ABBDCS Thyristor Power Converters for DC Drive Systems 25 to 5150 A Operating Instructions DCS 600 MultiDrive

This chapter contains safety instructions which must be complied

with during installation, operation and maintenance of the power

converters series DCS 600 MultiDrive. If these instructions are

not complied with, this may result in injuries (perhaps even with

fatal) or in damage to the power converter, the motor and the

driven machine. Before starting with any work whatsoever at or

with this unit, you must read the information given in this chapter.

Warnings Warnings provide information on states which if the specified

procedure for the state concerned is not meticulously complied

with may result in a serious error, in major damage to the unit, in

injury to persons and even in death.

They are identified by the following symbols:

Danger: High Voltage! This symbol warns you of

high voltages which may result in injuries to persons

and/or damage to equipment. Where appropriate, the

text printed adjacent to this symbol describes how

risks of this kind may be avoided.

● All electrical installation and maintenance work on the thyristor

power converter must be carried out by properly qualified staff

who have been thoroughly trained in electrical engineering.

● The thyristor power converter and its adjacent units must be

properly earthed by qualified professionals.

● You must NEVER perform any work on the thyristor power

converter while it is still switched on. First switch the unit off,

use a measuring instrument to make absolutely sure that the

power converter has really been de-energized, and only then

you may start with the work concerned.

● Due to external control circuits, there may be dangerously

high voltages present at the thyristor power converter even

after the line voltage has been switched off. So always work

at the unit with appropriate caution! Non-compliance with these

instructions may result in injury (or even death!).

General warning: this symbol warns you of nonelectrical risks and dangers which may result in serious or even fatal injury to persons and/or in damage

to equipment. Where appropriate, the text printed adjacent to this symbol describes how risks of this kind

may be avoided.

● When thyristor power converters are in use, the electric motors,

power transmission elements and the driven machines are

working in an extended operating range, which means they have

to cope with a relatively high loading.

● You should have made sure that all units, devices and appliances used are actually suitable for this higher loading.

● If you have to operate the thyristor power converter at a rated

motor voltage and/or a rated motor current significantly below

the figures stated in the thyristor power converter’s output data,

you must take appropriate precautionary measures to protect

the unit against overspeed, overload, breakage, etc., by modifying the software or hardware appropriately.

● For insulation testing, you must disconnect all cables from the

thyristor power converter. You should avoid operating your unit

at values other than the rated data. Non-compliance with these

instructions may cause lasting damage to the thyristor power

converter.

● The thyristor power converter possesses a number of automatic

reset functions. When these functions are executed, the unit will

be reset after an error and will then resume operation. These

functions should not be used if other units and devices are not

suitable for an operating mode of this kind, or if their use might

entail dangerous situations.

Warning of electrostatic discharge:

this symbol warns you against electrostatic discharges which may damage the unit. Where appropriate, the text printed next to this symbol describes

how a risk of this kind may be avoided.

Notes supply information on states requiring particular attention, or

indicate that additional information is available on a specific topic.

For this purpose, the following symbols are used:

CAUTION! Cautions are designed to draw your attention to a

particular state of affairs.

Note A note contains or refers you to additional information available on the particular topic concerned.

Mains connection You can use a switch disconnector (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 disconnector used must be a switch disconnector 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 disconnector must be locked in its

"OPEN" position during any installation and maintenance work.

EMERGENCY STOP

buttons

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 CDP 312 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 intended 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.

How to use this manual The purpose of these operating instructions is to provide detailed

information on how to start up a thyristor power converter from the

DCS 600 series.

Note: If it is not mentioned explicitly all details given in

these Operating Instructions will be valid for series

DCS 600!

Contents of this manual Chapter 1 - Introduction

It describes how to use this manual and the boundary conditions

applying.

Chapter 2 - Start-Up Instructions

We recommend working your way through the Start-Up Instructions

step by step, since in this way you will get to perform all important

parameter setting routines.

Chapter 3 - How to Handle the Control and Display Panel

This chapter describes how to operate the CDP 312 control and

display panel.

Chapter 4 - Signals and Troubleshooting

This chapter describes the available signals and possibilities of display with DCS 600. As far as fault signals are concerned there will

be indicated measures (actions) to be taken for troubleshooting.

Target group This manual is designed to help those responsible for planning, installing, starting up and servicing the thyristor power converter.

