Instruction/ maintenance manual of the product 500 DCS
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DCS 500 Thyristor Power Converters for DC Drive Systems 25 to 5150 A Operating Instructions DCS 500B / DCF 500B DCP 500B.
How the DCS 500 Documentation System works System Description DCS 50 0B 3ADW000 066 Volume I I D Operating Instructions DCS 50 0B 3ADW000 055 Volume I V D Technica l Data 3ADW000 054 Volume III Description of the converter DCS 500B Operating Instructions (documentation in hand) including in- formation and advise to commission the drive.
2002 ABB Automation Products GmbH. All rights reserved. Thyristor Power Converters Series DCS 500B / DCF 500B DCP 500B 25 to 5150 A OPERATING INSTRUCTIONS Code: 3ADW 000 055 R0401 Rev D DCS_OI_E_D.DOC EFFECTIVE: Oct. 30th, 2002 SUPERSEDES:Rev C Sept.
DCS 500B / DCP 500B Operating Instructions 3ADW000055R0401_DCS500B_Operating Instruction_e_d.
Safety Instructions DCS 500B / DCP 500B Operating Instructions i Overview This chapter contains safety instructions which must be complied with during installation, operation and maintenance of the power converters series DCS 500B / DCF 500B or DCP 500B .
Safety Instructions ii DCS 500B / DCP 500B Operating Instructions General warning: this symbol warns you of non- electrical risks and dangers which may result in seri- ous or even fatal injury to persons and/or in damage to equipment. Where appropriate, the text printed ad- jacent to this symbol describes how risks of this kind may be avoided.
Safety Instructions DCS 500B / DCP 500B Operating Instructions iii Notes Notes supply information on states requiring particular attention, or indicate that additional information is available on a specific topic.
Contents iv DCS 500B / DCP 500B Operating Instructions IV A O PERATING I NSTRUCTIONS Safety Instructions Chapter 1 - Introduction How to use this manual ..................................................................................................
Contents DCS 500B / DCP 500B Operating Instructions v Running the DC- Drive from the CDP31x ................................................................. 3-15 3.15 Speed Reference Setting for the Drive .............................................
vi DCS 500B / DCP 500B Operating Instructions 3ADW000055R0401_DCS500B_Operating Instruction_e_d.
Chapter 1 - Introduction DCS 500B / DCP 500B Operating Instructions IV A 1 - 1 How to use this manual The purpose of these operating instructions is to provide detailed in- formation on how to start up a thyristor power converter from the DCS 500B or DCP 500B series.
Chapter 1 - Introduction IV A 1 - 2 DCS 500B / DCP 500B Operating Instructions Incoming inspection After opening this package, you should check whether it contains the following items: ● DCS 500B / .
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 1 General notes CAUTION: it is absolutely essential that the applicable accident prevention regulations be observe.
Chapter 2 - Start-Up Instructions IV A 2 - 2 DCS 500B / DCP 500B Operating Instructions Phase sequence when connecting to the mains / Potential isolation No special phase sequence required for the mai.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 3 Symbols for switching the electronics or the power section ON and OFF - Switch ON electronics - Switch ON power .
Chapter 2 - Start-Up Instructions IV A 2 - 4 DCS 500B / DCP 500B Operating Instructions Symbol for altering parameters or for establishing new connections Enter at keyboard e.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 5 2.1 Preparatory work Check the unit for damage in transit or other damage. Install and wire unit; connect all inputs and outputs required. Proceed in the same way for the field supply unit as well.
Chapter 2 - Start-Up Instructions IV A 2 - 6 DCS 500B / DCP 500B Operating Instructions 2.2 Scaling intra-unit signals Make sure that the existing electronics supply voltage has been set on the SDCS- POW-1 power supply board as well, using the SW1 switch.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 7 Set this only for units of the DCP 500 series! 517 = Rated power converter current Enter numerical value from ra.
