DCS800

Selection, Installation and Start-up Manual for Optical Rebuild Kits

DCS800-R Rebuild Kits


DCS800 Drive Manuals
Language
Public. number E D I ES F CN RU PL PT
DCS800 Quick Guide 3ADW000191 x x x x x
DCS800 Tools & Documentation CD 3ADW000211 x
DCS800 Converter module
Flyer DCS800 3ADW000190 x x x x x
Technical Catalog DCS800 3ADW000192 x x x x x x x x x
Hardware Manual DCS800 3ADW000194 x x x x x x x x
Hardware Manual DCS800 update DCF503B/DCF504B 3ADW000194Z0301 x
Firmware Manual DCS800 3ADW000193 x x p x x x x x
Installation according to EMC 3ADW000032 x
Technical Guide 3ADW000163 x
Service Manual DCS800 3ADW000195 x x
12-Pulse Manual 3ADW000196 x
CMA-2 Board 3ADW000136 x
Flyer Hard - Parallel 3ADW000213 x
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
DCS800 Crane Drive
DCS800 Crane Drive Manual suppl. 3AST004143 x
DCS800 Crane Drive Product note PDC5 EN x
DCS800 Winder ITC
DCS800 Winder Product note PDC2 EN x
DCS800 Winder description ITC 3ADW000308 x
Winder Questionnaire 3ADW000253z x
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
Technical Catalogue DCS800-A 3ADW000198 x
Installation of DCS800-A 3ADW000091 x x
DCS800-R Rebuild System
Flyer DCS800-R 3ADW000007 x x
DCS800-R Rebuild Kits 3ADW000197 x
DCS800-R Optical Rebuild Kits 3ADW000415 x
DCS800-R DCS500/DCS600 Upgrade Kits 3ADW000256 x
Extension Modules
RAIO-01 Analogue IO Extension 3AFE64484567 x
RDIO-01 Digital IO Extension 3AFE64485733 x
RRIA-01 Resolver Interface Module 3AFE68570760 x
RTAC-01 Pulse Encoder Interface 3AFE64486853 x
RTAC-03 TTL Pulse Encoder Interface 3AFE68650500 x
AIMA R-slot extension 3AFE64661442 x
Door mounting kits
Door mounting DCS Control Panel (IP54, click in) 3AUA0000076085 x
Door mounting DCS Control Panel (fix mounting) 3AFE68294673 x
Door mounting DCS Control Panel (IP66, fix mounting) 3AFE68829593 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 04.2012
DCS800 Drive Manuals-List_k.doc
 DCS800-R Rebuild Kits

Selection, Installation and Start-up Manual for Optical Rebuild Kits

Code: 3ADW000415R0101 Rev A

DCS800-R Optical Rebuild Kits e a.doc

Effective: 03.2012
Supersedes: -

2012 ABB Automation Products GmbH. All rights reserved.

3ADW000415R0101 DCS800-R Optical Rebuild Kits e a
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Safety instructions

What this chapter contains

This chapter contains the safety instructions 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

The information is valid for the whole range of the product DCS800, the converter
modules DCS800-S0x size D1 to D7, field exciter units DCF80x, etc. like the
Rebuild Kit DCS800-R00-9xxx.

Usage 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, and advise on 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 or death and/or damage to the equipment.

General danger warning warns about conditions, other than those

caused by electricity, which can result in physical injury or death
and/or damage to the equipment.
Electrostatic sensitive devices 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
and/or damage to the equipment.

WARNING!

• 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 resistance or voltage withstand tests
on the drive or drive modules.
• Isolate the motor cables from the drive when testing the insulation
resistance or voltage withstand of the cables or the motor.
• 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 main 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 relay outputs of the drive
system (e.g. SDCS-IOB-2 and RDIO).
• DCS800 with enclosure extension: Before working on the drive,
isolate the whole drive system from the supply.

Safety instructions

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Grounding

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

WARNING!

• 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 and
marked 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 (e.g. conductive sleeves) of screened cable entries at
the cabinet lead-through plate.
• Do not install a drive equipped with an EMC filter to an
ungrounded power system or a high resistance-grounded (over 30
ohms) power system.

Note:

• Power cable shields are suitable as 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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Printed circuit boards and fiber optic cables

These instructions are intended for all who handle the circuit boards
and fiber optic cables. Ignoring the following instructions can cause
damage to the equipment.

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:

ABB order no.: 3ADV050035P0001

WARNING! Handle the fiber optic cables with care. When unplugging
optic cables, always grab the connector, not the cable itself. Do not
touch the ends of the fibers with bare hands as the fiber is extremely
sensitive to dirt. The minimum allowed bend radius is 35 mm (1.38 in.).

Safety instructions

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

WARNING!

• 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.

Safety instructions

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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 and/or damage to the equipment.

WARNING!

• 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 control the motor with the disconnecting device
(disconnecting mains); instead, use the control panel keys and
, or commands via the I/O board of the drive.
• Mains connection
You can use a disconnect switch (with fuses) to disconnect the
electrical components of the drive from the mains for installation
and maintenance work. The type of disconnect switch used must
be 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
drive will neither cause an emergency stop of the motor, 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.

Safety instructions

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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
DCS800 Drive Manuals .......................................................................................................... 2
Safety instructions 5
What this chapter contains ....................................................................................................... 5
To which products this chapter applies..................................................................................... 5
Usage of warnings and notes ................................................................................................... 5
Installation and maintenance work ........................................................................................... 6
Grounding ..................................................................................................................... 7
Mechanical installation ............................................................................................................. 9
Operation ............................................................................................................................... 10
Table of contents 13
Introduction 15
Chapter overview ........................................................................................................ 15
Before You Start ......................................................................................................... 15
What this manual contains .......................................................................................... 15
Target group ............................................................................................................... 15
Associated publications .............................................................................................. 15
Basic Selection 16
Technical requirements and limits .......................................................................................... 16
Selecting the suitable Optical Rebuild Kit ............................................................................... 16
Hardware conditions ................................................................................................... 16
Drive’s design conditions ............................................................................................ 17
Conditions caused by the application .......................................................................... 17
ID codes and options .................................................................................................. 18
Galvanic isolation ........................................................................................................ 19
Optical Rebuild Kits overview...................................................................................... 20
Hardware 21
Basic components .................................................................................................................. 21
Electronic housing (DCS800-R00-0000-00) ................................................................ 21
Loose parts ................................................................................................................. 23
Optional parts ............................................................................................................. 24
Dimensions ............................................................................................................................ 24
Environmental conditions ....................................................................................................... 24
Measurement board SDCS-PIN-51 ........................................................................................ 25
Wiring ......................................................................................................................... 26
Fastening .................................................................................................................... 26
PTC temperature sensor............................................................................................. 26
Type coding ................................................................................................................ 26
Voltage coding ............................................................................................................ 26
Current coding ............................................................................................................ 27
Firmware adaption ...................................................................................................... 28
Pulse conversion board SDCS-REB-11 ................................................................................. 29
Wiring ......................................................................................................................... 30
Fastening .................................................................................................................... 30
Functionality................................................................................................................ 30