These people should possess

• basic knowledge of physics and electrical engineering, electrical

wiring principles, components and symbols used in electrical engineering, and

• basic experience with DC drives and products.

Associated

publications

The DCS 600 documentation includes the following:

System Descriptions DCS 600

Technical Data DCS Thyristor Power Converters

Software Description DCS 600

Service Manual

12-Pulse Manual

Installation Manual

DCS 600 -


 











These Operating Instructions

Incoming inspection After opening this package, you should check whether it contains

the following items:

● DCS 600 thyristor power converter in the configuration

ordered

● DCS 600 publications

● Accessories, including manuals if ordered

● Final test report

Check the consignment for any signs of damage. If you find any,

please contact the insurance company or the supplier.

Check the particulars given on the unit’s rating plate to make sure

prior to installation and start-up that you have received the correct

unit type and unit version.

If the consignment is incomplete or contains any incorrect items,

please contact the supplier.

CAUTION! The thyristor power converter weighs quite a lot and

should therefore not be held by the front cover. Please put the unit

down only on its back (sizes C1 to C3). Always use due care when

handling the unit, so as to avoid injuries or damage.

Storage and transport If the unit had been in storage prior to installation or is transported

to another location, care must be taken to ensure that the environmental conditions are complied with (see "System Description

DCS 600").

Rating plate For purposes of identification, each thyristor power converter is fitted with rating plates, stating the type code and the serial number,

which serve for each unit’s individual identification.

The type code contains information on the characteristics and the

configuration of the unit. The first three digits of the serial number

refer to the year and week of manufacture. The last digits complete

the serial number so as to preclude two units receiving the same

type code and the same serial number.

The group 4 provides information on the unit’s software configuration.

The technical data and specifications are valid as of going to press.

ABB reserves the right to make subsequent alterations.

If you have any questions concerning your drive system, please

contact your local ABB agent.

CAUTION: it is absolutely essential that the applicable accident prevention

regulations be observed by the user (in this context, please also

read the chapter entitled "Safety Instructions")!

How this chapter is structured

For better understanding the individual steps of start-up work are distinguished by

a) frames without any additional marking on the left side:

These steps of start-up work must always be performed (= mandatory start-up work)!

Example:

42.06 = Rated line voltage

This is used to scale those parameters referring to the line voltage, .....

b) frames with marking on the left side (“columns” shaded in grey):

These steps of start-up work have to be performed only when the condition stated

(as heading) applies to the selected drive configuration! After this work has been

completed, the mandatory start-up work has to be continued.

Example:

Set this only for units with a rated current ≥ 2050A in case of control board exchange!

42.07 = Rated power converter current

Enter numerical value from rating plate here

Recommended motor voltages and field voltages

• Motor voltage UA when the following units are used

DCS 601: UAmax = Line voltage * 1.16 (2- quadrant unit)

DCS 602: UAmax = Line voltage * 1.05 (4- quadrant unit)

• Field voltage UF (= max. output voltage) when the following is being used

SDCS-FEX-1: UF = Line voltage * 0.9

If there is a divergence of more than 10 % between the field supply unit’s output

voltage and the rated field voltage UFrated stated on the motor’s rating plate, then the

connecting voltage UN should be reduced, using a matching transformer or a series

resistor Rv: Rv = (0.9 * UN - UF) / IF IF = Rated field current

(Note: also suitable for fine-balancing the maximum motor voltage)

• Field voltage UF when the following is being used

SDCS-FEX-2 /

DCF 503 / DCF 504: UF = Line voltage * 0.6 ... 0.8

• Field voltage UF when the following is being used

DCF 601: UF = Line voltage * 0.5 ... 1.1

Maximally possible output voltage UAmax using

DCF 601 / DCF 602: UAmax = Line voltage * 1.35

Phase sequence when connecting to the mains / Potential isolation

No special phase sequence required for the main connections U1, V1 and W1!

Phase coordination between electronics section and power section not necessary!

For potential isolation and for avoiding ground loops, an isolating transformer should be

installed upstream when an oscilloscope is being used.

Preventing unintended operating states / Shutting the drive down

CAUTION! As laid down in DIN 57100 Part 727 / VDE 0100 Part 727 (Preventing

unintended operating states), shutting the drive down by means of the

signals at the binary inputs DIx is not sufficient in itself as the sole

measure involved for avoiding unintended operating states or shutting

the drive down in the event of danger!