Chapter 2 - Start-Up Instructions IV A 2 - 8 DCS 500B / DCP 500B Operating Instructions 2.3 Presetting the field supply unit Make sure that existing supply voltages for power section, field supply unit (field ex- citer) and field winding, fan, etc. match the rated data of the components used.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 9 Only for armature-circuit power converters with SDCS-CON-2 control board & CDP 312 panel! 1201 = 5 Panel display: FEX2/3 AUTOTUNING Activates the field current controller's auto-tuning function.
Chapter 2 - Start-Up Instructions IV A 2 - 10 DCS 500B / DCP 500B Operating Instructions 2.4 Adjusting the current controller Make sure that static current limitation Bridge 1 (2307) and Bridge 2 (230.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 11 Drive must not turn! Do not preset an external reference! 1201 = 3 Panel display: ARM. AUTOTUNING Activate the current controller's auto-tuning function. Start the next two steps within the next 20 seconds! Switch ON power.
Chapter 2 - Start-Up Instructions IV A 2 - 12 DCS 500B / DCP 500B Operating Instructions 2.5 Speed feedback balancing E.M.F. control active? 2102 = 5 Panel display: EMF SPEED ACT Field weakening mode not selected? 1001 = 0 Panel display: CONSTANT FIELD 2103 = Desired speed / or motor rating plate Scale speed control circuit to maximum speed.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 13 Only when an encoder (pulse encoder) is being used! 12104 = Content of pulse counter If the shape of the curve .
Chapter 2 - Start-Up Instructions IV A 2 - 14 DCS 500B / DCP 500B Operating Instructions 2.6 Balancing the field supply unit and the e.m.f. controller When matching the field supply unit to the system conditions, differences in the proce- dures adopted must be taken into account; these different procedures result from the op- erating mode used.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 15 2.6.2 Field weakening control with setting range < 1 : 1.5 CAUTION: Not p ermi tte d whe n Ch apt er 2 .
Chapter 2 - Start-Up Instructions IV A 2 - 16 DCS 500B / DCP 500B Operating Instructions 2.6.3 Field weakening control with setting range > 1 : 1.5 CAUTION: Not per mitt ed w hen Cha pte r 2.5 was quit wit h e.m .f. c ont rol ! Only when unit is fitted with an SDCS-CON-1 control board! If the field time constant is known, e.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 17 Switch OFF power! 1201 = 0 Panel display: NOT ACTIVATED 11202 = SAVE MOT1 SET Save the altered values in the no.
Chapter 2 - Start-Up Instructions IV A 2 - 18 DCS 500B / DCP 500B Operating Instructions 12522 = decrease so that motor voltage is 90 %. Flux and thus the field current as well are reduced. How to proceed: 1. decrease 12522 (in steps of 100 at a time) 2.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 19 Only if analog tacho is used as speed feedback! Switch ON power; start drive. DANGER : System components now energized! 12516 = increase slowly up to 20000 (=100 % speed).
Chapter 2 - Start-Up Instructions IV A 2 - 20 DCS 500B / DCP 500B Operating Instructions 2.7 Balancing the speed controller, pl us fine-balancing the e.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 21 1204 = 0 1205 = 0 Switch OFF power, thus stopping the drive! 1701 = 11903 501 = Rated motor voltage set in Chapter 2.
Chapter 2 - Start-Up Instructions IV A 2 - 22 DCS 500B / DCP 500B Operating Instructions 2.9 Presetting the 3-phase field supply unit DCF 50xB This is a new functionality available for the first time with software version S21.
Chapter 2 - Start-Up Instructions DCS 500B / DCP 500B Operating Instructions IV A 2 - 23 alarm or fault indication / reaction, if DCF 506 has triggered 3601 = 15 only at DCF 50 2 B; bridge reversal delayed to app. 50ms 3602 = 15 only at DCF 50 2 B; in worst case bridge change over will take place when time of 3601 has elapsed plus app.