Table of contents

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Gate driver board SDCS-PIN-Rxx .......................................................................................... 31

Wiring ......................................................................................................................... 32
Fastening .................................................................................................................... 32
Functionality ............................................................................................................... 32
Interfacing the Electronics and Thyristors 33
General .................................................................................................................................. 33
Designation of thyristors ............................................................................................. 33
Forward bridge (2-Q) with single thyristors ............................................................................. 34
Forward and reverse bridge (4-Q) with single thyristors ......................................................... 36
Forward bridge (2-Q) with 3 serial / parallel thyristors ............................................................ 38
Forward and reverse bridge (4-Q) with 3 serial / parallel thyristors ........................................ 40
Forward and reverse bridge (4-Q) with 12 serial / parallel thyristors....................................... 42
Installation 44
General .................................................................................................................................. 44
Hints for mounting .................................................................................................................. 44
Hints for cabling ..................................................................................................................... 44
Cables overview ......................................................................................................... 45
Start-up 46
General .................................................................................................................................. 46
Safety Instructions ................................................................................................................. 46
Points to be observed because of the situation ...................................................................... 46
Tools ...................................................................................................................................... 46
Measurements with the ‘old’ equipment still working .............................................................. 47
Mounting the Optical Rebuild Kit ............................................................................................ 48
Wiring the Optical Rebuild Kit ................................................................................................. 48
Commissioning the Optical Rebuild Kit................................................................................... 49

Table of contents

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Introduction
Chapter overview
This chapter describes the purpose, contents and the intended use of this manual.
Before You Start
The purpose of this manual is to provide you with the information necessary to upgrade the
electronics of old DC drives using Optical Rebuild Kits. The manual DCS800 Selection, Installation
and Start-Up Manual for Rebuild Kits serves as the basic document. It is structured similar to this
one. Sometimes cross-references are given to the basic document.
Study carefully the Safety instructions at the beginning of this manual before attempting any work
on or with the drive. Read this manual before starting-up the drive.
What this manual contains
The Safety instructions are at the beginning of this manual.

Introduction, the chapter you are currently reading, introduces you to this manual.

Basic Selection, this chapter provides the information about the types of Optical Rebuild Kits, their
ID codes and available options.

Hardware, this chapter provides information about the boards and the components of Optical
Rebuild Kits.

Interfacing the Electronics and Thyristors, this chapter shows the connections between electronics
and power part.

Installation, this chapter gives hints for mounting and cabling Optical Rebuild Kits.

Start-up, this chapter gives general guidelines and cross references for commissioning and start-up
for Optical Rebuild Kits.

Target group
This manual is designed to help those responsible for planning, installing, starting up and servicing
DC drives.
These people should possess:
− Basic knowledge of physics, electrical engineering, electrical wiring principles, components as
well as symbols used in electrical engineering
− Basic experience with DC drives and DC products
Associated publications
A list of associated publications is published on the inner page of this manual’s cover, see DCS800
Manuals.
The above listed documentation can be found on the CD-ROM being attached to the DCS800
Quick Guide (3ADW000191).

Introduction

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Basic Selection
Technical requirements and limits
This document will often use the term valve instead of thyristor:
− A valve is made of several serial / parallel thyristors or a single thyristor
− The term thyristor is only used in the context of one single thyristor
The technical requirements and limits are identical to the ones listed in the basic document. The
Optical Rebuild Kits are dedicated to upgrade the electronics of old DC drives, which:
− Use up to 12 thyristors per valve (serial / parallel)
− Have long distances between the drive’s electronics and the power part

Selecting the suitable Optical Rebuild Kit

The basic structure of a DC drive looks like this:

The Optical Rebuild Kits can be used for armature bridges in non-regenerative or regenerative
mode with maximum 12 thyristors in serial / parallel per valve. In case there are more than 12
thyristors per valve please contact your local ABB organization.

When selecting an Optical Rebuild Kit the Hardware conditions must be checked first to become
aware of critical limitations. If this is done the Drive’s design conditions will give some guidelines for
the overall design. During that a decision must be made for the functionality of the interface
between the Optical Rebuild Kit and the overriding control. Depending on the above, the Optical
Rebuild Kit and additional electronic boards have to be chosen. Afterwards check, if all conditions
mentioned under Conditions caused by the application are fulfilled.
Hardware conditions
If an Optical Rebuild Kit is taken into consideration, the items listed below give some help to decide
whether an Optical Rebuild Kit a new converter module or a complete drive cabinet is the best
solution:
− Before an existing DC power part is upgraded by an Optical Rebuild Kit, it should be checked if a
new converter module is easier to install or is a more reliable solution (the power part is factory
tested)
− The existing power part should have maximum 12 thyristors per valve (more thyristors per valve
on request). It does not matter if the thyristors are in serial and / or parallel.
− The maximum distance between the drive’s electronics and the power part is 30 m (longer
distances on request)
− The supply voltage (phase to phase) used for the existing power part can be up to 2,500 VAC
because of the firing pulse board used to interface the electronics to the power part
− The thyristors must be disk type thyristors

