II F 1-i

3ADW000139R0401_DCS600_CraneDrive_System description_e_d
DCS Thyristor Power Converters
for DC Drive Systems
25 to 5200 A
System Description
DCS 600 CraneDrive
II F 1-ii
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
List of contents
II F SYSTEM DESCRIPTION
1 DCS 600 CraneDrive ................................... II F 1-1
2 DCS 600 CraneDrive components overviewII F 2-1
2.1 Environmental conditions .............................................. II F 2-3
2.2 DCS 600 power converter modules .............................. II F 2-4
2.3 DCS 600 overload capability ......................................... II F 2-7
2.4 Field Supply .................................................................. II F 2-9
2.5 Options for DCS 600 CraneDrive converter modules . II F 2-11
In-/output signals........................................................ II F 2-11
Serial interfaces
Operation by the panel .............................................. II F 2-14
Panel (control and display panel) .............................. II F 2-15
Operation by the PC .................................................. II F 2-16
Drive control ............................................................... II F 2-16
2.6 Options ........................................................................ II F 2-18
Line reactors for armature (DCS600) and
field (DCF600) supply ................................................ II F 2-18
Aspects of fusing for armature circuits and field
supplies of DC drives .............................................. ...II F 2-20
Semiconductor type F1 fuses and fuse holders for
AC and DC power lines ............................................. II F 2-22
Fuses F3.x fuses and fuse holders for 2-phase
field supply ................................................................. II F 2-22
Transformer T3 for field supply .................................. II F 2-22
Commutating reactor ................................................. II F 2-23
Auxiliary transformer T2 for electronic system /
fan supply ................................................................... II F 2-23
Residual current detection ......................................... II F 2-23
EMC filters ................................................................. II F 2-24
3 Overview of Crane Software ...................... II F 3-1
3.1 Basic structure of DCS 600 CraneDrive ....................... II F 3-1
3.2 Control modes ............................................................... II F 3-1
3.3 Start, Stop and Fault Reactions .................................... II F 3-2
3.4 Crane functions ............................................................. II F 3-3
3.5 Speed Control ............................................................... II F 3-4
3.6 Torque Control .............................................................. II F 3-4
3.7 HMI (Human Machine Interface) ................................... II F 3-4
3.8 Torque Generation ........................................................ II F 3-5
3.9 Software diagrams ........................................................ II F 3-6
4 Connection examples................................. II F 4-1
4.1 Control connections ...................................................... II F 4-1
4.2 Wiring diagram .............................................................. II F 4-6
How the DCS 600 CraneDrive Documentation
System works
This is to give you an overview how the system of
information for DCS 600 CraneDrive converters is
built up. The shaded part indicates the volume within
the total system you are just now working with. In
addition you see all other available documents for the
same system.

DCA 600 Enclosed
3ADW000121
DCS(F) 600
3ADW000080
3ADW000165

DCS 600 Crane
3ADW000072
DCA 600 ...
3ADW000091
DCS 500/600
3ADW000093
Technical Data
DCS 600
3AST000953R0125
System Description System Description
Installation Man.
Service Manual
Volume III
Volume II F
Volume VI F1
Volume VI A
Volume II F1
CraneDrive
Firmware manual
Volume V F2
II F 1-1
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
1 DCS 600 CraneDrive - the power converter
state-of-the-art technology
flexible design
user-friendly
Unit range
The range comprises of 5 sizes, C1, C2, A5, A6 and A7.
We can deliver both modules and standard cubicles.
Basic hardware components
Thyristor bridge(s) (from size A5 with installed
branch fuses)
Temperature monitor for the thyristor bridge(s)
Fan
Integrated power supply for the electronics
Microprocessor board
AMC (Application Motor Control) board with DSP
(Digital Signal Processor) for drive control and
DDCS link
Additional components integrated in the module
Field supply converter
uncontrolled full wave diode bridge, 6A or
half-controlled diode/thyristor bridge, 16A
Control panel
Moreover, the accessories listed below can be used
to individually customize the drive package in ac-
cordance with the application intended
External field supply units
Additional I/O boards (isolated)
Interface modules for various communication pro-
tocols
EMC filter
PC programs
C1 - Module DCA cubicle
ABBs long years of experience with variable-speed DC
drives, plus use of the latest state-of-the-art technolo-
gies, have been combined to create this product. The
DCS 600 CraneDrive contains a complete program
with ratings between 25 A and 5200 A as a power
converter module. It is suitable for all commonly used
three-phase systems.
All our products are CE approved.
The DC drives factory of ABB Automation Products,
Drives Division in Lampertheim has implemented and
maintains a quality management system according to
DIN EN ISO 9001 and an environmental manage-
ment system according to DIN EN ISO 14001.
DCS 600 CraneDrives are approved according to UL
(Underwriters Laboratory).
They also comply with the relevant EMC standards for
Australia and New Zealand and are C-Tick marked.
DCS 600 CraneDrive converter units are suitable for
standard and system drive applications.
Appropriate PC programs ensure that the drives are
engineered for user-friendly operator control.
DIN EN ISO 9001
DIN EN ISO 14001
II F 1-2
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Design and commissioning tools
DriveWindow
PC program for commissioning and maintenance un-
der Windows