Chapter 2 - Start-Up Instructions IV A 2 - 24 DCS 500B / DCP 500B Operating Instructions When the display shows NOT ACTIVATED (action correctly completed): Stop drive Switch OFF power! In case the autotuning failed: 1201 = 4 Panel display: ARM. MAN. TUNING ARM.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 1 3.1 Overview The Control and Display Panel [Control Panel] is used for parame- ter setting, for feedback value measuring and for drive control with series DCS 500B / DCF 500B and DCP 500B thyristor power con- verters.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 2 DCS 500B / DCP 500B Operating Instructions 3.2 Start Mode Note: The CDP 31x can be connected to the drive without dis- connecting the auxiliary.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 3 3.3 Panel Functions The CDP 31x has four different keypad modes: • Actual Signal Display Mode (ACT.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 4 DCS 500B / DCP 500B Operating Instructions Parameter Mode PA R The Parameter Mode is used for: - change the structure in the firmware - show signals and their actual status - show and change values of parameters, if they are not write-protected.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 5 Drive Mode DR I VE Drive mode is used to check the configuration. The display will show the type and ID-number of the drive to whom the CDP 31x is connected to.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 6 DCS 500B / DCP 500B Operating Instructions Step Function Press key Display after key is pressed 1. To enter the Parameter Mode Selection PAR 0 L 0.0 rpm 0 0 17 RAMP GENERATOR 01 RAMP . [IN] 119.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 7 3.5 Saving of the Parameters to backup memory Step Function Press key Display after key is pressed 1. To enter the Parameter Mode Selection PAR 0 L 0.0 rpm 0 0 2 A NALOG OU TPUTS 05 AO2.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 8 DCS 500B / DCP 500B Operating Instructions 3.6 FAULT RESETTING (RESET) FAULT resetting and EMERGENCY STOP resetting (RESET) can only be performed via the CDP 31x if LOCAL is active. If drive is in REMOTE, please check whether LOCAL is a critical condition.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 9 3.8 Fault History Display Up to 100 faults are stored time related and displayed together with the time they appeared after electronics supply switched on.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 10 DCS 500B / DCP 500B Operating Instructions 3.9 Uploading and Downloading of Pa rameters (UPLOAD/DOWNLOAD) CAUTION! The drive must be in standstill condition with given STOP command (controllers blocked, power section disconnected from the network) when UPLOAD/ DOWNLOAD function is selected.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 11 Depending on the drive´s condition and the status of the commis- sioning, UPLOAD has to take place.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 12 DCS 500B / DCP 500B Operating Instructions 3.10 Setting of the Display Contrast Step Function Press key Display after key is pressed 1. To enter the Function Mode . FUNC 0 L 0.0 rpm 00 UPLOAD <= <= DOWNLOAD => => CONTRAST 7 2.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 13 3.12 Selecting output pins Note for CDP 310 / CDP 311: Newly selected actual signals will be used for display until the elec- tronics power supply is switched OFF.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 14 DCS 500B / DCP 500B Operating Instructions 3.13 Drive Mode Display of the ID-number for the Drive and for the Control Panel CDP 31x as well as display of the status (Status Display) Step Function Press key Display after key is pressed 1.
Chapter 3 - Handling of Control Panel CDP 31x DCS 500B / DCP 500B Operating Instructions IV A 3 - 15 3.14 Running the Drive Operational Com- mand Keys Operational commands can be given from the Control Panel CDP31x every time when the status row is displayed.
Chapter 3 - Handling of Control Panel CDP 31x IV A 3 - 16 DCS 500B / DCP 500B Operating Instructions 3.15 Speed Reference Setting for the Drive Step Function Press key Display after key is pressed 1. Press one of these keys to get the status row displayed.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 1 4.1 Display of status, alarm and fault signals Categories of signals and possibilities of display The sign.
Chapter 4 - Signals and Troubleshooting IV A 4 - 2 DCS 500B / DCP 500B Operating Instructions 4.2 General messages The general messages will only be shown on the seven segment display of the control board SDCS-CON-x. Code seven segm. display Text on LCD of control panel CDP 31x Definition – Remark 8 Not available Program is not running – (1) .
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 3 4.4 Fault Signals (F) The fault signals will be shown on the seven segment display of the control board SDCS-CON-x as codes F . . as well as on the LCD of the control panel CDP 31x as clear text.
