 2H

3 8H Fuse switch OESA ....................................................................................................... 288 3H

3 9H Drilling pattern for CDP 312 ......................................................................................... 29 8 4H

4 0H Drilling pattern for DCS800 control panel (door mounting kit ACS/H-EXT).................. 30 8 5H

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4 1HDimension of DCS800-E panel and fixing holes .......................................................... 31 8 6H

4 2HSwing I/O unit, where the IOB-2x and IOB-3 are mounted in a vertical position.......... 32 8 7H

4 3HLower mounting support............................................................................................... 33

8 8H

4 4HUpper mounting support............................................................................................... 34

8 9H

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Mechanical Installation
How to use this manual
The purpose of this manual is to provide you with the information necessary to
mount the DCS800-E Panel into an empty cabinet.

As an example the mounting into an old ASEA Tyrak 8A cabinet is shown.

However the given information and described procedures are also valid for other
types of cabinets – mostly with only slight modifications. For that detailed
dimension drawings are given for you to check the compatibility with your cabinet.

The mounting is described using a mounting kit, consisting of mounting supports

and sliding rails. These are optional available and not in the standard scope of
delivery. You may check if you can use them for your cabinet by the dimension
drawing given in the appendix

This manual does not describe the commissioning of the DCS800 module itself.
For that please refer to the documentation of the module

Associated publications
For the commissioning of the module please refer to the module’s documentation,
that can be found on the DC Drives Documents CD-ROM which is part of the
document binder delivered with every DCS800-E Unit.

First information can be found in the DCS800 Quick guide (3ADW000191) which
too is part of the enclosed documentation

For mounting of the optional CDP312 Door Mounting kit please refer to the
corresponding installation instruction.

Basic information about the DCS800-E can be found in the DCS800-E Flyer,
document no. 3ADW000210

Detailed Circuit Diagrams and a list of apparatus are part of the enclosed
documentation of every DCS800-E panel.

For installation of converters in accordance with EMC, see document no.

3ADW000032

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DCS800-E lifted by crane

DCS800-E crane lift.dsf

Before installation
The drive must be installed in an upright position with the cooling section facing a
wall. Check the installation site according to the requirements below. Refer to
Dimensional drawings for frame details.

Requirements for the installation site

See Technical data for the allowed operation conditions of the drive.

Wall
The wall should be as close to vertical as possible, of non-flammable material and
strong enough to carry the weight of the unit. Check that there is nothing on the
wall to inhibit the installation.

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Cabinet installation
Preventing cooling air recirculation
If the cabinet is equipped with filters the rated current of DCS800-E device must be
reduced and air recirculation inside has to be prevented.

Main air flow out

Hot

Air baffle plates

COOL AREA

Main air flow in

prev recirc.dsf

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Preparations and considerations that can be done before the system shut down
If the DCS800-E is used to revamp an existing DC-Drive, usually all work should
be done as fast as possible to keep the system power down small. To decrease
this time a lot of preparations and considerations can be done before the shut
down. These are for example:
• Check the dimensions of the DCS800-E and the clearance inside the cabinet to see if
the DCS800-E panel fits.
• How will the DCS800-E panel will be brought into the cabinet? Check availability of a
crane or a fork-lift. The DCS800-E panel offers handles for manual movement. The
weights of the different DCS800-E types are given in the appendix.
• How will the Panel be fixed to the cabinet? Check if you can use the optional
available mounting supports and sliding rails (Dimensions can be found in the
appendix). If the mounting kit does not fit to your type of cabinet prepare the cabinet
or a mounting aid according to the fastening holes on the DCS800-E panel.
• If you want to mount the CDP312 onto the cabinet door, you may do this before the
system shut down. You can fix the panel either directly to the door by using the
enclosed drilling pattern or you use the optional available CDP312 door mounting kit.
• Check AC and DC power cables. Is their length still sufficient for the DCS800-E
panel? DC Output terminals at the very bottom of the Power unit are available as
option, as well as AC connection cables. Take also into consideration if you will re-
use components like load switches or chokes.
• Check also the control and tacho or encoder cables. Is their length still sufficient for
the DCS800-E panel? If not you may purchase some optional available spare cables
(check price list or flyer).
• Set T2 transformer tapping on correct input voltage.
This list is intended to give you some useful hints to think about. It cannot be
complete and you should consider the individual local situation.