Basic Selection

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− The minimum DC current of a power part should be higher than 1,000 ADC (no serial / parallel
thyristors). In case the DC current is lower, it is strongly recommended to use a new converter
module.
− The ratio between reverse / forward blocking voltage of the thyristors and the nominal line
voltage should be factor 3 or higher. The blocking voltage has to be measured using a thyristor
tester. In case the actual blocking voltage gives a lower ratio the thyristor needs to be replaced.
In such a case, please check if a new converter module is better choice.
Drive’s design conditions
It is intended to install the Optical Rebuild Kit into the existing drive cabinet whereas the firing pulse
board (SDSC-PIN-Rxx) has to be next to the thyristors. The following drive equipment will be
reused and should therefore be in good condition:
− All parts in the AC supply like busbars / cables, main disconnecting switch with fuses, main
contactor or similar
− The thyristor bridges itself (fuses, fixing devices, press clamps for thyristor mounting, …)
including the cooling equipment (e.g. heat sinks, fans, …)
− All parts in the DC supply like Motors and motor cables
− Analogue tachos and pulse encoders can be reused, more details see DCS800 Hardware
Manual
− All auxiliary devices like relays, contactors, external power supplies, transformers, etc.
If an Optical Rebuild Kit is used for the armature supply it is strongly recommended to upgrade the
field exciter:
− DCF803-0016 up to 16 A field current, single-phase or 3-phase supply maximum 500 VAC
− FEX-425-Int up to 25 A field current, single-phase or 3-phase supply maximum 500 VAC
− DCF803-0035 up to 35 A field current, single-phase or 3-phase supply maximum 500 VAC
− DCF80x-0050 / DCF50xB-0050 up to 50 A field current, single-phase supply maximum 500 VAC
− A standard DCS800 module up to 520 A field current (more on request), 3-phase supply
maximum 525 VAC
The Rebuild kit needs an armature current feedback signal for the current control loop. This signal
is normally taken from two current transformers (CTs) mounted at the AC side of the thyristor
bridge. The CTs output current should be between 0.5 A - 0.85 A, which corresponds to the nominal
current of the thyristor bridge (additional solutions on request).
Additionally a 115 VAC or 230 VAC supply for the Optical Rebuild Kit electronics is needed.
Conditions caused by the application
It has to be checked if the selected Optical Rebuild Kit type can handle the application of the
existing drive. As long as the existing one was used in a B6 configuration, there is usually no
limitation. If the existing bridge has been used in a configuration different to a B6 configuration,
additional engineering is needed:
− It should be checked at first, if a new converter module can be used for such a configuration
− The optical rebuild kit is also equipped to support 12-pulse configurations, M3, double M3 and
M6 configurations. For more details contact your local ABB organization.
− There are drives used in the past in a configuration sometimes named MASTER - FOLLOWER,
MASTER - SLAVE or similar. In all these applications, one drive generates references or
commands for the second, third, … drive. The Optical Rebuild Kit is basically prepared for those
configurations. For more details, please refer to the DCS800 Manuals.
− If the existing converter has been used in a non motor application usually a prepared solution is
not available, but it is possible to find an engineered solution. For more details contact your local
ABB organization.

Basic Selection

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ID codes and options

The main mechanical construction for all the different versions of the Optical Rebuild Kit is shown in
the next figure as DCS800-R00-0000-00. All other parts have to be placed in and around the power
part (Attention: Engineering needed!).
Due to the versatility of the Optical Rebuild Kit the ordering has to be done using ID codes:

Electronics / Printed circuit boards ID code

Electronic housing (DCS800-R00-0000-00) 3ADT220142R0001
SDCS-PIN-51 mounted on a card holder, including resistor 3ADT783025R0022
SDCS-REB-11 mounted on a card holder 3ADT317500R0001
SDCS-PIN-R00 mounted on a card holder, no BOD 3ADT317100R9999
SDCS-PIN-R15 mounted on a card holder, 2 * 1,500 BOD 3ADT317100R0015
SDCS-PIN-R22 mounted on a card holder, 2 * 2,200 BOD 3ADT317100R0022

Cables ID code
Flat cable, 16 pole, not shielded, 0.55 m 3ADT693564P0001
X12
Flat cable, 16 pole, not shielded, 0.55 m 3ADT693558P0001
X13, X113
Voltage measurement, single core, 6.3 mm faston on one end, DCA0020441P0001
U1, V1, W1, C1 and D1
Current measurement, twisted pair, system plug on one end, DCA0020450P0001
X23, X25
Plastic fiber optic single cable with plugs 5 m 3ADT693324R0004
Plastic fiber optic single cable with plugs 10 m 3ADT693324R0006
Plastic fiber optic single cable with plugs 15 m 3ADT693324R0007
Plastic fiber optic single cable with plugs 20 m 3ADT693324R0008
Plastic fiber optic single cable with plugs 30 m 3ADT693324R0009
Forward firing pulse cables, twisted pair, system plug on one end, 1 m 3ADT693662R0001
V11 - V16
Reverse firing pulse cables, twisted pair, system plug on one end, 1 m 3ADT693662R0002
V21 - V26

The options available for the Optical Rebuild Kits are identical to the ones for the DCS800 converter
modules. They can be ordered by means of ID codes.
All applications, which can be done with a DCS800, are available after a rebuilt. For engineering
support refer to the DCS800 Manuals. This manual focuses on items related to the engineering of
the Optical Rebuild Kits.

Basic Selection

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Galvanic isolation
Usually the DC- and AC-voltage is measured via high ohmic resistors with a scaling of 1 Mohm per
100 V. Galvanic isolation is used to isolate the DC- and AC- high resistance voltage measurement
circuits of the converter modules from high DC- and AC-voltages. It is typically used when either the
supply voltage (phase to phase) or the motor voltage is greater than 690 V.
Only the DC- and AC- high resistance voltage measurement circuits have to be galvanically
isolated, because the current measurement is already isolated via current transformers (CTs). To
isolate the AC-voltage measurement a special isolation AC transformer for all three phases is
needed. The DC-voltage measurement is isolated by means of a DC transducer. To complete the
galvanic isolation of the voltage measurement circuit a modified SDCS-PIN-5x-1190 board is
needed.
The transformer, the DC-DC transducer and the modified SDCS-PIN-5x-1190 are provided by ABB.

Part ID code
SDCS-PIN-5x-1190 3ADT780007R0002
3-phase AC transformer for supply voltages up to 1,200 VAC 3ADT745047P0001
Single-phase AC transformer for supply voltages up to 4,000 VAC 3ADT745054P0001
DC transducer P42000D3 for motor voltages up to UMotN = 1,200 VDC* 3ADN260008P0001
DC transducer P42001D3 for motor voltages up to UMotN = 1,600 VDC* 3ADV050096P0007
DC transducer P42100D3 for motor voltages up to UMotN = 2,600 VDC* 3ADV050096P0021
*max. supply voltage (phase to phase) is 1.35 * UMotN

Basic Selection

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Optical Rebuild Kits overview

Basic Selection

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Hardware
This chapter gives information about all the components and boards being used in the Optical
Rebuild Kits. Components which are used in DCS800 standard converters are simply mentioned
within this chapter, but not described in detail. It will be described here if those components need
special handling.
For better and easy engineering environmental conditions, dimensions and additional hints are
listed in this chapter too. All other components which may come or have been ordered together with
the Optical Rebuild Kits are described in detail within the DCS800 Manuals.

Basic components
All Optical Rebuild Kits can be ordered according to chapter Basic Selection via ID code. The
delivery can be subdivided into several parts:
− The electronic housing (DCS800-R00-0000-00) is pre-assembled
− The electronic boards SDCS-PIN-51, SDCS-REB-11 and SDCS-PIN-Rxx, all mounted on card
holders, as loose parts
− The cables to interconnect the electronic boards and control the existing thyristors, as loose
parts or supplied by the customer
− The ordered options, either built-in (plus code) or as loose parts (ID code)
Electronic housing (DCS800-R00-0000-00)

The electronic housing is pre-assembled and consists of:

− The electronic housing, see figure above
− DCS Control Panel, see figure above
− Control board SDCS-CON-4 (including interconnecting flat cables)
− Drive-to-drive interface board SDCS-DSL-4
− Power supply SDCS-POW-4, needs a single phase auxiliary voltage of 115 VAC or 230 VAC
− Flat cable interconnection board SDCS-CCB4
− As stated at the end of chapter Basic Selection it is possible to order options using a plus code.