for:
Parameter setting
Fault detection
Trending
Data logger
Fault logger
Local operation (Drives Panel)
CDP 312 removable control and display panel with
plain text display for:
Drive control signal
Parameter setting
Fault detection
Parameter uploading and downloading
Local operation
Monitoring functions
Self-test
Fault logger
Motor protection
In the event of:
Speed feedback error
Overtemperature
Overload
Overspeed
Zero speed
Armature overcurrent
Armature ripple
Armature overvoltage
Minimum field current
Field overcurrent
Power converter protection
Overtemperature
Software errors (watchdog function)
Incorrect supply protection
Mains overvoltage and undervoltage
Auxiliary undervoltage
Incorrect mains phase sequence (only inform.)
Basic functions
All units are provided with the same digital control
boards and software. The DCS 600 CraneDrive flexi-
bility allows the user to configure functions of the drive
easily, suitable for different applications. Functions of
the DCS 600 CraneDrive are normally activated by
parameters.
The basic software includes the following options:
Processing the speed reference with a speed ramp
generator (S-ramp capability, accel/decel ramp)
Processing the speed feedback
Speed controller
Torque reference processing
Current controller
Field weakening
Automatic/manual field reversal
Autotuning of current controller
Speed monitor
Drive control logic
Remote/local operation
Electrical disconnect (category 0)
Electronic circuits are not sensitive to line phase
sequence
Electrical and mechanical brake control
Motor overload supervision
Dual field
Programmable analogue outputs
Field supply
Master follower via fibre optics
Controlling and operating
via I/O's
analogue and digital inputs and outputs
via bus systems
e.g.: Profibus, Modbus Plus, AF100 etc.
via HMI (Human Machine Interface)
Outputs:
Alarms
Faults
Status information
Parameter setting
Local control of the drive
II F 1-3
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
DCS 600 CraneDrive
ABBs dedicated crane drive offers a standard range of
functions, which ensure safer and faster crane opera-
tions for both I/O stand-alone and fieldbus controlled
drives.
This is enabled by DCS 600 family benefits and a
proven standard crane software.
Available both for DCS 600 converter modules and
DCA 600 enclosed converter and line-ups.
DCS 600 CraneDrive benefits:
Wide power range.
Ready-to-use with proven modular crane function-
ality.
Easy installation and start-up reduces the total project
costs.
Smooth crane operation keeps the cost of damaged
goods low.
Accurate torque response increases the operational
productivity.
Small size and weight of the converter.
Small size and weight of the DC motor.
Low inertia of the DC motor.
Cost advantage for revamping of existing DC motor
installation.
Common control and monitoring structure with
ACS 600 CraneDrive.
Skilled local support people available in many coun-
tries worldwide.
Flexible User Interface
Joystick Interface. For control from a driver's cabin
with step or continuous speed reference.
Pendant Control. For low speed cranes controlled
from the floor with step button or motor potentiome-
ter reference.
Radio Control. For cranes controlled from the floor
with step or continuous speed reference.
Fieldbus Communication. Interface for several field-
bus modules when a PLC is used for controlling the
crane drive.
Limit Switch Supervision. Interfacing of pre and end
limits to ensure the crane works within a safe envelope.
Other Crane products
Grab control
Sway control
These crane products are supporting DCS 600 Crane-
Drive
The cost effective crane
drive with safety and per-
formance already built in.
CraneDrive functions
Mechanical brake control
Fast stop
Torque proving
Speed monitor
Torque monitor
Joystick interface
Limit switch supervision
II F 1-4
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
II F 2-1
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
2 DCS 600 CraneDrive Components Overview
The DCS 600 CraneDrive power converter range is a
system of components and complete standard cabinets to
control DC motors. It consists of individual components,
based on the DCS 600 power converter modules. This
chapter provides a brief description of the DCS 600
CraneDrive components available for matching the drive
with the conditions on site.
This overview has been designed to help you to familiarize yourself
with the system; its main components are shown in the diagram above.
The systems heart is the DCS 600 converter module.
Fig. 2/1: DCS 600 CraneDrive Components overview for armature converters
DCS 600 Armature converter
DCF 601 / 602
X
1
X
2
X
1
7
A
M
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II F 2-2
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
The DCF 600 field supply converter range is a system of
components and complete standard cabinets to control
the field supply of DC motors. It consists of individual
components, based on the DCS 600 power converter
modules. The difference to the armature converter is only
the modified power interface board SDCS-PIN-1x (if
used) and the reduced range of current and voltage types
(see table 2.2/2). The function for field supply will be
selected by software parameters.
Note: Armature and field converters use the same firmware.
This overview has been designed to help you to familiarize yourself
with the system; its main components are shown in the diagram above.
The systems heart is the DCF 600 field supply converter module.
Fig. 2/2: DCS 600 CraneDrive Components overview for field supply converters
DCF 600 Field supply converter
This overview has been designed to help you to familiarize yourself
with the system; its main components are shown in the diagram above.
The systems heart is the DCF 600 field supply converter module.
A
M
C
-
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C
D
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II F 2-3
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
2.1 Environmental Conditions
System connection
Voltage, 3-phase: 230 to 1000 V acc. to IEC 60038
Voltage deviation: 10% continuous; 15% short-time *
Rated frequency: 50 Hz or 60 Hz
Static frequency deviation: 50 Hz 2 %; 60 Hz 2 %
Dynamic: frequency range: 50 Hz: 5 Hz; 60 Hz: 5 Hz
df/dt: 17 % / s
* = 0.5 to 30 cycles.
Please note: Special consideration must be taken for voltage deviation
in regenerative mode.
Degree of protection
Converter Module and options
(line chokes, fuse holder,
field supply unit, etc.): IP 00
Enclosed converters: IP 20/21/31/41
Paint finish
Converter module: NCS 170 4 Y015R
Enclosed converter: light grey RAL 7035
Fig. 2.1/1: Effect of the site elevation above sea level
on the converters load capacity.
Current reduction to (%)
Fig. 2.1/2: Effect of the ambient temperature on the
converter module load capacity.
Current reduction to (%)
Regulatory Compliance
The converter module and enclosed converter components are designed for use
in industrial environments. In EEA countries, the components fulfil the require-
ments of the EU directives, see table below.
North American Standards
In North America the system components fulfil
the requirements of the table below.
70
80
90
100
110
30 35 40 45 50 55C
50
60
70
80
90
100
1000 2000 3000 4000 5000m
Environmental limit values
Permissible cooling air temperature
- at converter module air inlet: 0 to +55C
with rated DC current: 0 to +40C
w. different DC curr. acc. Fig. 2.1/2: +30 to +55C
- Options: 0 to +40C
Relative humidity (at 5...+40C): 5 to 95%, no condensation
Relative humidity (at 0...+5C): 5 to 50%, no condensation
Change of the ambient temp.: < 0.5C / minute
Storage temperature: -40 to +55C
Transport temperature: -40 to +70C
Pollution degree (IEC 60664-1, IEC 60439-1): 2
Site elevation:
<1000 m above M.S.L.: 100%, without current reduction
>1000 m above M.S.L.: with current reduct., see Fig. 2.1/1
Size Sound pressure level L
P
Vibration
(1 m distance)
as module enclosed conv. as module enclosed conv.
C1 59 dBA 57 dBA g, 2...150 Hz
C2 75 dBA 77 dBA g, 2...150 Hz
A5 73 dBA 78 dBA g, 2...150 Hz
A6 75 dBA 73 dBA g, 2...150 Hz
A7 82 dBA 80 dBA g, 2...150 Hz
0.5 g, 5...55 Hz
1 mm, 2...9 Hz
0.3 g, 9...200 Hz
e v i t c e r i D n o i n U n a e p o r u E e c n a r u s s A s ' r e r u t c a f u n a M
s d r a d n a t S d e z i n o m r a H
e l u d o m r e t r e v n o C r e t r e v n o c d e s o l c n E
e v i t c e r i D y r e n i h c a M
C E E / 7 3 / 8 9
C E E / 8 6 / 3 9
f o n o i t a r a l c e D
n o i t a r o p r o c n I
1 - 4 0 2 0 6 N E
] 1 - 4 0 2 0 6 C E I [
1 - 4 0 2 0 6 N E
] 1 - 4 0 2 0 6 C E I [
e v i t c e r i D e g a t l o V w o L
C E E / 3 2 / 3 7
C E E / 8 6 / 3 9
y t i m r o f n o C f o n o i t a r a l c e D
1 - 1 - 6 4 1 0 6 N E
] 1 - 1 - 6 4 1 0 6 C E I [
] - - C E I [ 8 7 1 0 5 N E
l a n o i t i d d a e e s
4 6 6 0 6 C E I
1 - 4 0 2 0 6 N E
] 1 - 4 0 2 0 6 C E I [
1 - 9 3 4 0 6 N E
] 1 - 9 3 4 0 6 C E I [
e v i t c e r i D C M E
C E E / 6 3 3 / 9 8
C E E / 8 6 / 3 9
y t i m r o f n o C f o n o i t a r a l c e D
l l a t a h t d e d i v o r P (
s n o i t c u r t s n i n o i t a l l a t s n i
e l b a c g n i n r e c n o c
d n a g n i l b a c , n o i t c e l e s
d e t a c i d e d r o s r e t l i f C M E
) . d e w o l l o f e r a r e m r o f s n a r t
3 - 0 0 8 1 6 N E
] 3 - 0 0 8 1 6 C E I [
3 - 0 0 8 1 6 N E
] 3 - 0 0 8 1 6 C E I [
h t i w e c n a d r o c c a n i
2 3 0 0 0 0 W D A 3
e c n a d r o c c a n i
/ 2 3 0 0 0 0 W D A 3 h t i w
1 9 0 0 0 0 W D A 3
Standards Rated
supply
voltage
Converter module Enclosed converter
to 600 V UL 508 C
Power Conversion
Equipment
CSA C 22.2 No. 14-95
Industrial Control
Equipment,
Industrial Products
Available for converter
modules including field
exciter units.
Types with UL mark:
see UL Listing
www.ul.com /
certificate no.
E196914
or on request
UL/CSA types: on request
> 600 V
to
1000 V
EN / IEC xxxxx see
table on the left
Available for converter
modules
including field exciter
units.
EN / IEC types: on request
(for details see table on the
left)

II F 2-4
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
2.2 DCS 600 Power Converter Modules
The power converter modules are modular in construc-
tion. They are based on the housing, which contains
the power section with the RC snubber circuit. There
are 4 different sizes, depending on current and voltage.
All units are forced cooled.
The power section is controlled by the units electronic
system, which is identical for the entire product range.
Parts of the units electronic system can be installed in
the unit, depending on the particular application in-
volved, e.g. a field supply for the motor, or an interface
board to connect the converter to an overriding control
system. A control/display panel is available for the
operator. It can be mounted to the power converter
module or installed in the cabinet's door by means of a
mounting kit.
Accessories such as external fuses, line reactors and the
like are available, for putting together a complete drive
system.
Reference variables
The voltage characteristics are shown
in Table 2.2/1. The DC voltage char-
acteristics have been calculated using
the following assumptions:
U
VN
= rated mains voltage, 3-phase
Voltage tolerance 10 %
Internal voltage drop approx. 1%
If a deviation or a voltage drop has
to be taken into consideration in
compliance with IEC and VDE
standards, the output voltage or
the output current must be re-
duced by the actual factor accord-
ing to table 2.2/1.
in case of a 2-Q converter, which is used in regenerative mode, 4-Q voltage
values have to be used.
Table 2.2/1: DCS 600 max. DC voltages achievable with a given mains voltage.
Mains DC voltage Ideal DC Recommended
voltage (max. Motor voltage) voltage DCS 600
U
v
U
d
without load Voltage class
2-Q 4-Q U
di0
y=
230 265 240 310 4
380 440 395 510 4
400 465 415 540 4
415 480 430 560 4
440 510 455 590 5
460 530 480 620 5
480 555 500 640 5
500 580 520 670 5
525 610 545 700 6
575 670 600 770 6
600 700 625 810 6
660 765 685 890 7
690 800 720 930 7
790 915 820 1060 8
1000 1160 1040 1350 9
1190 1380 1235 1590 1
II F 2-5
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Converter type y y=4 (400 V) y=5 (500 V) y=6 (600 V) y=7 (690 V)