Preparing the cabinet

Remove all old equipment that will not be re-used.

For a typical Tyrak 8 Revamp you may re-use besides the cabinet and busbars the
load switch and the main fuses.
Note: Typically only line fuses were used in Tyraks as incoming AC fuses. They
can be left in the cabinet and re-used, but the DCS800-E has its own SCR-fuses to
protect the DCS-module.
The Tyrak line chokes may also be re-used. But It’s recommended to use also the
1% uk-chokes on the DCS800-E panel, as the Tyrak chokes typical have a very
low inductance. But due to the low inductance the losses are very low, and so it
may even be operated in serial to the DCS800-E chokes, they do not interfere.
All external equipment, like Residual current detection or field transformer can be
re-used, but it’s recommended to remove it from the cabinet for installation of the
DCS800-E.

Ensure that there is enough free space for mounting of the DCS800-E panel
(check dimension drawings in the appendix). Consider also some free space for
connecting the cables.

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Fixing the mounting supports

Fix the upper and lower mounting support to the cabinet according to following
pictures. Screws M6 are delivered together with the supports.

The upper and lower mounting rails should be fixed into the cabinet with a distance
of 1520 mm between their lower edges. If your cabinet’s grid of fixing holes in the
mounting rail does not allow this distance, you may vary the distance by some
mms due to the elongated fixing holes in the panel.

The total position of the two mounting supports in the cabinet depends on its
clearance and the height of its base. It’s useful to install the supports in a way that
the lower mounting support is at the same height of the cabinet's base.

For a Standard Tyrak 8 cabinet a height of 122 mm from the floor is recommended.

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1520 mm from bottom to bottom

from
122 mm
gr ound *

* for Tyrak 8 standard cabinets

Inserting the sliding rails

The sliding rails are designed for easily sliding the DCS800-E into the cabinet until
its weight is carried fully by the lower mounting support.
The rails are put onto the upper mounting support. Their construction prevents the
rails from slipping off. In the front the sliding rails are put onto the cabinet base.

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Push the DCS800-E panel into the cabinet.

When using a crane, put the DCS800-E onto the front part of the sliding rails.
When using a fork lift, bring the panel to the same level of the sliding rails.

Then push the DCS800-E panel into the cabinet against the support in the back of
the cubicle.

To put the DCS800-E panel onto the lower mounting support, it has to be lifted
slightly in the back. For that it’s useful to throw it a little bit in direction outside the
cubicle at the top front edge.

Now the DCS800-E panel can be fixed to the upper and lower mounting support
with the enclosed M10-srews (17mm-size nut or wrench needed).

Removing the Sliding Rails

When the DCS800-E panel is fixed to the cabinet, the sliding rails can be removed.
First, remove the sliding rail below the power unit.

Then move the remaining sliding rail also below the power unit, so that it can be
easily removed.

The sliding rails now can be re-used for mounting of another DCS800-E panel.

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Mounting of the CDP312 or DCS800 panel on the cabinet door (optional)

CDP312 The control panel CDP312 can be easily mounted onto the cabinet door by fixing it
with two screws. For that 3 holes have to be put into the cabinet door:
2 holes (5 mm Ø) for the screws and one hole 14x16 mm (wxh) for the connection
cable. Drilling pattern see appendix.
Following items are needed in addition (not in the standard scope of delivery)
• 2 pc. screws (M4x10)
• 1 pc. control cable COM-8 board Æ CDP312, 3 m long, Id-No.
DCA0021499P0001 (refer to pricelist)
• SDCS-COM-8 board

DCS800 2 holes (4 mm Ø) for the screws and one hole (24 mm Ø) for the connection cable.
panel Drilling pattern see appendix.
Following items are needed in addition (not in the standard scope of delivery)
• 2 pc. screws (M3x10)
• control cable set ACS/H-EXT kit 3AFE68294673

The picture shows an example of CDP 312 mounted directly onto an old Tyrak
cabinet door.

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Electrical installation

What this chapter contains

This chapter describes the electrical installation procedure of the drive.