Range of application for the Start-Up Instructions

The Start-Up Instructions are referenced to the parameter settings in their as-delivered

condition (default values) and to the unit wiring as shown in the connection diagram

(see System description DCS 600).

These Operating Instructions only describe the start-up procedure via panel CDP 312

when in LOCAL mode or/and via PC program DRIVES WINDOW.

Method of functioning of the binary input DI5

• Binary input DI5; designation EM STOP

The binary input DI5, e.g. terminal X6:5 of control board SDCS-CON-2, must be

set to logical "1” in order to get no operation of the EMERGENCY STOP function.

This configuration takes into account the requirements of a fail-safe-circuit.

The incoming signal is inverted by means of the Parameter 13.12 thus setting the

internal signal EMERGENCY STOP to logical "0”. If the external signal is "0”,the

EMERGENCY STOP function will be active and the alarm signal A 102 will appear.

The drive will react in accordance with the setting of Parameter 21.04 EME_STOP_

MODE (presetting is: 1 = STOP WITH RAMP). The ramp time is set by Parameter 22.04. After resetting of the signal, i.e. external signal set back to

logical "1”, the ON command has to be repeated.

Software identification

The software identification of the SDCS-CON2 board is in parameter 4.11.

The software identification of the SDCS-AMC-DC board is in parameter 4.2.

The application identification from ABB Lampertheim is [DCS600xx] in parameter 4.3.

Different coded applications are handled and supported from local ABB organizations.

The software of the units series DCS 600 is divided into two parts which are handled

by processors integrated in the respective boards SDCS-CON-2 (Software 15.2xx) and

SDCS-AMC-DC (Software 15.6xx).

The upload of signals from SDCS-CON-2 to SDCS-AMC-DC board are operated by:

• 6 automatic channels

• 11 programmable channels, selectable in group 94 (see Software description - chapter

31)

The 6 automatic channels are used by the functions:

• Display signals at control panel CDP 312

• Monitor signals at DriveWindow Tool

• Data Logger at DriveWindow Tool

If

• more than 6 signals of the SDCS-CON-2 board are selected, or

• the function Signals and Parameter of DriveWindow, or

• the overriding control (AC 80, AC 70…)

is used for monitoring, the signals should be selected in group 94.xx

Note: In the below mentioned tables AMC / CON-2 will be used as type designations

instead of SDCS-AMC-DC / SDCS-CON-2.

• Fixed (defined) values

Cyclic transmission is used for fixed values. Fixed values are:

Cyclic transmission Parameter Function Cyclic transfrom --> to mission time

AMC --> CON-2  Internal Control Word 2 ms

AMC --> CON-2  Reserved 2 ms

AMC --> CON-2 2.13 Torque reference value 2 ms

AMC --> CON-2 5.06 Analogue output 1 2 ms

AMC --> CON-2 5.07 Analogue output 2 2 ms

AMC --> CON-2  Local reference 3 8 ms

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.

Check whether protective measures, earthing, screening, etc. have been taken in

accordance with the system conditions involved.

Check the rated value of the supply voltage for the electronics and the fan:

• matching transformer necessary when:

- electronics supply is not equal to 115 V/230 V

- single-phase-fan supply is not equal to 230 V

- three-phase-fan supply is not within the range of 400 V .... 690 V (star/delta

connection).

Check the rated value of the supply voltage for the armature-circuit converter’s

power section; the particulars given on the rating plate must be > than the rated

line voltage.

If this condition is not satisfied, then the following applies:

- use an isolating transformer, or

- use a suitable unit.

Check the rated value of the supply voltage for the field supply unit.

(Particulars on rating plate > rated line voltage?

Is an auxiliary transformer or perhaps a series resistor necessary?)

Check the wiring, fusing, the cross-sectional areas of the cables.

Check the system’s EMERGENCY STOP for proper functioning! Set the system-side

monitoring functions, and activate them. Check whether auxiliaries, such as motor fans

or unit fans, function properly; while doing this, also check for correct direction of rotation and voltage level as well!

2.2 Scaling intra-unit signals

Make sure that the existing electronics supply voltage has been set on the SDCSPOW-1 power supply board as well, using the SW1 switch.