Chapter 4 - Signals and Troubleshooting IV A 4 - 4 DCS 500B / DCP 500B Operating Instructions Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WORD_1/2) Remark F 3 Conv.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 5 Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WORD_1/2) Remark F 8 Current rise fault Actual current changed faster than allowed The rate of current change is monitored.
Chapter 4 - Signals and Troubleshooting IV A 4 - 6 DCS 500B / DCP 500B Operating Instructions Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WOR.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 7 Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WORD_1/2) Remark F 28 Armature over- voltage Armature (DC circuit) overvoltage Check: - Setting of param.
Chapter 4 - Signals and Troubleshooting IV A 4 - 8 DCS 500B / DCP 500B Operating Instructions Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WORD_1/2) Remark F 34 Arm. curent ripple Armature current ripple One or several thyristors carry no current.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 9 Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WOR.
Chapter 4 - Signals and Troubleshooting IV A 4 - 10 DCS 500B / DCP 500B Operating Instructions Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WO.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 11 Code seven segm. display Text on LCD of control panel CDP 31x Definition / Action Status signal (FAULT_WORD_1/2) Remark F 65 Reversal Fault Reversal of direction of current is not O.
Chapter 4 - Signals and Troubleshooting IV A 4 - 12 DCS 500B / DCP 500B Operating Instructions 4.5 Alarm Signals (A) The alarm signals will be shown on the seven segment display of the control board SDCS-CON-x as codes A . . as well as on the LCD of the control panel CDP 31x as plain text.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 13 Code seven segm. display Text on LCD of control panel CDP 31x Definition / Possible source Signal number .
Chapter 4 - Signals and Troubleshooting IV A 4 - 14 DCS 500B / DCP 500B Operating Instructions Code seven segm. display Text on LCD of control panel CDP 31x Definition / Possible source Signal number (ALARM_WORD _1/2) Remark A 127 Ext. FAN ack.alarm Alarm No Acknowledge from External FAN (of Motor) Check: - See Fault Code F 40.
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 15 Code seven segm. display Text on LCD of control panel CDP 31x Definition / Possible source Signal number .
Chapter 4 - Signals and Troubleshooting IV A 4 - 16 DCS 500B / DCP 500B Operating Instructions Code seven segm. display Text on LCD of control panel CDP 31x Definition / Possible source Signal number .
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 17 4.6 Status Signals The status of drive functions (autotuning of controllers; saving val- ues) is shown by status signals named 11201 and 11202.
Chapter 4 - Signals and Troubleshooting IV A 4 - 18 DCS 500B / DCP 500B Operating Instructions Para- meter Code / bit Text on LCD of con- trol panel CDP 31x Definition / explication of the signal Remark 11201 -- ---- Gives feedback status information when the DRIVEMODE parameter (1201) was used to start the drive function 3, 5 or 6 (autotuning).
Chapter 4 - Signals and Troubleshooting DCS 500B / DCP 500B Operating Instructions IV A 4 - 19 Para- meter Code / bit Text on LCD of con- trol panel CDP 31x Definition / explication of the signal Rema.
Chapter 4 - Signals and Troubleshooting IV A 4 - 20 DCS 500B / DCP 500B Operating Instructions Para- meter Code / bit Text on LCD of con- trol panel CDP 31x Definition / explication of the signal Rema.
Appendix A - Connection diagrams DCS 500B / DCP 500B Operating Instructions IV A A - 1 Connection diagram 1 For detailed information see System description DCS 500B / DCF 500B .
Appendix A - Connection diagrams IV A A - 2 DCS 500B / DCP 500B Operating Instructions Connection diagram 2 For detailed information see System description DCS 500B / DCF 500B .
Appendix A - Connection diagrams DCS 500B / DCP 500B Operating Instructions IV A A - 3 3ADW000055R0401_DCS500B_Operating Instruction_e_d.
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An important point after buying a device DCS 500 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought DCS 500 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data DCS 500 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, DCS 500 you will learn all the available features of the product, as well as information on its operation. The information that you get DCS 500 will certainly help you make a decision on the purchase.
If you already are a holder of DCS 500, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime DCS 500.
However, one of the most important roles played by the user manual is to help in solving problems with DCS 500. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device DCS 500 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