Hardware

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Such options are usually used together with the SDCS-CON-4. They will be plugged into their
correct place during production and therefore will come within the housing.
Since the electronic housing is equipped with the components mentioned before, no cooling fan is
needed. Nevertheless natural convection is necessary to keep the temperature of the used
components within the limits. Because of that it is important to mount the housing upright - see
figure above - so that the convection is not blocked.

100

 4.2
90
Weight: 7 kg

20
43.5 307
f. M6

MG_800_001_ext_a.dsf
for flat cable X12:
for flat cable X13:
screen clamp

M6
225
264
270
80
40

34.8 350
10.5
198 370.5

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Loose parts
The Optical Rebuild Kits are available in 2-Q or 4-Q depending on the usage of the SDCS-REB-11.
Both of them are available for power parts with up to 12 thyristors per valve (serial / parallel). Due to
the versatility of the Optical Rebuild Kit the ordering has to be done using ID codes. Some
components will be part of the delivery in every case like the DCS800-R00-0000-00 and the SDCS-
PIN-51 all others depend on the configuration. The following table shows examples for a B6
configuration:

1 - 4 thyristors per valve 5 - 8 thyristors per valve 9 - 12 thyristors per valve

2-Q 1 DCS800-R00-0000-00 1 DCS800-R00-0000-00 1 DCS800-R00-0000-00
1 SDCS-PIN-51 1 SDCS-PIN-51 1 SDCS-PIN-51
1 SDCS-REB-11 2 SDCS-REB-11 3 SDCS-REB-11
1*6 SDCS-PIN-Rxx or 5*6 SDCS-PIN-Rxx or 9*6 SDCS-PIN-Rxx or
2*6 SDCS-PIN-Rxx or 6*6 SDCS-PIN-Rxx or 10*6 SDCS-PIN-Rxx or
3*6 SDCS-PIN-Rxx or 7*6 SDCS-PIN-Rxx or 11*6 SDCS-PIN-Rxx or
4*6 SDCS-PIN-Rxx 8*6 SDCS-PIN-Rxx 12*6 SDCS-PIN-Rxx
4-Q 1 DCS800-R00-0000-00 1 DCS800-R00-0000-00 1 DCS800-R00-0000-00
1 SDCS-PIN-51 1 SDCS-PIN-51 1 SDCS-PIN-51
2 SDCS-REB-11 4 SDCS-REB-11 6 SDCS-REB-11
1*12 SDCS-PIN-Rxx or 5 *12 SDCS-PIN-Rxx or 9*12 SDCS-PIN-Rxx or
2*12 SDCS-PIN-Rxx or 6 *12 SDCS-PIN-Rxx or 10*12 SDCS-PIN-Rxx or
3*12 SDCS-PIN-Rxx or 7 *12 SDCS-PIN-Rxx or 11*12 SDCS-PIN-Rxx or
4*12 SDCS-PIN-Rxx 8 *12 SDCS-PIN-Rxx 12*12SDCS-PIN-Rxx

This is different for M3, double M3 and M6 configurations.

The parts serve different purposes:
− DCS800-R00-0000-00
The electronic housing contains the control board SDCS-CON-4 and the power supply SDCS-
POW-4 - see also chapter Electronic housing.
Note:
The 230 VAC cables have to be supplied by the customer - see Cable overview.
− SDCS-PIN-51
The measuring board is mounted on a card holder. A pluggable resistor for X22 is included.
For the interconnections 5 cables for the AC- and DC voltage measurement (single core, 6.3 mm
faston on one end), 2 cables for the current measurement via CTs (twisted pair; system plug on
one end) have to be ordered separately via ID code. For cable lengths, please refer to chapter
Interfacing the Electronics and Thyristors.
− SEDS-REB-11
The pulse conversion board for up to 4 thyristors per valve (serial / parallel) is mounted on a card
holder for fast installation on 35 mm conventional rails or DIN rails .
The flat cables for interconnections (16-pole) have to be ordered separately via ID code. For
cable lengths, please refer to chapter Interfacing the Electronics and Thyristors.
− SDCS-PIN-Rxx:
The gate driver board for one single thyristor is mounted on a card holder for fast installation on
35 mm conventional rails or DIN rails .
The fiber optic cable for the interconnections (plastic fiber optic single cable with plugs) and the
firing pulse cable (twisted pair, system plug on one end) have to be ordered separately via ID
code. For cable lengths, please refer to chapter Interfacing the Electronics and Thyristors.

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Note:
The 230 VAC cables and the cable from the thyristors anode to X3 (6.3 mm faston) on the SDCS-
PIN-Rxx have to be supplied by the customer - see Cable overview.
Optional parts
The options available differ in their usage. Some of them are related to the Optical Rebuild Kit,
some to the drive itself or to the application the drive is used for:
− Fex-425-Int (plus code +S164):
The FEX-425-Int is build into the electronic housing, when ordered via plus code. It can be
connected to a single-phase or 3-phase supply with up to 500VAC.
Field current ratings:
Single-phase supply: up to 16 A field current
3-phase supply: up to 25 A field current
− Subassembly SDCS-IOB-2x/IOB-3:
This subassembly is a part of the DCS800 converter module options. In case the standard inputs
or outputs of the SDCS-CON-4 do not fit to the application, this option may be a solution.
The subassembly needs to be placed close to the electronic housing.
Depending on the overall configuration and the needs caused by the application itself it may be
necessary to add other options. These options should be selected based on the Optical Rebuild Kit
overview.

Dimensions
See chapter Electronic housing.

Environmental conditions
For environmental conditions, please see the manual DCS800 Selection, Installation and Start-Up
Manual for Rebuild Kits.