If an encoder is being used as the speed feedback device, make sure that the correct

supply voltage has been set on the boards

SDCS-POW-1: ⇒ X3: / X4: / X5: SDCS-IOB-3: ⇒ S4

El Switch on the power supply to the electronics section.

The display of the Control Panel CDP 312 / DRIVES WINDOW may show a

fault or an alarm signal or the seven segment display may indicate an error code

as a sequence of characters and digits.

NOTE: For Software downloading observe the relevant instructions

given on the ”read_me” file of the corresponding Software disc!

Set this only for units with a rated current 25 ... 2000A in case of control board

exchange!

15.02 = 22

After successful saving of the altered data this Parameter 15.02 will be

reset to zero.

Set this only for units with a rated current ≥ 2050A in case of control board

exchange!

42.07 = Rated power converter current

Enter numerical value from rating plate here

42.08 = Rated power converter supply voltage / coding of voltage

 measurement (see technical data 5-12)

Enter numerical value from rating plate here

42.09 = 45 degrees Celsius

Temperature monitoring of power section

42.10 = C4 ⇒ Size C4 has been selected

Coding for unit type

42.11 = 1 : Single bridge (2-Q) converter ⇒ on rating plate: DCS 601 xxxx

4 : Double bridge (4-Q) converter⇒ on rating plate: DCS 602 xxxx

Coding for power section (bridge) type

CAUTION! Please don't forget!

Save the altered data of unit type, i.e. Parameters 42.07 ... 42.11:

15.02 = 22

After successful saving of the altered data this Parameter 15.02 will be

reset to zero.

Presetting of the EMERGENCY STOP function via binary input DI5:

Connection of this signal has to correspond with the configuration of a fail-safecircuit, i.e. if the signal applied to DI5 is "0” (parameter 12.16 EME STOP SEL is set to

DI5), the EMERGENCY STOP function will operate (will be activated).

13.12 = INVERTED

Inverting the incoming signals

21.04 = e.g. COAST STOP

The drive will coast to stop with this setting

22.04 = e.g. 1 ⇒ 1 sec

Setting of the ramp time with EMERGENCY STOP function provided that the

Parameter 21.04 = RAMP STOP has been selected

Input of data concerning the connected I/O boards:

98.08 = Make settings which correspond to the hardware configuration used.

Input of data is necessary as the software will check the availability of the I/O

bords as specified by settings.

Input of motor data and line voltage:

41.03 = Rated motor field current

Max. field current of the motor as indicated on rating plate. This is used to scale

those parameters referring to the motor field current, such as field current limitation

and field current monitoring.

42.06 = Rated line voltage

This is used to scale those parameters referring to the line voltage, such as line

undervoltage.

99.02 = Rated motor voltage

Scaling speed for speed control with EMF feedback.

99.03 = Rated motor current

This is used to scale those parameters referring to the rated motor current, such

as current limitation or torque limitation.

99.05 = Speed at field weakening point

Maximum speed of motor within armature control range and flux control.

Scaling speed for speed control with EMF feedback.

Note: Calculation of the nominal torque 4.22 is based on this parameter.

41.19 = Int EMF REF

Reference for voltage control in field weakening range.

50.01 = Speed scaling

Speed of the motor to be scaled to 20 000.

This scaling is used for overriding control and for internal dataprocessing, i.e.

scaling of the speed dependent parameters, such as min. and max. values.

Note 1: The Speed scaling must be set in the range of 87%…500% of the motor nominal speed (99.05).

Note 2: The Software DRIVES WINDOW and the Control Panel CDP 312 will

always display physical units!

2.3 Presetting the field supply unit

Make sure that existing supply voltages for power section, field supply unit (field

exciter) and field winding, fan, etc. match the rated data of the components used.

Switch ON power.

DANGER: System components now energized!

Please wait a few moments. During this time, the unit compares the phase sequence

set in the parameter with that obtaining at the power section.

If the unit outputs the "Phase sequence fault of power section” signal (F 38 PHAS

SEQU):

- switch off unit completely and disconnect from the mains, interchange two phases

at the input, and start again from the beginning of this chapter.

or

- enter: 42.01 = R-T-S and then acknowledge fault signal.