WARNING! The work described in this chapter may only be carried out by a
qualified electrician. Follow the Safety instructions on the first pages of this
manual. Ignoring the safety instructions can cause injury or death.

Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive was already connected to the mains, wait for 5 min.
after disconnecting mains power.
Reference: Technical Guide - publ. no.: 3ADW000163

Checking the insulation of the assembly

Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any
voltage tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part
of the drive. Check the insulation of the assembly as follows.

WARNING! Check the insulation before connecting the drive to the mains. Make
sure that the drive is disconnected from the mains (input power).

1. Check that the motor cable is disconnected from the drive output terminals
C1, D1, F+ and F-.
2. Measure the insulation resistances of the motor cable and the motor
between each circuit (C1, D1) or (F+, F-) and the Protective Earth by using
a measuring voltage of 1 kV DC. The insulation resistance must be higher
than 1 Mohm.
C1, D1
M
ohm
F+, F-
PE

ohm

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IT (ungrounded) systems
Don’t use EMC filters.
The screen winding of dedicated transformers must be grounded.

For installation without low voltage switch (e.g. contactor, air-circuit-breaker) use
overvoltage protection.
The voltage shift of isolated supply must be limited of a range of an earth fault.

Supply voltage
Check supply voltages of:
Aux X99, tapping of T2 transformer
Fan Terminals
AC voltage for field circuit U1, V1, W1 (if used)
AC voltage for armature circuit U1, V1, W1

Connecting the power cables

Grounding and screening of power cables see manual Technical Guide, see
Reference

Cross sectional areas and tightening torques of power cable see chapter Planning
the electrical installation

Supply transformer T2 for electronics and fan

Aux transformer setting

F2

T2
115
230

380
400
415
450
500
525
575
600
660
690
0

230 V 115 V T2_a.dsf 0V

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Application hint:
230 V

F2 The transformer is designed to work as a

230 V / 230 V transformer to open/avoid
ground loops. This is done via the 380 V
and 600 V tapping according to the left
picture.
T2

230 V 115 V T2_a.dsf 0V

Cross-sectional areas - Tightening torques

Recommended cross-sectional area to DINVDE 0276-1000 and DINVDE 0100-
540 (PE) trefoil arrangement, up to 50°C ambient temperature

Converter type U1, V1, W1(AK1, AK3, AK5) C1, D1 (AM1, KM1) PE Field
Connection at DC fuse holder Connection at ABB fuse switch stud WDU
M12 4 / 10
Iv IDC
/ /
[A~] XLP... [mm²] / stud [A-] OFAX... [mm²] / stud [mm²] max. [mm²]
DCS800-E01-0020-04/05-960t 15 18
DCS800-E02-0025-04/05-960t 18 22
1 x 10 / M8 1 x 6 / M10
DCS800-E01-0045-04/05-960t 34 41
00 2 x00S1L 1x6
DCS800-E02-0050-04/05-960t 37 45
DCS800-E01-0065-04/05-960t 50 61
1 x 25 / M8
DCS800-E02-0075-04/05-960t 55 67 6
1 x 25 / M10
DCS800-E01-0090-04/05-960t 67 81
1 x 25 / M10
DCS800-E02-0100-04/05-960t 73 90
DCS800-E01-0125-04/05-960t 95 115
1 x 35 / M10 2 x 1S1 1 x 35 / M10 1 x 25
DCS800-E02-0140-04/05-960t 103 125
1
DCS800-E01-0180-04/05-960t 132 160
1 x 95 / M10 1 x 95 / M10
DCS800-E02-0200-04/05-960t 147 180
DCS800-E01-0230-04/05-960t 172 210
1 x 95 / M10 1 x 95 / M10 1 x 25
DCS800-E02-0260-04/05-960t 184 225
2 x 2S1
DCS800-E01-0315-04/05-960t 234 285
2 2 x 70 / M12 2 x 50 / M10
DCS800-E02-0350-04/05-960t 266 300 16
DCS800-E01-0405-04/05-960t 300 365
2 x 95 / M12 1 x 50
DCS800-E02-0450-04/05-960t 332 405
3 2 x 3P1 2 x 95 / M10
DCS800-E01-0470-04/05-960t 328 400
2 x 95 / M12
DCS800-E02-0520-04/05-960t 369 450
DCS800-E01-0290-06-960t 213 260
2 1 x 95 / M12 2 x 2S1 1 x 95 / M10 1 x 50 16
DCS800-E02-0320-06-960t 233 285

Tightening torques: M6 => 6 Nm; M8 => 13 Nm; M10 => 25 Nm; M12 => 50 Nm

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AC-connection

The AC-connection point is at the top of the power unit, at the in-coming terminals
of the fuse-holder / fuse-switch.
AC-connection cables with cable lugs are available as option.