x=1 2-Q I
DC
[A] I
AC
[A] P [kW] P [kW] P [kW] P [kW]
x=2 4-Q 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q 4Q 2Q
DCS60x-0025-y1 25 25 20 20 10 12 13 15
DCS60x-0050-y1 50 50 41 41 21 23 26 29
DCS60x-0050-61 50 50 41 41 31 35
DCS60x-0075-y1 75 75 61 61 31 35 39 44
DCS60x-0100-y1 100 100 82 82 42 47 52 58
DCS60x-0110-61 110 100 90 82 69 70
DCS60x-0140-y1 140 125 114 102 58 58 73 73
DCS60x-0200-y1 200 180 163 147 83 84 104 104
DCS60x-0250-y1 250 225 204 184 104 105 130 131
DCS60x-0270-61 270 245 220 200 169 172
DCS60x-0350-y1 350 315 286 257 145 146 182 183
DCS60x-0450-y1 450 405 367 330 187 188 234 235 281 284
DCS60x-0520-y1 520 470 424 384 216 219 270 273
DCS60x-0680-y1 680 610 555 500 282 284 354 354
DCS60x-0820-y1 820 740 670 605 340 344 426 429
DCS60x-1000-y1 1000 900 820 738 415 418 520 522
DCS60x-0903-y1 900 900 734 734 563 630 648 720
DCS60x-1203-y1 1200 1200 979 979 498 558 624 696
DCS60x-1503-y1 1500 1500 1224 1224 623 698 780 870 938 1050 1080 1200
DCS60x-2003-y1 2000 2000 1632 1632 830 930 1040 1160 1400 1600
DCF60x-0025-y1 25 25 20 20 10 12 13 15
DCF60x-0050-y1 50 50 41 41 21 23 26 29
DCF60x-0075-y1 75 75 61 61 31 35 39 44
DCF60x-0100-y1 100 100 82 82 42 47 52 58
DCF60x-0200-y1 200 180 163 147 83 84 104 104
DCF60x-0350-y1 350 315 286 257 145 146 182 183
DCF60x-0450-y1 450 405 367 330 187 188 234 235
DCF60x-0520-y1 520 470 424 384 216 219 270 273
Table 2.2/2: Table of DCS 600 / DCF 600 units - construction types C1, C2, A5
Converter type y y=4 (400 V) y=5 (500 V) y=6 (600 V) y=7 (690 V) y=8 (790 V) y=9 (1000V) y=1 (1190V)
I
DC
[A] I
AC
[A] P [kW] P [kW] P [kW] P [kW] P [kW] P [kW] P [kW]
2-Q converters
DCS601-1903-y1 1900 1550 1740
DCS601-2053-y1 2050 1673 1190 1430 1640
DCS601-2503-y1 2500 2040 1160 1450 1750 2000 2300
DCS601-3003-y1 3000 2448 1395 1740 2090 2400 2750
DCS601-2053-y1 2050 1673 2390
DCS601-2603-y1 2600 2121 3030 on request
DCS601-3303-y1 3300 2693 1540 1925 2310 2660 3040 3850 on request
DCS601-4003-y1 4000 3264 1870 2330 2800 3220 3690 4670 on request
DCS601-4803-y1 4800 3917 3360 3860 4420
DCS601-5203-y1 5200 4243 2430 3030
4-Q converters
DCS602-1903-y1 1900 1550 1560
DCS602-2053-y1 2050 1673 1070 1280 1470
DCS602-2503-y1 2500 2040 1040 1300 1560 1800 2060
DCS602-3003-y1 3000 2448 1250 1560 1880 2150 2470
DCS602-2053-y1 2050 1673 2390
DCS602-2603-y1 2600 2121 3030 on request
DCS602-3303-y1 3300 2693 1375 1720 2060 2370 2720 3440 on request
DCS602-4003-y1 4000 3264 1670 2080 2500 2875 3290 4170 on request
DCS602-4803-y1 4800 3917 3000 3450 3950
DCS602-5203-y1 5200 4243 2170 2710
These converters are equipped with additional components. More information on request
Table 2.2/3: Table of DCS 600 units - construction type A6 / A7
II F 2-6
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Construction type C2 Construction type C1
Converter type Dimensions Weight Clearances Construct. Power loss Fan Semiconductor
H x W x D top/bottom/side type at 500V connection Fuses
[mm] [kg] [mm] P
V
[kW]
DCS60x-0025-y1 420x273x195 7.1 150x100x5 C1a < 0.2 230 V/1 ph external
DCS60x-0050-y1 420x273x195 7.2 150x100x5 C1a < 0.2 230 V/1 ph external
DCS60x-0050-61 420x273x195 7.6 150x100x5 C1a - 230 V/1 ph external
DCS60x-0075-y1 420x273x195 7.6 150x100x5 C1a < 0.3 230 V/1 ph external
DCS60x-0100-y1 469x273x228 11.5 250x150x5 C1b < 0.5 230 V/1 ph external
DCS60x-0110-61 469x273x228 11.5 250x150x5 C1b - 230 V/1 ph external
DCS60x-0140-y1 469x273x228 11.5 250x150x5 C1b < 0.6 230 V/1 ph external
DCS60x-0200-y1 505x273x361 22.3 250x150x5 C2a < 0.8 230 V/1 ph external
DCS60x-0250-y1 505x273x361 22.3 250x150x5 C2a < 1.0 230 V/1 ph external
DCS60x-0270-61 505x273x361 22.8 250x150x5 C2a - 230 V/1 ph external
DCS60x-0350-y1 505x273x361 22.8 250x150x5 C2a < 1.3 230 V/1 ph external
DCS60x-0450-y1 505x273x361 28.9 250x150x10 C2a < 1.5 230 V/1 ph external
DCS60x-0520-y1 505x273x361 28.9 250x150x10 C2a < 1.8 230 V/1 ph external
DCS60x-0680-y1 652x273x384 42 250x150x10 C2b < 1.6 230 V/1 ph external
DCS60x-0820-y1 652x273x384 42 250x150x10 C2b < 2.0 230 V/1 ph external
DCS60x-1000-y1 652x273x384 42 250x150x10 C2b < 2.5 230 V/1 ph external
DCS60x-0903-y1 1050x510x410 110 300x100x20 A5 - 230 V/1-ph internal
DCS60x-1203-y1 1050x510x410 110 300x100x20 A5 < 5.2 230 V/1-ph internal
DCS60x-1503-y1 1050x510x410 110 300x100x20 A5 < 5.5 230 V/1-ph internal
DCS60x-2003-y1 1050x510x410 110 300x100x20 A5 < 6.6 230 V/1-ph internal
DCS60x-1903-81 1750x460x410 180 x0x50 A6 - 400...500 V/3-ph
DCS60x-2053-y1 1750x460x410 180 x0x50 A6 < 7.9 at y = 4, 5, 8 internal
DCS60x-2503-y1 1750x460x410 180 x0x50 A6 < 9.3 500...690 V/3-ph
DCS60x-3003-y1 1750x460x410 180 x0x50 A6 < 11.9 at y = 6, 7
DCS60x-2053-y1L 1750x770x570 315 A7 - 400/690 V/3-ph
DCS60x-2603-y1L 1750x770x570 315 A7 - 400/690 V/3-ph internal
DCS60x-3203-y1L 1750x770x570 315 A7 - 400/690 V/3-ph
DCS60x-3303-y1L 1750x770x570 315 A7 < 15 400/690 V/3-ph
DCS60x-4003-y1L 1750x770x570 315 A7 < 16 400/690 V/3-ph
DCS60x-4803-y1L 1750x770x570 315 A7 - 400/690 V/3-ph
DCS60x-5203-y1L 1750x770x570 315 A7 < 20 400/690 V/3-ph
Busbar connection on the right side is optional
Example for the type designation: connection left DCS60x-5203-y1L; connection right DCS60x-5203-y1R)
x=1 2-Q; x=2 4-Q; y=4...9/1 400...1000 V/1190 V supply voltage
Exhaust air must leave enclosure via air channel
also available as field supply converter DCF60x (for 500 V s. also table 2.2/3). Data are the same as the armature current converter DCS60x
Table 2.2/4: Table of DCS 600 units
Construction type A5 Construction type A6 Construction type A7
left busbar connection
to be installed
in cubicle
II F 2-7
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
2.3 DCS 600 Overload Capability
Unit type I
DC I
I
DC II
I
DC III
I
DC IV
contin- 100 % 150 % 100 % 150 % 100 % 200 %
uous 15 min 60 s 15 min 120 s 15 min 10 s
400 V / 500 V [A] [A] [A] [A]
DCS 60x-0025-41/51 25 24 36 23 35 24 48
DCS 60x-0050-41/51 50 44 66 42 63 40 80
DCS 60x-0075-41/51 75 60 90 56 84 56 112
DCS 60x-0100-41/51 100 71 107 69 104 68 136
DCS 601-0140-41/51 125 94 141 91 137 90 180
DCS 602-0140-41/51 140 106 159 101 152 101 202
DCS 601-0200-41/51 180 133 200 132 198 110 220
DCS 602-0200-41/51 200 149 224 146 219 124 248
DCS 601-0250-41/51 225 158 237 155 233 130 260
DCS 602-0250-41/51 250 177 266 173 260 147 294
DCS 601-0350-41/51 315 240 360 233 350 210 420
DCS 602-0350-41/51 350 267 401 258 387 233 466
DCS 601-0450-41/51 405 317 476 306 459 283 566
DCS 602-0450-41/51 450 352 528 340 510 315 630
DCS 601-0520-41/51 470 359 539 347 521 321 642
DCS 602-0520-41/51 520 398 597 385 578 356 712
DCS 601-0680-41/51 610 490 735 482 732 454 908
DCS 602-0680-41/51 680 544 816 538 807 492 984
DCS 601-0820-41/51 740 596 894 578 867 538 1076
DCS 602-0820-41/51 820 664 996 648 972 598 1196
DCS 601-1000-41/51 900 700 1050 670 1005 620 1240
DCS 602-1000-41/51 1000 766 1149 736 1104 675 1350
DCS 60x-1203-41/51 1200 888 1332 872 1308 764 1528
DCS 60x-1503-41/51 1500 1200 1800 1156 1734 1104 2208
DCS 60x-2003-41/51 2000 1479 2219 1421 2132 1361 2722
DCS 60x-2053-51 2050 1550 2325 1480 2220 1450 2900
DCS 601-2503-41/51 2500 1980 2970 1880 2820 1920 3840
DCS 602-2503-41/51 2500 2000 3000 1930 2895 1790 3580
DCS 601-3003-41/51 3000 2350 3525 2220 3330 2280 4560
DCS 602-3003-41/51 3000 2330 3495 2250 3375 2080 4160
DCS 60x-3303-41/51 3300 2416 3624 2300 3450 2277 4554
DCS 60x-4003-41/51 4000 2977 4466 2855 4283 2795 5590
DCS 60x-5203-41/51 5200 3800 5700 3669 5504 3733 7466
600 V / 690 V
DCS 60x-0050-61 50 44 66 43 65 40 80
DCS 601-0110-61 100 79 119 76 114 75 150
DCS 602-0110-61 110 87 130 83 125 82 165
DCS 601-0270-61 245 193 290 187 281 169 338
DCS 602-0270-61 270 213 320 207 311 187 374
DCS 601-0450-61 405 316 474 306 459 282 564
DCS 602-0450-61 450 352 528 340 510 313 626
DCS 60x-0903-61/71 900 684 1026 670 1005 594 1188
DCS 60x-1503-61/71 1500 1200 1800 1104 1656 1104 2208
DCS 601-2003-61/71 2000 1479 2219 1421 2132 1361 2722
DCS 60x-2053-61/71 2050 1520 2280 1450 2175 1430 2860
DCS 601-2503-61/71 2500 1940 2910 1840 2760 1880 3760
DCS 602-2503-61/71 2500 1940 2910 1870 2805 1740 3480
DCS 601-3003-61/71 3000 2530 3795 2410 3615 2430 4860
DCS 602-3003-61/71 3000 2270 3405 2190 3285 2030 4060
DCS 60x-3303-61/71 3300 2416 3624 2300 3450 2277 4554
DCS 60x-4003-61/71 4000 3036 4554 2900 4350 2950 5900
DCV 60x-4803-61/71 4800 3734 5601 3608 5412 3700 7400
790 V
DCS 60x-1903-81 1900 1500 2250 1430 2145 1400 2800
DCS 601-2503-81 2500 1920 2880 1820 2730 1860 3720
DCS 602-2503-81 2500 1910 2865 1850 2775 1710 3420
DCS 601-3003-81 3000 2500 3750 2400 3600 2400 4800
DCS 602-3003-81 3000 2250 3375 2160 3240 2000 4000
DCS 60x-3303-81 3300 2655 3983 2540 3810 2485 4970
DCS 60x-4003-81 4000 3036 4554 2889 4334 2933 5866
DCS 60x-4803-81 4800 3734 5601 3608 5412 3673 7346
1000 V
DCS 60x-2053-91 2050 1577 2366 1500 2250 1471 2942
DCS 60x-2603-91 2600 2000 3000 1900 2850 1922 3844
DCS 60x-3303-91 3300 2551 3827 2428 3642 2458 4916
DCS 60x-4003-91 4000 2975 4463 2878 4317 2918 5836
1190 V Data on request
x=1 2-Q; x=2 4-Q
To match a drive systems components as efficiently as possible to the driven
machines load profile, the armature power converters DCS 600 can be dimensio-
ned by means of the load cycle. Load cycles for driven machines have been defi-
ned in the IEC 146 or IEEE specifications, for example.
The currents for the DC I to DC IV types of load (see diagram on the following page) for the power converter
modules are listed in the table below.
Table 2.3/1:
Power converter module
currents with corresponding
load cycles.
The characteristics are
based on an ambient tem-
perature of max. 40C and
an elevation of max. 1000 m
a.s.l.
II F 2-8
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Load Load for Typical applications Load cycle
cycle converter
DC I I
DC I
continuous (I
dN
) pumps, fans
DC II I
DC II
for 15 min and extruders, conveyor belts
1,5 * I
DC II
for 60 s
DC III * I
DC III
for 15 min and extruders, conveyor belts
1,5 * I
DC III
for 120 s
DC IV * I
DC IV
for 15 min and
2 * I
DC IV
for 10 s