Unit will automatically adapt to phase sequence; this signal is to be interpreted as

information to the effect that the fans' direction of rotation may be wrong for size-C3

or size-C4 units (observe direction of arrow on the fan).

Only for uncontrolled field supply with SDCS-FEX-1!

15.05 = 1

Check field current and field voltage by measuring them.

Switch OFF power!

 Continue with Chapter 2.4

Only for controlled field supply with SDCS-FEX-2 or DCF 503/DCF 504!

15.05= 2

41.03 = Rated motor field current has already been set

44.17= Field current for "Under-excitation" signal

Check field current and field voltage by measuring them;

if necessary, correct field current with 41.03

15.02 = 5

Activates the field current controller’s auto-tuning function.

Action has been completed when ”0” (zero) is shown on the

display.

Note: use online mode in DriveWindow

If the unit aborts the auto-tuning routine with the signal 15.02 = -1, the probable

cause of this can be read out of Parameter 6.02 and has to be eliminated as far

as possible (supply, switching sequence, field contactor wiring etc.).

Afterwards repeat the auto-tuning routine.

If necessary, perform manual balancing.

Switch OFF power

15.05= 2

41.03 = Rated motor field current (first field exciter) has already been set.

44.17= Field current (first field exciter) for "Under-excitation" signal

Switch OFF power!

Before adjustment of the armature-circuit power converter is continued

(Chapters 2.4 etc.), first perform the start-up routine for the DCF 601 or

DCF 602 field supply unit.

Make sure the correct wiring between 3-phase Field exciter DCF 601, DCF 602 and the

overvoltage protection unit DCF 505, DCF 506

• powercircuit

• Digital feedback signal of DCF 506

El Switch ON DCF 601, DCF 602.

DANGER: System components now energized!

15.16 = 5 (Field Exc)

99.02 = 02 Rated motor field voltage

99.03 = 03 Rated motor field current

(same as in 41.03 of DCS armature converter)

50.03 = 4

43.13 = 4 or higher (Bridge reversal time)

43.06 = 0

28.22 = 500% (disable overvoltage monitoring)

Switch ON DCF 601, DCF 602.

check field current and field voltage by measuring them

Disable reference

15.02= 5 (start autotuning current controller)

Activates the field current controller’s auto-tuning function.

Action has been completed when ”0” (zero) is shown on the

display.

Note: use online mode in DriveWindow

If the unit aborts the auto-tuning routine with the signal 15.02 = -1, the probable cause

of this can be read out of Parameter 6.02 and has to be eliminated as far as possible

(supply, switching sequence, field contactor wiring etc.). Afterwards repeat the autotuning routine. If necessary, perform manual balancing.

Switch OFF power!

X16: Field exciter communication see chapter 2.10 - Start-up of the serial communication -part DCS 600 and DCF 600 by FEXlink

DCF converter 15.21 = ? DCS converter 15.05 = ?

15.22 = ? 41.03 = ? (for display purpose)

46.07 = ?

Note: The field current control parameters of the armature converter (44.02, 44.08, ...)

are not used.

Make sure that static current limitation Bridge 1 (20.12) and Bridge 2 (20.13; with

4Q-unit) have been set to the same value; values of all parameters for current

reference limitation must be bigger than 20 %; conditions have been satisfied if

default setting has been taken as starting point; setting to maximally required motor

current is recommended.

Drive must not turn! Do not preset an external reference!

15.02 = 3

Activate the current controller’s auto-tuning function.

Start the next two steps within the next 20 seconds!

Switch ON power.

DANGER: System components now energized!

Start drive.

When the display shows ”0” (zero) stop drive; it may happen that the unit runs

armature-circuit current since EMF control is active.

Note: use online mode in DriveWindow

Switch OFF power!

If the unit aborts the auto-tuning routine with the signal 15.02 = -1, the probable

cause of this can be read out of Parameter 6.02 and has to be eliminated as far

as possible (supply, switching sequence, field contactor wiring, missing field contactor

etc.).

Afterwards repeat the auto-tuning routine.

If necessary, perform manual balancing.

Only if the unit aborts the auto-tuning routine with a fault signal FIELD REMOVAL?!

Read out values of:

41.11 = ......... 41.12 = ......... 43.02 = ......... 43.03 = ............ 43.06 = .........

15.05 = 0

El Switch OFF power supply to the electronics section!