DC-connection

The DC-connection point is at the DC output terminals of the DCS module, or at

the secondary side of the DC-fuse-holder, if ordered.
If the existing motor cables are too short, a DC block terminal at the very bottom of
the DCS800-E panel is available as option. The block terminals are capable for
one cable, if double armature cables are used a short 3-hole-busbar (not in the
scope of delivery) has to be used.

DCS module output

terminal

DCS module output

terminal

DC connection
extension (option)

Electrical Installation

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Control cable connection

The control cables usually are connected to the I/O-cards on the I/O unit. Rails for
fixing the cable shields are included for every I/O card.
4x2x0.5 mm² shielded cable for IOB-3, pulse transmitter, etc. and 4 m long cable
7x1 mm² unshielded control cable, all with cable lugs are available as option.
Commissioning
After all electrical connections are done the installation will be completed with the
commissioning of the DCS-Module. Therefore please refer to the DCS-Module-
Documentation

Further parts of electrical installation e.g.

• Location R-Extension and Interface Modules

• I/O Board Configuration
• Pulse encoder connection
• Pulse encoder receiver
• Connecting the signal and control cables
• Routing the cables
• DCS Link Wiring

see Hardware manual publication no. 3ADW000194

Electrical Installation

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Installation Checklist
The mechanical and electrical installation of the DCS800-E should be checked
before start-up. It is advisable to go through the checklist below together with
another person. Study carefully the Safety Instructions on the first pages of this
manual before attempting any work on, or with, the unit.

MECHANICAL INSTALLATION (see chapter Mechanical Installation)

† The ambient operating conditions are acceptable (e.g. environmental conditions in

the chapter Technical data, fan data in the DCS800 hardware manual and free
space requirements in chapter - Mechanical Installation)

† The unit is mounted properly

† Cooling air will flow freely:

• the lifting bars or sliding rails (if used) are removed
• the cabinet roof is attached properly
• the finger protections are mounted properly

Installation Checklist

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ELECTRICAL INSTALLATION (see chapter Electrical Installation)

† The AC busbars and PE busbars are properly connected (see chapter Mechanical
Installation)

† The internal control cables are properly connected

† The converter unit and cabinets are earthed properly

† The mains voltage matches the DC converter nominal input voltage

† The setting of the internal 220/115 V transformer T2 corresponds to the supply

voltage

† The mains (input power) connections at U, V and W are OK

† The appropriate mains fuses are installed for units D1, D2, D3, D4 (see chapter
Technical Data)

† Motor cable routing (armature and excitation) is OK

† Check that the screens are properly installed at the motor and in the drive cabinet

† The connections at L+, L-, F+ and F- are OK

† The control connections are OK

† If pulse encoder is used, check the encoder cables and correct direction of rotation
(see chapter Technical Data)
† PT 100, PTC, Klixon cables: Check that the connections are appropriate for the
type of sensor used in the motor

† Check the prevention of unexpected start-up (on inhibit, coast stop) cables

† Check the emergency stop cables

† For all external cables make sure that both ends of the cables are connected and
the cables do not cause any damage or danger when power is being switched on

† Cleanliness of the cabinets and surroundings, e.g.:

• there are no tools or other foreign objects inside the cabinets or waste left
from installation e.g. cable trimmings

• there is no garbage under the cabinets (the cooling air fan will draw the
garbage inside the cabinets)

• use a vacuum cleaner to remove any dirt. Do not use compressed air!

Installation Checklist

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Technical Data
This chapter contains the technical specifications of the drive, e.g. the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.