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Measurement board SDCS-PIN-51

This board is always required using the Optical Rebuild Kits. Usually one SDCS-PIN-51 is used per
Optical Rebuild Kit.
The SDCS-PIN-51 supports following functions:
 Connection to the controller board SDCS-CON-4
 Connection to the pulse conversion board / boards SDCS-REB-11
 Interface for the heat sink temperature measurement with a PTC
 Measurement and scaling of AC and DC voltage via high resistance resistors
 Measurement and scaling of the armature current
SDCS-PIN-51 mounted on a card holder:
10

Card holder for SDCS-PIN-51

80

5
10

8 331

347
~ 60

W5
PTC see diagram Conductive
R123 power part supports
168.5
line potential ! 121.5

1 X23 2 1 X24 2 1 X25 2

U1 W5 W4 W3 W2 W1 X22 X122
3 4 Two PTC
S3 1 2 One PTC
R1 ....... R21
V1 W11 W9 W8 W7 W6
W10 W70 W71 W72 R22
100
X12

X12S X413S
W1 W16 W15 W14 W13 W12 W80 W81 W82 R26
80

W83
X13S X313S
C1 W21 W20 W19 W18 W17
Isolating S2 S1
X513

X113

X213

X413

X313

supports
X13

D1 W26 W25 W24 W23 W22

4.8 SDCS-PIN-51
5 305
10

182.5 100.7

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Wiring
EXISTING PART
X12:
SDCS-PIN-51
a A

b B

a A

b B
* * Fuse data
1A, suitable voltage
*

*
*
X22:
X22:
X122:
X122:
SS_800_001_rebuild_a.dsf

− If the distance between the SDCS-PIN-51 terminals C1, D1, U1, V1, W1 and the power terminals
of the existing power part exceeds 1 m, an additional fuse has to be used per wire, see figure
above
− Make sure, that the CTs are mounted and wired properly, see figure above
Fastening
The SDCS-PIN-51 is mounted on a card holder, which got six M4 mounting holes. Using this card
holder care must be taken to have a good connection to ground.
PTC temperature sensor
If there is no temperature sensor in the power part a separate resistor (2.21 kOhm; 0.5 W; 1 % is
included) must be connected between terminals X22:1 and X22:3 of the SDCS-PIN-51. Set jumper
S3 to position 1-2. Thus the temperature measurement reads a fixed value and is disabled.
Type coding
The type coding is done via parameters in the firmware, thus all jumpers W70 to W72 and W80 to
W83 and W10 should be kept uncut (default condition). In case a modified board is used, with the
above listed jumpers cut, nothing needs to be done. The board can be used without further
modification. Just leave the jumpers as they are. They will not be read by the converter’s firmware
and therefore not taken into consideration.
Voltage coding
Use the settings given by the table below. Depending on the supply voltage of power part the
jumpers need to be removed accordingly (supply voltages under 200 VAC on request).
Note:
For power parts connected to high supply voltages the option Galvanic isolation should be taken
into consideration because of personal and functional safety reasons.

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Voltage applied appr.

to the power stack 200...500 V 501...600 V 601...700 V 701...800 V 801...990 V

Value for
500 600 690 800 1000
S ConvScaleVolt (97.03)
W1, 6, 12, 17, 22
W2, 7, 13, 18, 23
W3, 8, 14, 19, 24
W4, 9, 15, 20, 25
W5, 11, 16, 21, 26
indicates a removed jumper

Current coding
Ratio of the CTs is either 2,500:1 or 4,000:1
If the ratio of the CTs is either 2,500:1 or 4,000:1 (standard ABB CTs) use the table below to scale
the nominal converter current IdN.
Note:
As long as the nominal converter current IdN is close to the currents listed in the table below and the
ratio of the CTs is either 2,500:1 or 4,000:1 use this coding for current scaling. Remove the jumpers
on the SDCS-PIN-51 board according to the selected nominal converter current IdN and set S
ConvScaleCur (97.02) accordingly.

Current transf. ratio 2500:1 4000:1

Nominal current IdN [A] 900 1200 1500 2000 2500 3000 2600 3300 4000 4800 5200
R1-R4 18 Ω
R5 18 Ω
R6 18 Ω
R7 18 Ω
Rated current scaling

R8 18 Ω
R9 18 Ω
R10 18 Ω
R11 18 Ω
R12 18 Ω
R13 18 Ω
R14 18 Ω
R15 18 Ω
R16 18 Ω
R17 33 Ω
R18 68 Ω
R19 120 Ω
R20 270 Ω
R21 560 Ω
R22 47 Ω
Zero current

47 Ω
detection

R23
R24 47 Ω
R25 47 Ω
R26 100 Ω
indicates a removed jumper DCS800-R volt & curr coding.dsf

For all other configurations

For all other configurations the burden resistor has to be calculated. The scaling is done by cutting
resistors R1 to R21. Following definitions are important:

− The nominal converter current IdN is equivalent to 1.5 V across the nominal current burden

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resistors (R1 to R21)

− The current measurement is designed to handle peak currents Ipeak up to two times IdN
(equivalent to 3 V)
− The zero current detection is done automatically (no cutting required)

Most often the nominal converter current IdN is the thermal current of the power part and the peak
current Ipeak is the highest current running through the motor.
In case the peak current Ipeak is higher than two-times IdN the nominal converter current needs to be
redefined. As new nominal current of the Optical Rebuild Kit IdNDCR has to be used. For IdNDCR is valid:

I dnDCR = 0.5 • I peak

Calculate the needed total burden resistance Rbr:

1.5V with: IdN = nominal converter current

Rbr = roct • roct = ratio of CT (e.g. 2,500:1)
I dN

Calculate the resistors which will remain within R1 to R21 according to the following formula. The
resulting resistance should be as close as possible to the above calculated burden resistance Rbr:

1 1 1 1 1
= + + + ... +
Rbr R1 R2 R3 R21

All resistors not used in this formula have to be cut. For values of resistors R1 to R21 click here.
The minimum available value for Rbr is: 1.06 ohm.
Firmware adaption
The following settings have to be done by firmware parameters:

Converter Parameter Settings Remarks

Type code TypeCode (97.01) None
Nominal current S ConvScaleCur (97.02) xxxx A as coded
Nominal voltage S ConvScaleVolt (97.03) xxxx V as coded
Power part temperature S MaxBrdgTemp (97.04) xxxx°C inactive when set to 150°C
2-Q or 4-Q mode S BlockBridge2 (97.07) BlockBridge2 2-Q power part
RelBridge2 4-Q power part

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Pulse conversion board SDCS-REB-11

This board is always required using the Optical Rebuild Kits. Up to 6 SDCS-REB-11 can be used
per Optical Rebuild Kit.
The SDCS-REB-11 supports following functions:
− Connection to the controller board SDCS-CON-4
− Connection to the measurement board SDCS-PIN-51
− Defining if used for forward or reverse bridge
− Setting of the optical power between 20 mA and 40 mA
− Providing connections for the measurement of the firing pulses via oscilloscope
− Quadruplicate the electrical firing pulses and converting them into optical firing pulses
− Connection to the gate driver boards SDCS-PIN-Rxx via fiber optic cables
SDCS-REB-11 mounted on a card holder using an UM 72-profile:

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Wiring
− The firing pulses coming from X13 of the SDCS-CON-4 and connected to X13 of the SDCS-
REB-11. Then the firing pulses are transferred from X113 to either X13 of the next SDCS-REB-
11 or to X13 of the SDCS-PIN-51.
− The optical firing pulse cables can be connected from V1:A to V6:D
Fastening
The SDCS-REB-11 is mounted on a card holder for fast installation on 35 mm conventional rails
or DIN rails .
Functionality
At the input connector X13 firing pulses 1 to 6 are received including the forward / reverse bridge
signals SR1 and SR2. Theses signal are routed directly to X113 and can be connected for further
use.
The board quadruplicates the electrical firing pulses converts them into optical firing pulses and
distributes them to fiber optic connectors V1:A to V6:D.
Electrical characteristics of the SDCS-REB-11
− The SDCS-REB-11 is supplied from the SDCS-CON-4. The SDCS-CON-4 is able to support up
to 3 SDCS-REB-11 boards in each direction (maximum 3 forward and maximum 3 reverse). Thus
maximum 6 SDCS-REB-11 boards can be connected to one SDCS-CON-4.
− Each SDCS-REB-11 provides up to 4 optical firing pulses per valve. Thus it is possible to control
up to 12 thyristors per valve (serial / parallel).
− Due to the nature of the fiber optic cables it is possible to have long distances, up to 30 m,
between the drive’s electronics and the power part
Switches
− S1 to S6 define the optical current and thus the length of the fiber optic cable. Switch open
provides 20 mA for a length of 5 - 10 m. Switch closed provides 40 mA for a length of 10 - 30 m.
− S7 defines the used bridge. SR1 is the forward bridge and SR2 is the reverse bridge.
− At XP it is possible to measure the firing pulses 1 to 6 including the forward / reverse bridge
signals SR1 and SR2 via a scope

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Gate driver board SDCS-PIN-Rxx

This board is always required using the Optical Rebuild Kits. Per thyristor one SDCS-PIN-Rxx is
needed.
The SDCS-PIN-Rxx supports following functions:
− Connection to the gate driver boards SDCS-PIN-Rxx via fiber optic cables
− Converting the optical firing pulse into an electrical firing pulse
− Amplifying the electrical firing pulse and sending it to the thyristor
− In case of a control electronics failure a forced firing of the thyristor via two BOD elements is
provided. The voltage threshold over the thyristor depends on the used BOD elements.
There are 3 versions of the SDCS-PI-Rxx:
1. SDCS-PIN-R00 without BOD elements
2. SDCS-PIN-R15 with two 1,500 V BOD elements in series. Thus the thyristor is fired at a peak
voltage of 3,000 V.
3. SDCS-PIN-R22 with two 2,200 V BOD elements in series. Thus the thyristor is fired at a peak
voltage of 4,400 V.
SDCS-PIN-Rxx mounted on a card holder using an UM 72-profile:

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Wiring
− The SDCS-PIN-Rxx is supplied by 230 VAC at X1:1. The supply voltage needs to be supervised
(e.g. by a relay connected to a DI on the SDCS-CON-4 and external fault) - see also Optical
Rebuild Kit overview.
− The optical firing pulse is coming from the SDCS-REB-11 and connected to U100 of the SDCS-
PIN-Rxx
− The thyristor is connected to X3 (Anode), X4 (Gate) and X5 (Cathode). The cable length should
be less than 1 m. Use 6.3 mm faston plugs. Run a twisted pair cable for X4 / X5 to the thyristor
and route the cable connected at X5 next to it.
Note:
Keep the cables isolation strength in mind. The SDCS-PIN-Rxx can be used for supply voltages
(phase to phase) up to 2,500 VAC!
Fastening
The SDCS-PIN-Rxx is mounted on a card holder for fast installation on 35 mm conventional rails
or DIN rails .
Functionality
The gate driver board SDCS-PIN-Rxx is used to fire one single thyristor.
The optical firing pulse is received at the fiber optic connector U100 and indicated by the LED. The
board converts the optical firing pulse into an electrical firing pulse and amplifies it. The firing pulse
is send to the thyristor via connectors X3 to X5.
Electrical characteristics of the SDCS-PIN-Rxx:
− The SDCS-PIN-Rxx is supplied by 230 VAC, ± 10 %, 50 Hz / 60 Hz. Connector X1 provides two
additional terminals to easily daisy chain the supply voltage for up to 24 boards in series. The
maximum current consumption is 50 mA per board.
− The SDCS-PIN-Rxx amplifies the firing pulse and provides an insulation voltage of 2,500 VAC

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Interfacing the Electronics and Thyristors

General
There is basically only one possibility to connect the firing pulses from the control electronic to the
interface boards and then to the thyristors. The assignment of power part, mains connection and
wiring to the SDCS-PIN-51 is fixed. The SDCS-CON-4 uses this assignment as the basis for
generating the firing pulse sequence.
With an existing power part, we recommend to follow our configuration when numbering the
thyristors to avoid problems. The arrangement of the thyristors in an anti-parallel B6 bridge is
shown in the figure below. Thyristors for the forward bridge (SR1) are numbered V111, V112, ...,
V116 and thyristors for the reverse bridge (SR2) are numbered V121, V122, ..., V126:

C1
(+)

V111 V113 V115

V124 V126 V122

A B
(L1) U1
a b
(L2) V1
A B
(L3) W1
a b

V114 V116 V112

V121 V123 V125

(-)
D1
SS_800_002_u-i-meas_a.dsf

I actual U AC actual U DC actual

to SDCS-PIN-51

Note:
In a 2-Q converter only the forward bridge is used.
Designation of thyristors
In a power part with parallel / serial thyristors every thyristor is assigned a 3 digit number Vxyz:
− x = parallel / serial numbers of thyristors (e.g. 3 with 3 parallel thyristors)
− y = 1 forward bridge, y = 2 reverse bridge
− z = normal firing sequence number

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Forward bridge (2-Q) with single thyristors

The SDCS-REB-11, set to forward bridge, is connected to the 6 SDCS-PIN-Rxx for the thyristors.

Interfacing the Electronics and Thyristors

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Interfacing the Electronics and Thyristors

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Forward and reverse bridge (4-Q) with single thyristors

One SDCS-REB-11, set to forward bridge, is connected to the 6 SDCS-PIN-Rxx for the forward
thyristors. The other SDCS-REB-11, set to reverse bridge, is connected to the 6 SDCS-PIN-Rxx for
the reverse thyristors.

Interfacing the Electronics and Thyristors

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Interfacing the Electronics and Thyristors

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Forward bridge (2-Q) with 3 serial / parallel thyristors

One SDCS-REB-11, set to forward bridge, is connected to the 18 SDCS-PIN-Rxx for the forward
thyristors.