Make sure that no field current is flowing, e.g. by removing the supply fuses!

El Switch the electronics section’s power supply on again!

Drive must not turn! Do not preset an external reference!

15.02 = 3

Activate the current controller’s auto-tuning function.

Start the next two steps within the next 20 seconds!

Switch ON power.

DANGER: System components now energized!

Start drive.

When the display shows ”0” (zero) stop drive; it may happen that the unit runs

armature-circuit current since EMF control is active.

If the unit aborts the auto-tuning routine with the signal 15.02 = -1, the probable

cause of this can be read out of Parameter 6.02 and has to be eliminated as far

as possible (supply, switching sequence etc.).

Afterwards repeat the auto-tuning routine.

If necessary, perform manual balancing.

Switch OFF power!

Read out values of:

41.11 = ......... 41.12 = ......... 43.02 = ......... 43.03 = ............ 43.06 = .........

Use values of 41.11 and 43.06 from the first auto-tuning routine.

Re-activate the field unit used by entering:

a) 15.05 = 1

or

b) 15.05 = 2

and install the supply fuses removed before

2.5 Speed feedback balancing

Activate EMF speed feedback:

50.03 = CALC BY EMF

Select no field weakening mode:

15.06 = FIX

50.01 = Desired speed / or motor rating plate

Scale speed control circuit to maximum speed.

Switch ON power.

DANGER: System components now energized!

Start drive.

Increase reference value in LOCAL mode to 10 % of the maximum speed.

Drive should run up to 10 % of the rated voltage.

Continue with one of the following sections:

• Only when an analog tacho is being used!

• Only when an encoder (pulse encoder) is being used!

• Only when the EMF signal is being used as speed feedback!

Only when an analog tacho is being used!

Connect measuring instrument:

- to X3: 1... 3 or X1: 1... 3

+ to X3: 4 or X1: 4

Check to make sure that the tacho voltage does not exceed the input voltage range

selected with maximum speed.

Turn Potentiometer R2716 [on SDCS-CON-2 board] or R9 [on PS5311 board; if

SDCS-IOB-3 board is used with PS5311] to minimum (left-hand stop).The

measured value must have a positive sign; if necessary interchange tacho cables.

Stop the drive and switch OFF power!

50.03 = ANALOGUE TAC

Analog tacho is used for speed control.

Switch ON power.

DANGER: System components now energized!

Start drive.

Increase reference value in LOCAL mode to 10 % of the maximum speed.

Drive should run up to 10 % of the rated voltage.

Use Potentiometer R2716 [on SDCS-CON-2 board] or R9 [on PS5311 board] to

set the tacho voltage to 10 % of the maximum tacho voltage.

Stop the drive and switch OFF power!

Only when an encoder (pulse encoder) is being used!

3.07 = Content of pulse counter *)

If the shape of the curve corresponds to the diagram below, this means

the wiring is correct and the pulses will be correctly evaluated [see

also documentation entitled “Technical Data”, Chapter I/O boards].

*) This Parameter must be transmitted from the SDCS-CON-2 board to the SDCS-AMC-DC board!

Fig.: Curve shape of the encoder’s pulse counter for sense of rotation "forwards”

Switch OFF power, thus stopping the drive; drive coasts.

50.04 = Number of encoder pulses

As specified on the encoder’s rating plate

50.03 = CON- ENCODER

The encoder connected to the SDCS-CON-2 board is used for speed control.

Switch ON power.

DANGER: System components now energized!

Start drive.

Increase reference value in LOCAL mode to 10 % of the maximum speed

Drive should run at 10 % of the desired speed;

if possible, check with manual tacho.

Stop the drive and switch OFF power!

Only when the EMF signal is being used as speed feedback!

Drive should run at 10 % of the desired speed;

if possible, check with manual tacho.

Stop the drive and switch OFF power

Balancing the field supply unit and the EMF controller

When matching the field supply unit to the system conditions, differences in the procedures must be taken into account; these different procedures result from the operating

mode used. Only the work of that section has to be performed which deals with

the operating mode actually used in your system!

Constant field current control ⇒ Section 2.6.1

Field weakening control with setting range smaller than 1 : 1.5 ⇒ Section 2.6.2

Field weakening control with setting range larger than 1 : 1.5 ⇒ Section 2.6.3

2.6.2 Field weakening control with setting range < 1 : 1.5

CAUTION: Not permitted when Chapter 2.5 was quit with EMF control!