100%
150%100%
150% 100%
200% 100%
15 min
15 min
15 min
If the driven machines load cycle does
not correspond to one of the examples
listed, you can determine the necessary
power converter using the DCSize soft-
ware program.
This program can be run under Microsoft

Windows,
and enables you to dimension the motor and the power
converter, taking types of load (load cycle), ambient
temperature, site elevation, etc. into account. The
design result will be presented in tables, charts, and can
be printed out as well.
To facilitate the start-up procedure as much as possible
the converters software is structured similar as the
inputs made at the program. Because of that many of
the data can be directly utilized at the converter like
high current, line voltage and others.
Fig. 2.3/1: Entry screen of DCSize.
Microsoft is a registered trademark. Windows is a designation of the Microsoft Corporation.
Types of load
* Load cycle is not identical with menu item Duty cycle in DCSize !
Table 2.3/2: Definition of the load cycles
II F 2-9
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
2.4 Field Supply
General data
SDCS-FEX-1
Diode bridge.
6 A rated current.
Internal non adjustable minimum field current
monitor.
Construction and components have been designed
for an insulation voltage of 600 V AC.
Output voltage U
A
:
9 . 0 *
% 100
% 100
*
|
.
|

\
| +
=
TOL
U U
V A
TOL = tolerance of line voltage in %
U
V
= Line voltage
Recommendation:
Field voltage ~ 0.9 * U
V
SDCS-FEX-2A
Half controlled thyristor/diode bridge (1-Q)
Microprocessor control, with the electronic system
being supplied by the armature converter.
Construction and components have been designed
for an insulation voltage of 600 V AC.
Fast-response excitation is possible with an appro-
priate voltage reserve; de-excitation takes place by
field time constant.
Output voltage U
A
:
9 . 0 *
% 100
% 100
*
|
.
|

\
| +
=
TOL
U U
V A
TOL = tolerance of line voltage in %
U
V
= Line voltage
Recommendation:
Field voltage 0.6 to 0.8 * U
V
All field power converters (except for the SDCS-FEX-
1) are controlled by the armature converter via a serial
link with a speed of 62.5 kBaud. The link serves to
parameterize, control and diagnose the field power
converter and thus provides an exact control. Moreo-
ver, it enables you to control an internal (SDCS-FEX-
2A) and an external (DCF 601/602/503A/504A) or
two external field supply units (2 x DCF 601/602/
503A/504A). The respective software function required
is available in every DC power converter.
Field converter types
Currents from 6 to 520 A.
Minimum field current monitor.
Integrated or external field power converter or in a
completely separate cabinet.
2-phase or 3-phase model.
Fully digital control (except SDCS-FEX-1).
We recommend integrating an autotransformer in the
field power converter's supply to adjust the AC input
voltage to the field voltage, to reduce the voltage and
current ripple of the field.
SDCS-FEX-1
SDCS-FEX-2A
II F 2-10
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
DCF 503A
Half controlled thyristor/diode bridge (1-Q).
Microprocessor control with the control electronics
being supplied separately (115...230 V/1-ph).
Construction and components have been designed
for an insulation voltage of 690 V AC.
Output voltage U
A
:
9 . 0 *
% 100
% 100
*
|
.
|

\
| +
=
TOL
U U
V A
TOL = tolerance of line voltage in %
U
V
= Line voltage
Recommendation:
Field voltage 0.6 to 0.8 * U
V
DCF 504A
Fully controlled antiparallel thyristor bridges (4-Q).
With this unit fast response excitation / de-excita-
tion and field reversal is possible. For fast response
excitation an appropriate voltage reserve is neces-
sary.
In steady-state condition, the fully controlled bridge
runs in half controlled mode to keep the voltage
ripple as low as possible. With a fast changing field
current, the bridge runs in fully controlled mode.
Same design as DCF 503A
DCF 600
This field power converter is used mainly for armature
converters with rated currents of 2050 to 5200 A. It is
a modified armature circuit converter.
Output voltage U
A
respectively U
dmax 2-Q
:
see table 2.2/1.
Recommendation:
Field voltage 0.5 to 1.1 * U
V
The three-phase field supply converters DCF 600
needs a separate active overvoltage protection unit
DCF 506 for protecting the power part against too
high voltages.
The overvoltage protection unit DCF 506 is suita-
ble for 2-Q converters DCF 601 and for 4-Q
converters DCF 602.