Interfacing the Electronics and Thyristors

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Interfacing the Electronics and Thyristors

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Forward and reverse bridge (4-Q) with 3 serial / parallel thyristors

One SDCS-REB-11, set to forward bridge, is connected to the 18 SDCS-PIN-Rxx for the forward
thyristors. The other SDCS-REB-11, set to reverse bridge, is connected to the 18 SDCS-PIN-Rxx
for the reverse thyristors.

Interfacing the Electronics and Thyristors

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Interfacing the Electronics and Thyristors

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Forward and reverse bridge (4-Q) with 12 serial / parallel thyristors

Maximum 3 SDCS-REB-11, set to forward bridge, are connected to the 6 * 12 SDCS-PIN-Rxx for
the forward thyristors. The other maximum 3 SDCS-REB-11, set to reverse bridge, are connected
to the 6 * 1 SDCS-PIN-Rxx for the reverse thyristors.

Interfacing the Electronics and Thyristors

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Interfacing the Electronics and Thyristors

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Installation
General
The information given within this chapter shall help the installation personnel to select a place for
the different components of the Optical Rebuild Kit, to mount them and do the interconnections
between the boards and the existing hardware.

Hints for mounting

The installation of the kit can be subdivided into 2 parts:
− Part 1 is the electronic housing (DCS800-R00-0000-00) with the electronic power supply SDCS-
POW-4 and the control board SDCS-CON-4. All options which can be connected to the SDCS-
CON-4 are left out for easier reading. They are listed in chapter the Optical Rebuild Kits
overview. The detailed description of these options is in the DCS800 Hardware Manual.
All components belonging to the first and second part should be mounted close to each other in
the existing drive cabinet.
− Part 2 covers the SDCS-PIN-51 and the SDCS-REB-11 boards. The amount of SDCS-REB-11
within this part may be different depending on the final configuration needed for the existing
power part. The cable connections within these boards are quite short; so the boards have to be
mounted close to each other.
All components belonging to the first and second part should be mounted close to each other in
the existing drive cabinet.
− Part 3 consists of the SDCS-PIN-Rxx boards, which have to be mounted as close as possible to
their thyristor

Hints for cabling

The cables / parts have to be ordered by ID code. The next table lists all cables / parts. Together
with the figure below it is possible to identify the proper cable / part for all connections.

Name Cable / Part ID code

A Resistor (2.21 kohm; 0.5 W; 1 %), part of ID code 3ADT783025R0022
B Flat cable, 16 pole, not shielded, 0.55 m, X12 3ADT693564P0001
Flat cable, 16 pole, not shielded, 0.55 m, X13, X113 3ADT693558P0001
C Voltage measurement, single core, 6.3 mm faston on one end, DCA0020441P0001
U1, V1, W1, C1 and D1
D Current measurement, twisted pair, system plug on one end, DCA0020450P0001
X23, X25
E Plastic fiber optic single cable with plugs 5 m 3ADT693324R0004
Plastic fiber optic single cable with plugs 10 m 3ADT693324R0006
Plastic fiber optic single cable with plugs 15 m 3ADT693324R0007
Plastic fiber optic single cable with plugs 20 m 3ADT693324R0008
Plastic fiber optic single cable with plugs 30 m 3ADT693324R0009
F Forward firing pulse cables, twisted pair, system plug on one 3ADT693662R0001
end, 1 m, V11 - V16
Reverse firing pulse cables, twisted pair, system plug on one 3ADT693662R0002
end, 1 m, V21 - V26
G Cable for 230 VAC by customer
H Firing pulses, single core, 6.3 mm faston on one end, by customer
e.g. cable type: AWG20, UL10203, 2

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Cables overview

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Start-up
General
This chapter describes the commissioning procedure for an Optical Rebuild Kit. This is done based
on the procedure used for DCS800 converter modules. Only the actions and steps, which are
different, are listed here.

Safety Instructions
The Optical Rebuilt Kit together with the power part and other components being reused will form a
converter and a drive system very similar as a new converter module or a new drive cabinet.
Thus the danger installation and commissioning personal is exposed to during the work is similar,
sometimes even higher than for ready made converter modules. There is some work, which will
only become necessary together with an Optical Rebuild Kit.
Because of that the Safety Instructions at the beginning of this manual have to be observed with
extreme care!
When listing the different steps of the start-up procedure additional warnings will be given. Based
on the possible variations caused by the individual projects not all conditions can be covered.
Please take this procedure as a general guideline and be prepared to take individual decisions
concerning safety and security.

Points to be observed because of the situation

All relevant safety regulations must be observed during installation, commissioning and
maintenance work, since it is possible to touch the main and auxiliary connections and other
electrical parts without any protection during installation of the Optical Rebuild Kit.
After the supply voltage is disconnected by means of the main switch, make sure by measuring that
no part of the system has either voltage or the system is protected with sufficient protection against
touch before any work is started.
Be aware of live terminals inside the drive cabinet even after the supply voltage has been
disconnected by the main switch, e.g. incoming busbars before the main switch itself or external
auxiliary power supplies.
Avoid unnecessary voltage withstand tests on any part of the unit.
General Hint:
In addition to the work specifics for the installation of the Optical Rebuild Kits attention should be
paid to features related to drives in general. There is the engineering and the interface to other
components in general, the selection of control cables their routing, grounding, screening and other
points which need further considerations. The manual Technical Guide gives some help within the
chapter EMC Compliant Installation and Configuration for a Power Drive System. This chapter gives
information specific to fulfill the needs necessary for the CE marking. Most often CE marking is not
the most important target for a system upgraded by an Optical Rebuild kit. Nevertheless using
some of the ideas will make the complete system safer.

Tools
Following software tools are mandatory:
− DriveWindow Light including commissioning wizard and DWL AP for Adaptive Program
− DriveWindow for fast drive monitoring using SDCS-COM-8

Following tools are mandatory in addition to standard tools:

− A scope including memory function with either galvanically isolating transformer or isolating

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amplifier (probe) for safe measurements. It can also be a hand held (portable) oscilloscope.
− A clamp on current probe. An AC type is sufficient for gate firing pulse measurements. In case
the scaling of the DC load current needs to be checked, a DC type is needed.
− A voltmeter (at least CAT III 1000 V):

− 3,000 V probes and test leads:

− An ESD-field service kit (ABB Service

Finland code 0001ESD / MS-Antistatic):

Attention:
Make sure, all equipment in use is suitable for the voltage level applied to the power part!

Measurements with the ‘old’ equipment still working

Some measurements should be carried out before the existing installation is switched
off and dismantled. They serve to document the existing performance. Record the
actual signals of:
− Speed
− Armature and field current
− Line, armature and field voltage
− Other application related signals
Record line and armature voltage to determine their names on the single line and
confirm the positive and negative DC - terminals. This will be an alternative to
disassemble the thyristor stack to check the orientation of the thyristors. At power parts
with more than one thyristor per valve record the firing pulse and the thyristor current of
each thyristor to be sure, all of them are conducting.