15.06 = EMF CON

Field weakening function activated

99.05 = Speed at field weakening point according to motor rating plate

41.19 = ? reference armature voltage scaled to Supply voltage

Switch ON power.

DANGER: System components now energized!

Start drive.

Measure motor voltage with the ARM_VOLT_ACT signal, Parameter 1.14 *).

Increase speed reference value in LOCAL mode slowly while observing the

motor voltage.

The motor voltage must not exceed the recommended motor voltage; see General

notes at the beginning of this chapter.

Check that field is being weakened.

Do not exceed the maximum motor speed permitted. When an analog tacho is being

used, the display at the CDP 312 panel is not yet necessarily correct.

The motor voltage must not exceed the recommended motor voltage; see General

notes at the beginning of this chapter.

If the field is not being properly weakened, or not being weakened at all, perform the

work of section "Field weakening control with setting range larger than 1 : 1.5” !

*) This Parameter must be transmitted from the SDCS-CON-2 board to the SDCS-AMC-DC board!

Measure speed with manual tacho;

check rated speed when an analog tacho is being used;

if necessary, correct with Potentiometer R2716 [on SDCS-CON-2 board] or

R9 [on PS5311 board].

Stop the drive and switch OFF power!

2.6.3 Field weakening control with setting range > 1 : 1.5

CAUTION: Not permitted when Chapter 2.5 was quit with EMF control!

 15.06 = EMF CON

Field weakening function activated.

46.01 = 0

46.02 = 0

EMF controller switched off by limitation.

46.07 = EXT REF

Links up the Parameter 45.01 as the flux

reference value; this will only be possible, if there

is still no connection to an APC.

45.01 = 100 % (in the PC program DRIVES WINDOW = 99.98 %)

Flux reference value set to 100 %

The next steps serve to determine the motor’s field characteristic. For this purpose,

the reference setting in ”LOCAL” mode is used to adjust a speed n which is within

the motor's basic speed range and can be easily converted into 90 %, 70 % and 40 %.

Example: if n is selected so as to produce a motor voltage of 300 V, then 90 % will

correspond to 270 V, 70 % to 210 V and 40 % to 120 V.

For determination of the motor's field characteristic the actual values EMF_V

(Parameter 1.17) and FIELD1 CUR_ACT (Parameter 3.19) will be required.

Both values have to be set by means of the Control Panel in ”ACT” (Actual Signal

Display) mode and must be transmitted from the SDCS-CON-2 board to the SDCSAMC-DC board. The Parameter 94.11 already includes Parameter 3.19 as default

setting, i.e. only the value of Parameter 1.17 has to be set to e.g. 94.01 = 117:

94.01 = 117 (only required, if the values are to be displayed on DRIVES WINDOW!).

Switch ON power.

DANGER: System components now energized!

Start drive.

Increase speed reference value in LOCAL mode until the Parameter 1.17 will show

a value of 100 % for RL EMF VOLT ACT (⇒ 300 V in the example) as desired in the

aforementioned steps.

45.01 = decrease so that RL EMF VOLT ACT (1.17) is 90 %.

Flux and thus the field current as well are reduced.

How to proceed using the Control Panel:

1. decrease 45.01 (in steps of 5 at a time)

2. press ACT, read off Parameter 1.17

3. press PAR and correct 45.01 if necessary (then continue with 2.)

Read out and note down value of:

3.19 = ......... % (value for 41.16; will later be entered

45.01 = decrease so that RL EMF VOLT ACT (1.17) is 70%.

Flux and thus the field current as well are reduced.

Proceed as described in (1. / 2. / 3.) above!

Read out and note down value of:

3.19 = ......... % (value for 41.15; will later be entered)

45.01 = decrease so that RL EMF VOLT ACT (1.17) is 40%.

Flux and thus the field current as well are reduced.

Proceed as described in (1. / 2. / 3.) above!

Read out and note down value of:

3.19 = ......... % (value for 41.14; will later be entered)

Stop the drive and switch OFF power!

45.01 = 100 %

46.01 = 10

46.02 = - 99

46.07 = SEL REF

As-delivered values (default values) for all 4 parameters restored.