`
)
auxiliary supply (115...230V) if necessary via matching trans-
former; external fuse; Dimensions HxWxD: 370x125x342 [mm]
DCF506-140-51,
without cover
DCF601/602
Assignment Field supply converter to Overvol-
tage protection unit
DCF503A/504A
Unit type Output Supply Installation Remarks
current I
DC
voltage site
[A] [V]
SDCS-FEX-1-0006 0.02...6 110V -15%...500V/1-ph +10% internal external fuse, 6 A I
Frated
SDCS-FEX-2A-0016 0.3...16 110V -15%...500V/1-ph +10% internal ext. fuse, reactor; for C1: 0.3 ... 8 A , not to be used for A6/A7 mod.!
DCF 503A-0050 0.3...50 110V -15%...500V/1-ph +10% external
DCF 504A-0050 0.3...50 110V -15%...500V/1-ph +10% external
DCF 60x-xxxx-41/51 see table 200V...500V/3-ph external
2.2/2
Current reduction see also 2.1 Environmental conditions Fig.: 2.1/1 and 2.1/2
Table 2.4/1: Data field converter units
are based on the hardware of the DCS 600 and additional
hardware components (DCF 506); auxiliary supply (115/230 V)
Field supply converter Overvoltage Protection
for motor fields
DCF60x-0025-51
... DCF506-0140-51
DCF60x-0140-51
DCF60x-0200-51
... DCF506-0520-51
DCF60x-0520-51
II F 2-11
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
In-/output signals
addition to this an extension of I/Os by SDCS-IOE 1
is possible.
Fig. 2.5/1: I/Os via SDCS-CON-2
Analogue I/Os: standard
Digital I/Os: not isolated
Encoder input: not isolated
Fig. 2.5/2: I/Os via SDCS-CON-2 and SDCS-IOB-2
Analogue I/Os: standard
digital I/Os: all isolated by means of opto-
coupler/relay; the signal status
is indicated by LED
Fig. 2.5/3: I/Os via SDCS-CON-2 and SDCS-IOB-3
Analogue I/Os: more input capacity
digital I/Os: not isolated
encoder input: isolated
current source for: PT100/PTC element
Fig. 2.5/4: I/Os via SDCS-IOB-2 and SDCS-IOB-3
Analogue I/Os: more input capacity
digital I/Os: all isolated by means of opto-
coupler/relay; the signal status
is indicated by LED
current source for: PT100/PTC element
The converter can be connected in 4 different ways to
a control unit via analogue/digital links. Only one of
the four choices can be used at the same time. In
X3: X4: X5: X6: X7:
X2: X1:
X17:
SDCS-CON-2
1 2
X3: X4: X5:
X2: X1:
X17:
SDCS-CON-2
X3: X1:
SDCS-IOB-2
1
4
X1: X2:
SDCS-IOB-3
X6: X7:
X2:
X17:
X1:
3
2
SDCS-CON-2
X2:
SDCS-IOB-3
X2:
X17:
SDCS-CON-2
X1:
SDCS-IOB-2
X1:
X1: X3:
3 4
2.5 Options for DCS 600 CraneDrive converter modules
II F 2-12
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Description of I/O signals SDCS-CON-2
Mechanical system integrated in control board
Terminals
Screw type terminals for finely stranded wires up to 2.5 mm
2
Functionality
1 tacho input
Resolution: 12 bit + sign; differential input; common mode range 20 V
3 ranges from 8...30...90...270 VDC with n
max
4 analogue inputs
Range -10...0...+10 V, 4...20 mA, 0...20 mA
All as differential inputs; R
E
= 200 k; time constant of smoothing
capacitor 2 ms
Input 1: Resolution: 12 bit + sign; common mode range 20 V
Inputs 2, 3, 4: Resolution: 11 bit + sign; common mode range 40 V
Current source for PTC element evaluation via jumper and input 2
2 outputs
+10 V, -10 V, I
A
5 mA; sustained short-circuit-proof
voltage supply for reference potentiometer
1 analogue output
bipolar current actual - from power section; decoupled
IdN = 3 V; I
A
5 mA, short-circuit-proof
2 analogue outputs
Range -10...0...+10 V; I
A
5 mA
Output signal and scaling can be selected by means of software
Resolution: 11 bit + sign
1 pulse generator input
Voltage supply for 5 V/12 V/24 V pulse generators (sustained short-
circuit-proof)
Output current with 5 V: I
A
0.25 A
12 V: I
A
0.2 A
24 V: I
A
0.2 A
Input range: 12 V/24 V: asymmetrical and differential
5 V: differential
Pulse generator as 13 mA current source: differential
Line termination (impedance 120), if selected
max. input frequency 300 kHz
Description of I/O signals SDCS-IOB-2x & SDCS-IOB-3
Mechanical system always external, outside the module
Terminals
Screw type terminals for finely stranded wires up to 2.5 mm
2
Functionality of SDCS-IOB-3
1 tacho input
Resolution: 12 bit + sign; differential input; common mode range 20 V
Range 8 V- with n
max
; if higher tacho voltages are in use tacho adaptation
board PS 5311 is needed.
4 analogue inputs
All as differential inputs; time constant of smoothing capacitor 2 ms
Input 1: Range -10 V...0...+10 V; -20 mA...0...+20 mA; 4... 20 mA
unipolar; R
E
= 200 k/ 500/ 500; Resolution: 12 bit + sign; common
mode range 20 V
Inputs 2+3: Range see input 1, in addition -1 V...0...+1 V
R
E
= 200 k/ 500/ 500/ 20k; Resolution: 11 bit + sign; common
mode range with -1 V...0...+1 V range 10 V, otherwise 40 V
Input 4: Range see input 1
R
E
= 200 k/ 500/ 500; Resolution: 11 bit + sign; common mode
range 40 V
Residual current detection in combination with analogue input 4
(sum of phase currents 0)
2 outputs
+10 V, -10 V; I
A
5 mA; sustained short-circuit-proof
voltage supply for reference potentiometer
1 analogue output
Bipolar current actual - from power section; decoupled
IdN = 3 V (at gain = 1); I
A
5 mA; U
Amax
= 10 V; gain can be adjusted by
means of a potentiometer between 0.5 and 5; short-circuit-proof
2 analogue outputs
Range -10...0...+10 V; I
A
5 mA; short-circuit-proof
Output signal and scaling can be selected by means of software
Resolution: 11 bit + sign
Current source for PT 100 or PTC element
I
A
= 5 mA / 1.5 mA
1 pulse generator input
Voltage supply, output current, input range: see SDCS-CON-2
Inputs electrically isolated from 0 V (housing) by means of optocoupler
and voltage source.
Functionality of SDCS-IOB-2x
3 different designs available:
SDCS-IOB-21 inputs for 24...48 V DC; R
E
= 4.7 k
SDCS-IOB-22 inputs for 115 V AC; R
E
= 22 k
SDCS-IOB-23 inputs for 230 V AC; R
E
= 47 k
Terminals
Screw type terminals up to 4 mm
2
8 digital inputs
The functions can be selected by means of software.
The signal status is indicated by LED.
All isolated by means of optocouplers.
Input voltage: IOB-21:0...8 V "0 signal", 18...60 V "1 sig."
IOB-22:0...20 V "0 signal", 60...130 V "1 sig."
IOB-23:0...40 V "0 signal", 90...250 V "1 sig."
Filter time constant: 10 ms (channels 1...6); 2 ms (channels 7+8)
Auxiliary voltage for digital inputs: +48 V DC; 50 mA; sustained short-
circuit-proof; referenced to the unit housing potential.
8 digital outputs
The functions can be selected by means of software.
The signal status is indicated by LED.
6 of them potential isolated by relay (N.O. contact: AC: 250 V/ 3 A /
DC: 24 V/ 3 A or 115/230 V/ 0.3 A), protected by VDR component.
2 of them potential isolated by optocoupler, protected by zener diode
(open collector) 24 V DC external, I
A
50 mA.
8 digital inputs
The functions can be selected by means of software.
Input voltage: 0...8 V "0 signal", 16...60 V "1 signal"
Time constant of smoothing capacitor: 10 ms
R
E
= 15 k
The signal refers to the unit housing potential.
Auxiliary voltage for digital inputs: +48 V DC, 50 mA, sustained short-
circuit-proof
7+1 digital outputs
The function can be selected by means of software.
7 outputs: relay driver with free-wheeling diode, total current limitation
160 mA; short-circuit-proof.
1 relay output - on power board SDCS-POW-1 (N.O. contact:
AC: 250 V/ 3 A / DC: 24 V/ 3 A or 115/230 V/ 0.3 A) protected
by VDR component.
II F 2-13
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Please note:
Unless otherwise stated, all signals are referenced to a 0 V potential. Within the power
pack subassembly (SDCS-POW-1) and on all other PCBs, this potential is firmly
connected with the units housing by means of plating through at the fastening
points.
X17:
SDCS-IOE-1
X3: X4: X5: X6: X7:
X2: X1:
X17:
SDCS-CON-2
4

x

a
n
a
l
o
g
1

x

T
a
c
h
o
7

x

d
i
g
i
t
a
l
8

x

d
i
g
i
t
a
l
2

x

a
n
a
l
o
g
P
u
l
s
g
e
b
e
r 5
The digital inputs of SDCS-IOE-1 (DI 9...DI 15) can
be connected to pre-defined functions (see software
group 1o). This board is normally used for stand-alone
mode / joystick operation.
Fig. 2.5/5: Additional Inputs via SDCS-IOE1
Analogue inputs: extended
Digital inputs: all isolated by means of opto-
coupler, the signal status is in-
dicated by LED
current source for: PT100/PTC element
Description of input signals SDCS-IOE-1
Mechanical system always external, outside the module
Terminals
Screw type terminals for finely stranded wires up to 2.5 mm
2
Functionality of SDCS-IOE-1
7 digital inputs
The functions can be selected by means of software.
The signal status is indicated by an LED.
All isolated by means of optocouplers.
Input voltage: 0...8 V "0 signal", 16...31 V "1 signal"
Potentialwise arranged in two groups (DI 9...DI 12 and DI 13...DI 15)
Filter time constant: 2 ms
2 analogue inputs
No pre-defined functions
Current source for PT 100 or PTC element
I
A
= 5 mA / 1.5 mA
The signals are referenced to the unit housing potential
II F 2-14
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
There are various serial interface options available for
operation, commissioning, diagnosis and controlling.
For the control and display panel CDP 312 are serial
connections X33:/X34: on the SDCS-CON-2 availa-
ble. Three additional serial interfaces are available on
the SDCS-AMC-DC 2 board.
These interfaces use plastic or HCS optical fibres.
Channel 3 is used for drive/PC interfacing. Channel 0
for fieldbus module interfacing or communication to
the overriding control system. Channel 2 is used for
Master-Follower link or for I/O extension. All three
serial interfaces are independent from each other.
Fig. 2.5/6: Options for serial communication
Different SDCS-AMC 2 boards are available to adapt
optical cables, cable length and serial interfaces. The
different SDCS-AMC 2 boards are equipped with 10
or 5 Mbaud optical transmitter and receiver devices.
A few basic rules must be considered:
Never connect 5 Mbaud and 10 Mbaud devices.
5 Mbaud can handle only plastic fibre optic.
10 Mbaud can handle plastic or HCS cable.
The branching unit NDBU 95 extends the maxi-
mum distance.
The maximum distance and suitable configuration
can be found in the manual Configuration Instruc-
tions NDBU 85/95; Doc no.: 3ADW000100.
Fig. 2.5/7: LED Monitoring Display
LED Monitoring Display
If the CraneDrive door Mounting kit is used it is
possible to insert up to three LED monitoring displays
for indicating status as run, ready and fault and a
selectable parameter indicator (0...150%) per drive.
The display is connected to the SDCS-CON-2 board
(X33:/X34:) or to the panel socket NDPI through a
universal Modbus link.
R
D
Y
R
U
N
F
L
T
0 50 100 150
1
Remark:
Fieldbus modules Nxxx
(CH0) require the
SDCS-AMC-DC Classic 2
board - all others (FCI,
AC80...) require the
SDCS-AMC-DC 2 board.
Fig. 2.5/8: Connection of the LED Monitoring Display
Serial interfaces
Operation by panel
Panel location
There are different possibilities for mounting the panel:
On the converter module.
With CraneDrive door mounting kit.
X33:/
X34:
SDCS-CON-2
R
D
Y
R
U
N
F
L
T
0 50 100 150
1
NLMD
SDCS-CON-2
N
D
P
I
NLMD
R
D
Y
R
U
N
F
L
T
0 50 100 150
1
CDP 312
X33:/
X34:
X16:
PC
3 m
CDP 312
D
2
0
0
C
H

3
T
x
D
R
x
D
C
H

2
T
x
D
R
x
D
C
H

0
T
x
D
R
x
D
D
4
0
0
S
D
C
S
-
A
M
C
-
D
C

2
S
D
C
S
-
A
M
C
-
D
C

C
l
a
s
s
i
c

2
AC800M
FCI
AC80
Nxxx
Nxxx-01
xxxxxxxx
ADAPTER
BUS
TERMINATION
ON
OFF
RXD
TXD
PE SHF DG D(N) D(P)
X1
X2
PE SHF DG D(N) D(P) SH
XMIT
REC
ERROR
+24V 0V SH
X33:
X34:
SDCS-CON-2
Dcs6_com1b.dsf
electrical
connection
o
p
t
i
c
a
l