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Mounting the Optical Rebuild Kit

When starting the installation work make sure the equipment is disconnected from the
power supply and checked for safe condition! The figures within chapter Interfacing the
Electronics and Thyristors show all the components needed for the different
configurations possible.
Use the one which fits the best to the actual power part, depending on the number of
thyristors per valve and the configuration. Mounting the parts of the Optical Rebuild Kit
can be subdivided into 3 steps:
− Select a place for the electronic housing (DCS800-R00-0000-00) and mount it. Be
aware of the cable lengths between SDCS-CON-4, SDCS-REB-11 board(s), SDCS-
PIN-51, CTs and voltage measurement (AC and DC voltage).
− Select a place for the SDCS-REB-11 board(s), the SDCS-PIN-51 and mount them.
Be aware of the cable lengths between SDCS-CON-4, SDCS-REB-11 board(s),
SDCS-PIN-51, CTs and voltage measurement (AC and DC voltage).
All components have to be mounted on the same metal plate to ensure good contact
between conductive supports / card holders and the drives cabinet. Make sure, that
the metal plate has good contact with the drives cabinet and that the drives cabinet
is grounded as well.
− Select a place for all SDCS-PIN-Rxx boards as close as possible beside their
thyristor

Wiring the Optical Rebuild Kit

The system still has to be in a safe condition! The figures within chapter Interfacing the
Electronics and Thyristors used for the mechanical work should now be used for the
electrical wiring too. Take the hints given in chapter Interfacing the Electronics and
Thyristors into consideration especially the part about the Designation of thyristors.
Before the wiring work is started, check for labels on the existing power part naming the
thyristors and phases according to figure Arrangement of thyristors in an anti-parallel
bridge. In case of existing labels check, if they are correct and fit to each other. If there
are no or incorrect labels do the following:
− Search phase U1 (L1) and mark it. Do the same for V1 (L2) and W1 (L3)
− Search thyristor V11 and mark it. If this turns out to be difficult do this:
1. Follow the busbar U1. The thyristor connected to that busbar is either V11 or
V24.
2. The cathode of V11 (or the heatsink) has electrical contact to the C1(+) of the
power part
3. The disk type thyristors orientation can easily be recognized by the shorter
distance between cathode and gate compared to the longer distance between
gate and anode
4. In case the location of V11/V24 is found, but the orientation is not clear or the
thyristor is not visible take both firing pulse leads (one of them is connected to
the cathode) and check both for electrical contact to C1(+) of the power part
using an ohm-meter
− Search the other thyristors and mark them accordingly
− Parallel connected thyristors or thyristor bridges have to be marked as well
Following cable connections have to be made:
− All I/O connections of SDCS-CON-4 and SDCS-POW-4, including power part
monitoring (e.g. klixon, fan monitoring)
− The auxiliary voltage for the SDCS-POW-4

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− All flat cable connections between SDCS-CON-4, SDCS-REB-11 board(s) and

SDCS-PIN-51
− Voltage-, current- and temperature measurement of the SDCS-PIN-51
− The auxiliary voltage for all SDCS-PIN-Rxx boards
− The fiber optic cables between SDCS-REB-11 and all SDCS-PIN-Rxx boards
Attention:
Do not connect any of the firing pulse cables between the SDCS-PIN-Rxx and their
thyristors! This will be done during the commissioning of the Optical Rebuild Kit.

Commissioning the Optical Rebuild Kit

The commissioning of a DC drive equipped with an Optical Rebuild Kit is based on the
manuals used for a standard DCS800 converter module. Please refer to the DCS800
Manuals.
Some additional steps are needed and are shown below. Start with the commissioning
steps used for standard DCS800 converter modules:
− Safety Instructions, local safety regulations, etc.
− Check the engineering, e.g. make sure the selected voltage levels are correct and
selector switches (if existing) are in the correct position
− Make sure safety equipment is working properly
− Set the parameters in group 97 according to table Firmware adaption
In contrast with the normal commissioning procedure additional precautions should be
made to avoid damage to components of the drive system in case of wrong wiring or
unknown data.
− Check for proper routing of the firing pulses for each valve (including all thyristors)
using parameter TestFire (97.28) - see DCS800 Firmware Manual and the LED on
the SDCS-PIN-Rxx boards
− After all valves have been checked connect the gate leads to valves V11, V13 and
V15
− Before the drive is released the first time, set ArmAlphaMin (20.15) = 150°. This
limits the output voltage of the drive and gives a safe operation, even with a fault in
the current feedback circuit. Precautions should be made do avoid a turning motor
(disable the field current and lock the motor), if the drive will be released.
− Give an On command and make sure, no Run command is given. This causes the
pulse firing logic to work and to generate single firing pulses:
1. Now no current should flow. Check with a scope connected to the fixed AO I-act
(X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3).
2. Check the firing pulses using a current probe
3. Make sure, that ArmAlpha (3.13) = 150°
− Remove the On command
− Connect the gate leads to valves V14, V16 and V12
− Give an On command and make sure, no Run command is given. This causes the
pulse firing logic to work and to generate single firing pulses:
1. Now no current should flow. Check with a scope connected to the fixed AO I-act
(X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3).
2. Check the firing pulses using a current probe
3. Make sure, that ArmAlpha (3.13) = 150°
− If everything is fine, give a Run command
− Give a small current reference using CurSel 43.02 and CurRefExt (43.03). If the
current follows the current reference, everything is fine - see MotCur (1.06). Check

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for the proper amount of current pulses with a scope connected to the fixed AO I-act
(X4:9/10 on the SDCS-CON-4 or X4:5/6 on the SDCS-IOB-3):

Depending on the setting of ArmAlphaMin (20.15) there might be no current at all or

only a very small one. In this case lower ArmAlphaMin (20.15) step by step until a
value around 100° is reached.
− Remove the Run and On command
− In case of problems check the wiring to the CTs, the routing of the fiber optic cables
and the gate leads for open loops or wrong connections
− In case everything is fine and the power part consists of a reverse bridge repeat the
procedure used for the forward bridge. Keep the value of ArmAlphaMin (20.15) and
check for correct connections.
− If current is flowing in forward and reverse direction in a controlled manner set
ArmAlphaMin (20.15) back to default
− Continue the commissioning by using the wizard in DWL

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3ADW000415R0101 DCS800-R Optical Rebuild Kits e a

 Ident. No.: 3ADW000415R0101 Rev A


04.2012

ABB Automation Products

Wallstadter-Straße 59
68526 Ladenburg • Germany
Tel: +49 (0) 6203-71-0
Fax: +49 (0) 6203-71-76 09 *415R0101A2160000*
www.abb.com/motors&drives *415R0101A2160000*