41.19 = ? reference armature voltage scaled to Supply voltage

41.16 = enter the 1st noted down value of 3.19

41.15 = enter the 2nd noted down value of 3.19

41.14 = enter the 3rd noted down value of 3.19

Linearization function matched to field circuit.

99.02 = 90 % of the rated motor voltage.

99.05 = 90 % of the value on the motor rating plate.

These settings provide a bigger safety margin for the motor voltage during start-up.

Only if analog tacho is used as speed feedback!

Switch ON power; start drive.

DANGER: System components now energized!

Increase the reference value in LOCAL mode slowly up to maximum speed.

Check motor voltage; if value has been set with 99.02, motor voltage must

remain constant, or must not exceed this value.

Measure speed with manual tacho; balance maximum speed with Potentiometer

R2716 [on SDCS-CON-2 board] or R9 [on PS5311 board].

Stop the drive and switch OFF power!

2.7 Balancing the speed controller, plus fine-balancing the EMF

The balancing procedure indicated below assumes that the coupled load will withstand speed jumps. If this is not allowed for the load, a different setting of the listed

parameters will be required.

Reference values switching over between the internal potentiometers POT1 and POT2

(Parameters 17.01 and 17.02) will be used for balancing the controllers. Parameter

PERIOD 17.03 defines the period of switch-over; value 1 corresponds to 10 msec.

15.02 = 9

Switch-over of reference value for the speed controller, also suitable for the EMF

controller.

17.04 = SQWAVE

Selection of the reference value switching over between POT1 and POT2.

22.01 = 0,1 s

Ramp-up time of ramp-function generator

22.02 = 0,1 s

Ramp-down time of ramp-function generator

Adjusting the potentiometers for speed controller balancing:

During acceleration/ braking, the drive should reach the current limitation, if necessary

increase the value of POT1.

Scaling of 17.01 and 17.02 ⇒ 20 000 corresponds to 100 % speed.

17.01 (POT1) = 10%...20% max. speed

17.02 (POT2) = 0

17.03 (PERIOD) = Adapt as necessary.

Switch ON power; start drive.

DANGER: System components now energized!

Drive should run at speed values corresponding to POT1 and “0”.

For assessing control quality, the figure below can be used.

Oscillograph speed feedback via D/A output, or if one is to hand, use program DRIVES

WINDOW to depict it via the Monitor menu and Parameter 1.04.

t

A

B

C D E F

Fig.: Transient response of controller

A: reference value jump

B: undercompensated; reset time and P-gain too small

C: undercompensated; P-gain too small

D: normal

E: slightly overcompensated; when a higher dynamic response is required

F: overcompensated; short reset time and a high P-gain

For this purpose, the following parameters at the speed controller must be adapted:

24.03 (KPS) = desired response (behaviour) of controller

24.09 (TIS) = desired response (behaviour) of controller

Only when fine-balancing of the EMF controller is wanted!

(Necessary when work as per section 2.6.3. has been performed)

 For assessing control quality, the Fig. entitled "Transient response of controller"

( ⇒ beginning of this chapter) can be used.

41.19 = ? reference armature voltage scaled

to Supply voltage

- If fine-balancing of the EMF controller is wanted,

 potentiometers’ settings must be adapted:

17.01 (POT1) approx. 10 % bigger than speed at

field weakening point

17.02 (POT2) approx. 10% smaller than speed at

field weakening point

The following parameters at the EMF controller

must be adapted:

46.03 (EMF_KP) = desired response (behaviour) of controller

46.04 (EMF_KI) = desired response (behaviour) of controller.

Stop the drive and switch OFF power!

15.02 = 0

17.01 = 0

17.02 = 0

99.02 = Rated motor voltage as set in Chapter 2.2

99.05 = Speed at rated motor voltage as set in Chapter 2.2.

2.8 Matching the thyristor power converter unit to the system conditions concerned

- Ramp function generator

- Binary inputs and outputs

- Limit-value messages

- Additional functions

- Link up APC or Fieldbus

2.9 Manual balancing of the controllers

Balancing of the controllers for the armature-circuit current and the field current can be

performed by auto-tuning. If this is not possible for some reason, balancing of these controllers as well as balancing of the controllers for speed and EMF has to be performed

by the skilled technical start-up personnel.

See also the separate Software Description DCS 600, chapter ”Manual Tuning”