f
i
b
r
e
Power supply
Control Operation
- Master-Follower link
to the PLC
Interface
II F 2-15
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Panel (control and display panel)
The CDP 312 control and display panel communicates
with the power converter via a serial connection in
accordance with the RS 485 standard at a transmission
rate of 9.6 kBaud. It is an option for the converter unit.
After completion of commissioning, the panel is not
necessarily required for diagnostic. The basic unit has
a 7-segment display indicating errors.
Fig. 2.5/9: Function keys and various displays on the removable
control and display panel.
Actual
Selects the display of feedback values plus the
signal group and the error memory group.
Parameters
For selecting and adjusting
all parameters and signals.
Function
Selects the functions operating mode; can be used
to perform special functions such as uploading and
downloading of parameter sets.
Drive
for extensions
Twin arrow keys
are used to change the group. In the parameter and
reference presetting modes, you can alter the param-
eter value or the reference setting ten times faster by
means of the twin arrow keys than by means of the
single arrow key.
Arrow keys
are used to select parameters within a group. You al-
ter the parameter value or the reference setting in the
parameter and reference presetting modes. In the
feedback signal display mode, you select the line you
want.
Enter
is used in the following modes:
Parameter setting: enter new parameter value
Actual value
signal display: enter the current signal selec-
tion mode
Signal selection: accept selection and return to
the feedback value signal dis-
play mode
Local/Remote
is used to select local (control
panel) or remote control.
Reset
Fault acknowledge key.
Reference
is used to activate the reference presetting mode.
Start
starts the drive in local mode.
Stop
shuts the drive down if you are in local mode.
On
in local mode switches the main contactor on.
Off
in local mode switches the main contactor off.
Features
16 membrane pushbuttons in three function groups
LCD display has four lines with 20 characters each
Language: English
Options for the CDP 312:
Cable to separate the panel from the converter.
Kit for mounting the panel in the cabinet door.
Status row
Functions to be
selected
Display contrast
setting
0 L 0,0 rpm 00
UPLOAD <==
DOWNLOAD ==>
CONTRAST
Group
and name
Subgroup
and name
0 L 0,0 rpm 00
17 RAMP GENERATOR
08 ACCEL 1
20.0 s
Value
0 L 0,0 rpm 00
SPEEED ACT 0,0 rpm
CONV CUR 0 A
U ARM ACT 0 V
ID number
of the
drive
selected
Control
location
L = local
= remote
Main contactor
status
0 = open
1 = closed
Speed
reference
rpm
Run status
1 = Run
0 = Stop
Status row
Actual signal
name and value
Cursor shows
the row selected
0 L 0,0 rpm 00
1 LAST FAULT
Emergency stop
3212:59:35:56
1 = last fault
2 = last-but-one fault
99 = last fault
Total time after
switch-on
HHHH:MM:SS.ss
Name of Fault
or alarm
II F 2-16
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Drive control
Components required:
Plastic optical fibre for distances up to 15 m.
Field bus module Nxxx-xx
FCI (CI810)
AC80 (PM825)
AC800 M
Functionality:
Depends on the used module, interface e.g. to:
PROFIBUS with NPBA-12
MODBUS+ with NMBP-01
AF100 with FCI (CI810)
AC80 (PM825) or
AC800 M
further modules on request
You will find more detailed information on data ex-
change in the specific PLC or fieldbus module docu-
mentation.
Operation by PC
Components required:
Plastic optical fibre for distances up to 20 m.
Network up to 200 drives (same as for ACS 600).
HCS optical fibre cable up to 200 m.
See separate manual Configuration Instructions
NDBU 85/95; Doc no.: 3ADW000100.
Functionality:
DriveWindow software package for commission-
ing, diagnosis, maintenance and trouble shooting;
structure of connections see Technical Data; Doc
no.: 3ADW000165.
System requirements/recommendation:
PC (IBM-compatible) with 486 processor or higher
(min. 50 MHz).
8 MB RAM.
DOS version 5.0 or later.
Windows 3.1, 3.11, Windows95/98; Windows
NT4.0.
VGA monitor.
CD-ROM drive.
PCMCIA slot or PCI/PCMCIA bridge.
In addition to the options provided by the CDP 312
control and display panel, there are further functions
available, and these are described on the following page.
For further information see the specific publica-
tions
II F 2-17
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Operation by PC (continued)
DriveWindow 2.xx
Windows
TM
-based, user-friendly
ABB's DriveWindow is an advanced, easy-to-use tool
for the commissioning and maintenance of drive sys-
tems in different industries. Its host of features and
clear, graphical presentation of the operation make it a
valuable addition to your system providing informa-
tion necessary for troubleshooting, maintenance and
service, as wellas training.
DriveWindow is fully 32 bit and runs in the newer
Microsoft