Reference: Hardware extension RAIO Analog I/O Extension publ.no.:3AFE64484567

Hardware extension RDIO Digital I/O Extension publ.no.:3AFE64485733
DCS800 1131 Programming target publ.no.:3ADW000199
Branching units NDBU-95 publ.no.:3ADW000100
Environmental Conditions
System connection Environmental limit values
Voltage, 3-phase: 230 to ≤ 1000 V acc. to IEC 60038 Permissible cooling air temperat.
Voltage deviation: ±10% continuous; ±15% short-time * - at converter module air inlet: 0 to +55°C
Rated frequency: 50 Hz or 60 Hz with rated DC current: 0 to +40°C
Static frequency deviation: 50 Hz ±2 %; 60 Hz ±2 % w. different DC curr. acc. Fig. +30 to +55°C
below:
Dynamic: frequency range: 50 Hz: ±5 Hz; 60 Hz: ± 5 Hz - Options: 0 to +40°C
df/dt: 17 % / s Relative humidity (at 5...+40°C): 5 to 95%, no condensation
* = 0.5 to 30 cycles. Relative humidity (at 0...+5°C): 5 to 50%, no condensation
Please note: Special consideration must be taken for voltage Change of the ambient temp.: < 0.5°C / minute
deviation in regenerative mode.
Degree of protection Storage temperature: -40 to +55°C
Converter Module and Transport temperature: -40 to +70°C
options (line chokes, fuse Pollution degree (IEC 60664-1, 2
holder, IEC 60439-1):
field supply unit, etc.): IP 00 / NEMA TYPE OPEN Vibration class 3M3 - D1...D4
Enclosed converters: IP 20/21/31/41 3M1 - D5...D7
Paint finish Site elevation
Converter module: light grey RAL 9002 <1000 m above M.S.L.: 100%, without current
reduction
Enclosed converter: light grey RAL 7035 >1000 m above M.S.L.: with curr. reduct., see Fig.
below
Size Sound pressure level LP (1 m Vibration Shock Transport in Short circuit withstand rating
distance) original The DCS800 is suitable for use in a
package circuit capable of delivering not more
than:
as module enclosed conv. as module
D1 55 dBA 54 dBA 1.2 m 65 kA rms symmetrical amps at
D2 55 dBA 55 dBA 1.5 mm, 2...9 Hz 7 g / 22 ms maximum 600 VAC
D3 60 dBA 73 dBA 0.5 g, 9...200 Hz 1.0 m
D4 66...70 dBA, 77 dBA
depending on fan
D5 73 dBA 78 dBA 0.25 m 100 kA rms symmetrical amps at
D6 75 dBA 73 dBA 0.3 mm, 2...9 Hz 4 g / 22 ms Shock monitor maximum 600 VAC
0.1 g, 9...200 Hz
D7 82 dBA 80 dBA
Effect of the site elevation above sea level on the Effect of the ambient temperature on the converter module
converter’s load capacity load capacity

100 110

90
100

80
90
70

80
60

50 70
1000 2000 3000 4000 5000 m 30 35 40 45 50 55°C

Current reduction to (%) Current reduction to (%) for converter modules

Technical data

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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

Harmonized Standards
Assurance
Converter module Enclosed converter
Machinery Directive
98/37/EEC Declaration of EN 60204-1 EN 60204-1
93/68/EEC Incorporation [IEC 60204-1] [IEC 60204-1]
Low Voltage Directive
73/23/EEC Declaration of Conformity EN 61800-1 EN 60204-1
93/68/EEC [IEC 61800-1] [IEC 60204-1]
EN 60204-1 EN 60204-1
[IEC 60204-1] [IEC 60204-1]
EMC Directive
89/336/EEC Declaration of Conformity EN 61800-3 ➀ EN 61800-3 ➀
93/68/EEC [IEC 61800-3] [IEC 61800-3]
(Provided that all
installation instructions
concerning cable ➀ in accordance with ➀ in accordance with
selection, cabling and 3ADW 000 032 3ADW 000 032/3ADW 000
EMC filters or dedicated 091
transformer are followed.)

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 • see UL Listingwww.ul.com / UL types: on request
certificate no. E196914

Approval: cULus
The spacings in the modules were
evaluated to table 36.1 of UL 508 C.
Spacings also comply with table 6 and
table 40 of C22.2 No. 14-05.