Windows environments such as WIN NT

/ 2000 / XP.
With DriveWindow the user is able to follow the co-
operation of twoor more drives simultaneously by
collecting the actual values from the drives onto a single
screen or printout.
Additionally, the client part of DriveWindow may
reside on one Local Area Network PC, and the server
side on another PC closer to the drives. This enables
plant-wide monitoring to be easily accomplished with
two PCs.
Powerful and versatile
DriveWindow can access all drives connected to
the high speed fiber optic network see manuals:
- Configuration Instructions NDBU-85/95
(3ADW000100).
- NDBU-85/95 Branching Units
(3BFE64285513).
- DDCS Cabling and Branching
(3AFE63988235).
Signal values can be viewed as graphs from the
drive/drives.
A screenful of signals and parameters from the
drive can be monitored and edited at one time
(off-line or on-line).
View data collected and stored in the drive.
Fault diagnosis; DriveWindow indicates the status
of drives, and also reads fault history data from
the drive.
Remote monitoring, plant wide monitoring with
two PCs.
Back-up of drive parameters; in fault situations
the file can be easily reloaded, resulting in time
savings.
Back-up parameters or software from the drive
into PC files. This version allows the entire con-
trol board content to be saved and restored later -
even to empty control boards.
DriveWindow is part of the Drive
IT
folder of the
Industrial
IT
.
Features
Easy-to-use tool for com-
missioning and mainte-
nance.
Several drives connected
and monitored at the same
time.
Monitor, edit or save sig-
nals and parameters, clear
graphical presentation.
High speed communica-
tion between PC and drive
Versatile back-up func-
tions.
II F 2-18
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
2.6 Options
Line reactors
for armature (DCS 60x) and field
(DCF 60x) supply
When thyristor power converters operate, the line
voltage is short-circuited during commutation from
one thyristor to the next. This operation causes voltage
dips in the mains. For the connection of a power
converter system to the mains, a decision is made
between the following configurations:
With reference to the power converter:
The line reactors listed in table (2.6/1)
- have been allocated to the units nominal current
- are independent of converter's voltage classifica-
tion; at some converter types the same line choke
is used up to 690 V line voltage
- are based on a duty cycle
- can be used for DCS 600 as well as for DCF 600
converters
Connecting
point
Line
u
k LR
ca. 1%
Configuration A
When using the power converter, a
minimum of impedance is required to
ensure proper performance of the snub-
ber circuit. A line reactor can be used to
meet this minimum impedance require-
ment. The value must therefore not
drop below 1% u
k
(relative impedance
voltage). It should not exceed 10% u
k
, due to consider-
able voltage drops which would then occur.
Connecting
point
Line
L
Line
L
LR
Configuration B
If special requirements have to be met at
the connecting point, different criteria
must be applied for selecting a line
reactor. These requirements are often
defined as a voltage dip in percent of the
nominal supply voltage.
The combined impedance of Z
Line
and
Z
LR
constitute the total series imped-
ance of the installation. The ratio be-
tween the line impedance and the line reactor imped-
ance determines the voltage dip at the connecting
point. In such cases line chokes with an impedance
around 4% are often used.
Configuration C
If an isolation transformer is used, it is
possible to comply with certain con-
necting conditions per Configuration
B without using an additional line reac-
tor. The condition described in Con-
figuration A will then likewise be satis-
fied, since the u
k
is >1 %.
Connecting
point
Line
Configuration C1
If 2 or more converters should be sup-
plied by one transformer the final con-
figuration depends on the number of
drives in use and their power capability.
Configuration A or B has to be used
which are based on commutation
chokes, if the drive system consists of
C1, C2 or A5 converters. In case only
two converters type A6 / A7 (A6 + A6,
A6 + A7, A7 + A7) are involved no
commutation chokes are necessary because the design
of these converters is adapted to that wiring.
Line
Connecting
point
L
LR
L
LR
You will find further information in publication:
Technical Guide chapter: Line reactors
II F 2-19
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Fig. 1
Fig. 2 Fig. 3
DCS Type Line choke Design Line choke Design
400V-690V type for Fig. type for Fig.
50/60 Hz configur. A configur. B
DCS60x-0025-41/51 ND01 1 ND401 4
DCS60x-0050-41/51 ND02 1 ND402 4
DCS60x-0050-61 ND03 1 on request -
DCS60x-0075-41/51 ND04 1 ND403 5
DCS60x-0100-41/51 ND06 1 ND404 5
DCS60x-0110-61 ND05 1 on request -
DCS60x-0140-41/51 ND06 1 ND405 5
DCS60x-0200-41/51 ND07 2 ND406 5
DCS60x-0250-41/51 ND07 2 ND407 5
DCS60x-0270-61 ND08 2 on request -
DCS60x-0350-41/51 ND09 2 ND408 5
DCS60x-0450-41/51 ND10 2 ND409 5
DCS60x-0450-61 ND11 2 on request -
DCS60x-0520-41/51 ND10 2 ND410 5
DCS60x-0680-41/51 ND12 2 ND411 5
DCS601-0820-41/51 ND12 2 ND412 5
DCS602-0820-41/51 ND13 3 ND412 5
DCS60x-1000-41/51 ND13 3 ND413 5
DCS60x-0903-61/71 ND13 3 on request -
DCS60x-1203-41/51 ND14 3 on request -
DCS60x-1503-41/51/61/71 ND15 3 on request -
DCS60x-2003-41/51 ND16 3 on request -
DCS601-2003-61/71 ND16 * 3 on request -
* with forced cooling
Line reactors L1
Table 2.6/1: Line reactors (for more information see publication Technical Data)
Fig. 5 Fig. 4
II F 2-20
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Aspects of fusing for armature circuits and field supplies of DC drives
Conclusion for the armature supply
Due to cost saving standard fuses are used instead of the
more expensive semiconductor fuses at some applica-
tions. Under normal and stable operating conditions,
this is understandable and comprehensible, as long as
fault scenarios can be ruled out.
In the event of a fault , however, the saving may cause
very high consequential costs. Exploding power semi-
conductors may not only destroy the power converter,
but also cause fires.
Adequate protection against short-circuit and earth
fault, as laid down in the EN50178 standard, is possi-
ble only with appropriate semiconductor fuses.
General
Unit configuration
Protection elements such as fuses or overcurrent trips
are used whenever overcurrents cannot entirely be
ruled out. In some configurations, this will entail the
following questions: firstly, at what point should which
protective element be incorporated? And secondly, in
the event of what faults will the element in question
provide protection against damage?
Fig. 2.6/1 Arrangement of the switch-off elements in the
armature-circuit converter
Aspects of fusing for the armature-circuit and field supplies of DC drives
M
.
.
.
.
.
3
2
2
For field supply
see Fig. 2.6/2
AC supply: public mains / plant's mains
Cabinet
You will find further information in publication:
Technical Guide chapter: Aspects for fusing
Complies with Basic Principles on:
1 Explosion hazard yes
2 Earth fault yes
3 Hard networks yes
4 Spark-quenching gap yes
5 Short-circuit yes
6 2Q regenerative yes
M M
DCS converter
2-Q non-regen.
Semiconductor
fuses
Semiconductor
fuses
Semiconductor
fuses
4-Q resp.
2-Q regenerative
DCS converter
ABB's recommendations
II F 2-21
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Conclusion for the field supply
Basically, similar conditions apply for both field supply
and armature-circuit supply. Depending on the power
converter used (diode bridge, half-controlled bridge,
fully controlled 4-quadrant bridge), some of the fault
sources may not always be applicable. Due to special
system conditions, such as supply via an autotrans-
former or an isolating transformer, new protection
conditions may additionally apply.
The following configurations are relatively frequent:
In contrast to the armature-circuit supply, fuses are
never used on the DC side for the field supply, since a
fuse trip might under certain circumstances lead to
greater damage than would the cause tripping the fuse
in the first place (small, but long-lasting overcurrent;
fuse ageing; contact problems; etc.).
Semiconductor fuse F3.1 (super-fast acting) should be
used, if conditions similar to those for armature-circuit
supply are to apply, like for example protection of the
field supply unit and the field winding.
2
F3.1
ND30 /
built-in
Fig 2.6/2 Configuration for field supplies
The F3.2 and F3.3 fuse types serve as line protectors
and cannot protect the field supply unit. Only pure
HRC fuses or miniature circuit-breakers may be used.
Semiconductor fuses would be destroyed, for example,
by the transformers starting current inrush.
F3.3
2
2
F3.2
F3.1
F3.1
FF_ASP_b.dsf
ND30 /
built-in
Fig 2.6/3 Configurations for field supplies
II F 2-22
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Field converter type for field current Transformer
500 V; 50/60 Hz I
F
type 50/60 Hz
U
prim
= 500 V
SDCS-FEX-1 6 A T 3.01
SDCS-FEX-2A 12 A T 3.02
SDCS-FEX-2A 16 A T 3.03
DCF503A/4A-0050 30 A T 3.04
DCF503A/4A-0050 50 A T 3.05
U
prim
= 600 V
SDCS-FEX-1 6 A T 3.11
SDCS-FEX-2A 12 A T 3.12
SDCS-FEX-2A 16 A T 3.13
U
prim
= 690 V
DCF503A/4A-0050 30 A T 3.14
DCF503A/4A-0050 50 A T 3.15
Table 2.6/4: Autotransformer data (details see Technical Data)
Transformer T3 for field supply to match voltage levels
Fig. 2.6/4: T3 autotrans-
former
Type of converter Type Fuse holder
DCS60x-0025-41/51 170M 1564 OFAX 00 S3L
DCS60x-0050-41/51 170M 1566 OFAX 00 S3L
DCS60x-0050-61 170M 1566 OFAX 00 S3L
DCS60x-0075-41/51 170M 1568 OFAX 00 S3L
DCS60x-0100-51 170M 3815 OFAX 1 S3
DCS60x-0110-61 170M 3815 OFAX 1 S3
DCS60x-0140-41/51 170M 3815 OFAX 1 S3
DCS60x-0200-41/51 170M 3816 OFAX 1 S3
DCS60x-0250-41/51 170M 3817 OFAX 1 S3
DCS60x-0270-61 170M 3819 OFAX 1 S3
DCS60x-0350-41/51 170M 5810 OFAX 2 S3
DCS60x-0450-41/51/61 170M 6811 OFAS B 3
DCS60x-0520-41/51 170M 6811 OFAS B 3
DCS60x-0680-41/51 170M 6813 OFAS B 3
DCS60x-0820-41/51 170M 6813 OFAS B 3
DCS60x-1000-41/51 170M 6166 3x 170H 3006
Table 2.6/2: Fuses and fuse holders (details see Technical Data)
Semiconductor type F1 fuses and fuse holders for AC and DC power lines
(DCS 601 /DCS 602 - DCF 601/DCF 602)
The converter units are subdivided into two
groups:
Unit sizes C1 and C2 with rated currents
up to 1000 A require external fuses.
In unit sizes A5, A6 and A7 with rated
currents of 900 A to 5200 A, the semicon-
ductor fuses are installed internally (no
additional external semiconductor fuses
are needed).
The table on the right assigns the AC fuse
type to the converter type. In case the con-
verter should be equipped with DC fuses
according to the hints use the same type of
fuse used on the AC side now in the plus and
minus line. Blade type fuses are used for all
the converters construction type C1 and C2
except the biggest one.
The field supply units insulation voltage is
higher than the rated operating voltage (see
Chapter Field supplies), thus providing an
option in systems of more than 500 V for
supplying the power section of the converter
directly from the mains for purposes of arma-
ture supply, and using an autotransformer to
match the field supply to its rated voltage.
Moreover, you can use the autotransformer
to adjust the field voltage (SDCS-FEX-1
diode bridge) or to reduce the voltage ripple.
Different types (primary voltages of 400...500
V and of 525...690 V) with different rated
currents each are available.
Depending on the protection strategy
different types of fuses are to be used.
The fuses are sized according to the
nominal current of the field supply de-
vice. If the field supply unit is connected
to two phases of the network, two fuses
should be used; in case the unit is con-
nected to one phase and neutral only one
fuse at the phase can be used. Table 2.6/
3 lists the fuses currents with respect to
table 2.6/2.
The fuses can be sized according to the
maximum field current. In this case take
the fuse, which fits to the field current
levels.
Fuses F3.x and fuse holders for 2-phase field supply
Field conv. Field F3.1 F3.2 F 3.3
current
SDCS-FEX-1 I
F
6 A 170M 1558 OFAA 00 H10 10 A
SDCS-FEX-2A
SDCS-FEX-2A I
F
12 A 170M 1559 OFAA 00 H16 16 A
SDCS-FEX-2A I
F
16 A 170M 1561 OFAA 00 H25 25 A
DCF 503A
DCF 504A
DCF 503A I
F
30 A 170M 1564 OFAA 00 H50 50 A
DCF 504A
DCF 503A I
F
50 A 170M 1565 OFAA 00 H63 63 A
DCF 504A
Type of protection Semiconduct. LV HRC type circuit breaker
elements type fuse for for 690 V; fuse for 500 V or
fuse holder hold. OFAX 00 690 V
type OFAX 00
Table 2.6/3: Fuses and fuse holders for 2-phase field supply
II F 2-23
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Auxiliary transformer T2 for electronic
system / fan supply
The converter unit requires various auxiliary voltages,
e.g. the units electronics require 115 V/1-ph or 230 V/
1-ph, the unit fans require 230 V/1-ph or 400 V/690
V/3-ph, according to their size. The T2 auxiliary
transformer is designed to supply the units electronic
system and all the single-phase fans including the fan of
the A5 converter.
Input voltage: 380...690 V/1-ph; 50/60 Hz
Output voltage: 115/230 V/1-ph
Power: 1400 VA
Fig. 2.6/5: T2 auxiliary transformer
Residual current detection
This function is provided by the standard software. If
needed, the analogue input AI4 has to be activated, a
current signal of the three phase currents should be
supplied to AI4 by a current transformer. If the addi-
tion of the three current signal is different from zero, a
message is indicated (for more information, see publi-
cation Technical Data).
Commutating reactor
When using the SDCS-FEX-2A field power converter,
you should additionally use a commutating reactor
because of EMC considerations. A commutating reac-
tor is not necessary for the SDCS-FEX-1 (diode bridge).
With DCF 503A/504A field power converters, it is
already installed.
Converter Reactor
500 V; 50/60 Hz
SDCS-FEX-2A ND 30
Table 2.6/4: Commutating reactor (for more information
see publication Technical Data)
II F 2-24
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Fig. 2.6/5: Classification
Not applicable
First environment (residential area with light industry) with restricted distribution
Not applied, since general distribution sales channel excluded
satisfied
satisfied
The paragraphs below describe selection of the electri-
cal components in conformity with the EMC Guide-
line.
The aim of the EMC Guideline is, as the name implies,
to achieve electromagnetic compatibility with other
products and systems. The guideline ensures that the
emissions from the product concerned are so low that
they do not impair another product's interference
immunity.
In the context of the EMC Guideline, two aspects must
be borne in mind:
the product's interference immunity
the product's actual emissions
The EMC Guideline expects EMC to be taken into
account when a product is being developed; however,
EMC cannot be designed in, it can only be quantita-
tively measured.
Note on EMC conformity
The conformity procedure is the responsibility of both
the power converter's supplier and the manufacturer of
the machine or system concerned, in proportion to
their share in expanding the electrical equipment in-
volved.
EMC filters
You will find further in-
formation in publica-
tion:
Technical Guide
chapter: EMC Com-
pliant Installation and
Configuration for a
Power Drive System
M M
Mains filter
Converter
Line reactor
Supply transformer for a residential
area (rating normally 1,2 MVA)
Earthed public 400-V
network with neutral
conductor
Medium-voltage network
Earthed
neutral
T
o

o
t
h
e
r

l
o
a
d
s
,

e
.
g
.