• or on request
>600 V to 990 V EN / IEC xxxxx see table above. EN / IEC types: on request
Available for converter modules (for details see table above)
including field exciter units.

Technical data

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DCS800-E Panel Solution unit types

Unit type DC I ➀ Power loss ➁ Weight Air volume

[A] [kW] [kg] [m³/h]
400 V / 525 V
DCS800-E01-0020-04/05-960t 18 <0.58
90
DCS800-E02-0025-04/05-960t 22 <0.58
DCS800-E01-0045-04/05-960t 41 <0.65
91
DCS800-E02-0050-04/05-960t 45 <0.65
DCS800-E01-0065-04/05-960t 61 <0.72
95
DCS800-E02-0075-04/05-960t 67 <0.72
DCS800-E01-0090-04/05-960t 81 <0.90
103
DCS800-E02-0100-04/05-960t 90 <0.95
360
DCS800-E01-0125-04/05-960t 115 <1.10
103
DCS800-E02-0140-04/05-960t 125 <1.15
DCS800-E01-0180-04/05-960t 160 <1.50
DCS800-E02-0200-04/05-960t 180 <1.55
121
DCS800-E01-0230-04/05-960t 210 <1.60
DCS800-E02-0260-04/05-960t 225 <1.60
DCS800-E01-0315-04/05-960t 285 <1.85
126
DCS800-E02-0350-04/05-960t 300 <1.90
DCS800-E01-0405-04/05-960t 365 <2.47
141
DCS800-E02-0450-04/05-960t 405 <2.55
720
DCS800-E01-0470-04/05-960t 400 <2.57
144
DCS800-E02-0520-04/05-960t 450 <2.70
600 V
DCS800-E01-0290-06-960t 260 <1.85
126 360
DCS800-E02-0320-06-960t 285 <1.85

t=1 Standard type ➀ Given Ratings are typical values for mounting in IP 21 cabinets; actual
t=2 P&P type values may differ and are strongly depending on the cabinet and its cooling,
Voltage class: (example: DCS800-E02-0025-04-960t) especially with higher protection classes
4 400V 5 525V 6 600V ➁ Values are valid for Standard Scope of delivery without options

Technical data

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Fuse switch OESA

M6

Bolt and nut

M6 Bolt
M6

Fuse switch OESA.dsf

Mounting the fuse switch (option)

Technical data

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Drilling pattern for CDP 312

Ø5 6
11

6 1
15

2 16

14

Silhuette of panel CDP 312 in full-scale

166
Holes to be made:
1 Ø 5mm holes for fixing screws (M4)
2 Hole for cable

1 6

6 Ø5

80

Technical data

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Drilling pattern for DCS800 control panel (door mounting kit ACS/H-EXT)

Mounting Template scale 1:1

Ø 3.5 (2x) Ø 24

22.5

87.1
30.6
(outline of the connector)

70.5
(outline of the panel)

56

Technical data

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Dimension of DCS800-E panel and fixing holes

Clearance 515
min. 200 mm
25 195 320
air exit

1523 1597
1519
+9,5mm
-15,5mm

air entry A
(grid)

32

515 30 13
35 DCS800-E_dimensions.dsf
40
35
125 250

air entry B

air exit 320 x 350 mm

air entry 320 x 350 mm

Technical data

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Swing I/O unit, where the IOB-2x and IOB-3 are mounted in a vertical position

Technical data

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Lower mounting support

lower_mounting_support.dsf
15

45
M6
45

18
9
9
40

10

45
70

14
250

°12.7

548
246.5

125
46.5

14
35 10
80

Technical data

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250 45
246.5
7
46.5
125 M6
20

27
Upper mounting support

7 100 80

°12.7
14 °12.7 10 9
20
18

520

20
45

upper_mounting_support.dsf
548

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Technical data
34
 35

Technical data

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 Ident. No.: 3ADW000224R0101 Rev A

ABB Automation Products

05_2007

Wallstadter-Straße 59
68526 Ladenburg • Germany
Tel: +49 (0) 6203-71-0
Fax: +49 (0) 6203-71-76 09
www.abb.com/motors&drives *224R0101A7190000*
*224R0101A7190000*