d
r
i
v
e

s
y
s
t
e
m
s
An isolating transformer
with an earthed screen
and earthed iron core
renders mains filter and
line reactor superfluous.
Operation at public
low-voltage network
together with other
loads of all kinds.
Residential area
T
o

o
t
h
e
r

l
o
a
d
s

w
h
i
c
h

h
a
v
e

t
o

b
e

p
r
o
t
e
c
t
e
d

f
r
o
m

t
h
e

s
y
s
t
e
m

d
i
s
t
u
r
b
a
n
c
e
s

c
a
u
s
e
d

b
y

p
o
w
e
r

c
o
n
v
e
r
t
e
r
s

(
H
F

i
n
t
e
r
f
e
r
e
n
c
e

a
n
d

c
o
m
m
u
t
a
t
i
o
n

n
o
t
c
h
e
s
)
Converter
M M M M M M
a
l
t
e
r
n
a
t
i
v
e
a
l
t
e
r
n
a
t
i
v
e
Line reactor +
Y-capacitor
Medium-voltage network
Supply transformer for a residential
area (rating normally 1.2 MVA)
Earthed
neutral
Earthed public 400-V
network with neutral
conductor
T
o

o
t
h
e
r

l
o
a
d
s
,

e
.
g
.

d
r
i
v
e

s
y
s
t
e
m
s
Mains filter
Line reactor
Converter Converter
Mains filter
Line reactor
Converter Converter
An isolating transformer
with an earthed screen
and earthed iron core
renders mains filter and
line reactor superfluous.
Operation at public
low-voltage network
together with other
loads of all kinds.
T
o

o
t
h
e
r

l
o
a
d
s
,

e
.
g
.

d
r
i
v
e

s
y
s
t
e
m
s
T
o

o
t
h
e
r

l
o
a
d
s

w
h
i
c
h

h
a
v
e

t
o

b
e

p
r
o
t
e
c
t
e
d

f
r
o
m

t
h
e

s
y
s
t
e
m

d
i
s
t
u
r
b
a
n
c
e
s

c
a
u
s
e
d

b
y

p
o
w
e
r

c
o
n
v
e
r
t
e
r
s

(
H
F

i
n
t
e
r
f
e
r
e
n
c
e

a
n
d

c
o
m
m
u
t
a
t
i
o
n

n
o
t
c
h
e
s
)
Earthed public 400-V
network with neutral
conductor
Operation at public
low-voltage network
together with other
loads of all kinds.
Light industry
Residential area
II F 2-25
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
EN 61800-3
EN 61000-6-3
EN 61000-6-4
EN 61000-6-2
EN 61000-6-1
satisfied
satisfied
Second environment (industry) with restricted distribution
on customer's request satisfied
Not applicable
Standards
Classification
The following overview
utilises the terminology
and indicates the action
required in accordance
with Product Standard
EN 61800-3
For the DCS 500B series,
the limit values for emit-
For compliance with the protection objectives of the
German EMC Act (EMVG) in systems and machines,
the following EMC standards must be satisfied:
Product Standard EN 61800-3
EMC standard for drive systems (PowerDriveSys-
tem), interference immunity and emissions in resi-
dential areas, enterprise zones with light industry
and in industrial facilities.
This standard must be complied with in the EU for
satisfying the EMC requirements for systems and
machines!
For emitted interference, the following apply:
EN 61000-6-3 Specialised basic standard for emissions in light industry can
be satisfied with special features (mains filters, screened power
cables) in the lower rating range *(EN 50081-1).
EN 61000-6-4 Specialised basic standard for emissions in industry
*(EN 50081-2)
For interference immunity, the following apply:
EN 61000-6-1 Specialised basic standard for interference immunity in residen-
tial areas *(EN 50082-1)
EN 61000-6-2 Specialised basic standard for interference immunity in indus-
try. If this standard is satisfied, then the EN 61000-6-1 standard
is automatically satisfied as well *(EN 50082-2).
* The generic standards are given in brackets
The field supply is not depicted in
this overview diagram. For the
field current cables, the same
rules apply as for the armature-
circuit cables.
ted interference are complied with,
provided the action indicated is car-
ried out. This action is based on the
term Restricted Distribution used in
the standard (meaning a sales chan-
nel in which the products concerned
can be placed in the stream of com-
merce only by suppliers, customers
or users which individually or jointly
possess technical EMC expertise).
For power converters without addi-
tional components, the following
warning applies:
This is a product with restricted
distribution under IEC 61800-3.
This product may cause radio inter-
ference in residential areas; in this
case, it may be necessary for the
operator to take appropriate action
(see adjacent diagrams).
M M M M
Supply transformer for a
residential area (rating
normally 1.2 MVA)
Earthed 400-V network
with neutral conductor;
3~ 400 A
Operation at low-voltage network together with
other loads of all kinds, apart from some kinds
of sensitive communication equipment.
T
o

o
t
h
e
r

l
o
a
d
s
,

e
.
g
.

d
r
i
v
e

s
y
s
t
e
m
s
Line reactor +
Y-capacitor Line reactor
Converter Converter
Mains filter
Earthed
neutral
Medium-voltage network
Industrial zone
a
l
t
e
r
n
a
t
i
v
e
a
l
t
e
r
n
a
t
i
v
e
M M M M
Converter
transformer
C
a
s
e
-
r
e
f
e
r
e
n
c
e
d

E
M
C

a
n
a
l
y
s
i
s
a
l
t
e
r
n
a
t
i
v
e
Converter
transformer
with earthed

iron core
(and earthed
screen where
appropriate)
a
l
t
e
r
n
a
t
i
v
e
I > 400 A
and/or
U > 500 V
Operation with separate power converter transformer. If there
are other loads at the same secondary winding, these must be
able to cope with the commutation gaps caused by the power
converter. In some cases, commutating reactors will be
required.
T
o

o
t
h
e
r

l
o
a
d
s
,

e
.
g
.

d
r
i
v
e

s
y
s
t
e
m
s
Converter Converter
Line reactor
Medium-voltage network
Industrial zone
Legend
Unscreened cable with restriction
Screened cable
II F 2-26
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Converter I
DC
[A] Const. Filter type for y=4 Filter type for y= 5 Filter type for y=6 or 7
type
DCS60x-0025-y1 25A C1a NF3-440-25 NF3-500-25 ---
DCS60x-0050-y1 50A C1a NF3-440-50 NF3-500-50 ---
DCS60x-0075-y1 75A C1a NF3-440-64 NF3-500-64 ---
DCS60x-0100-y1 100A C1b NF3-440-80 NF3-500-80 ---
DCS60x-0140-y1 140A C1b NF3-440-110 NF3-500-110 ---
DCS60x-0200-y1 200A C2a NF3-500-320 NF3-500-320 ---
DCS60x-0250-y1 250A C2a NF3-500-320 NF3-500-320 ---
DCS60x-0270-61 250A C2a NF3-500-320 NF3-500-320 NF3-690-600
DCS60x-0350-y1 350A C2a NF3-500-320 NF3-500-320 ---
DCS60x-0450-y1 450A C2a NF3-500-600 NF3-500-600 NF3-690-600
DCS60x-0520-y1 520A C2a NF3-500-600 NF3-500-600 ---
DCS60x-0680-y1 680A C2b NF3-500-600 NF3-500-600 ---
DCS601-0820-y1 740A C2b NF3-500-600 NF3-500-600 ---
DCS602-0820-y1 820A C2b NF3-690-1000 NF3-690-1000 ---
DCS60x-1000-y1 1000A C2b NF3-690-1000 NF3-690-1000 ---
DCS60x-0903-y1 900A A5 NF3-690-1000 NF3-690-1000 NF3-690-1000
DCS60x-1203-y1 1200A A5 NF3-690-1000 NF3-690-1000 NF3-690-1000
DCS60x-1503-y1 1500A A5 NF3-690-1600 NF3-690-1600 NF3-690-1600
DCS60x-2003-y1 2000A A5 NF3-690-1600 NF3-690-1600 NF3-690-1600
3000A A6 NF3-690-2500 NF3-690-2500 NF3-690-2500
Filter only available on request
Three - phase filters
EMC filters are necessary to fulfil the standard for
emitted interference if a converter shall be run at a
public low voltage line, in Europe for example with 400
V between the phases. Such lines have a grounded
neutral conductor. ABB offers suitable three - phase
filters for 400 V and 25 A...600 A and 500 V filters for
440 V lines outside Europe.
Converter type of dc current Filter type
field supply unit U
max
= 250 V
[A]
SDCS-FEX-1 6 NF1-250-8
SDCS-FEX-2A 8 NF1-250-8
SDCS-FEX-2A 16 NF1-250-20
DCF 503A-0050 50 NF1-250-55
DCF 504A-0050 50 NF1-250-55
further filters for 12 NF1-250-12
30 NF1-250-30
The filters can be optimized for the real field currents: I
Filter
=
I
Field

Filter in a grounded line (earthed TN or TT

network)
The filters are suitable for grounded lines only, for
example in public European 400 V lines. According to
EN 61800-3 filters are not needed in insulated indus-
trial lines with own supply transformers. Furthermore
they could cause safety risks in such floating lines (IT
networks).
Single - phase filters for field supply
Many field supply units are single - phase converters for
up to 50 A excitation current. They can be supplied by
two of the three input phases of the armature supply
converter. Then a field supply unit does not need its
own filter.
If the phase to neutral voltage shall be taken (230 V in
a 400 V line) then a separate filter is necessary. ABB
offers such filters for 250 V and 6...30 A.
The filters can be optimized for the real motor currents:
I
Filter
= 0.8 I
MOT max
; the factor 0.8 respects the current
ripple.
Lines with 500 V to 1000 V are not public. They are
local lines inside factories, and they do not supply
sensitive electronics. Therefore converters do not need
EMC filters if they shall run with 500 V and more.
II F 2-27
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Commutation and line reactors
(see also Section Line reactors in this chapter)
Due to the maximum power of public 400 V trans-
formers (P
MAX
= 1.2 MVA I
MAX
= 1732 A) and due
to their relative voltage drop of 6% or 4% the maxi-
mum AC current which is available for a converter is
346 A or 520 A (I
DC
422 A or 633 A).
Isolating transformers
An isolating transformer makes line chokes unneces-
sary because of its leakage inductance, and a grounded
screen between its windings saves an EMC filter. The
screen and the iron core must be well connected with
the mounting plate of the converter.
Converter transformers
A converter transformer transfers a high power directly
from a medium voltage network to a single large
converter or to a local low voltage network for several
converters. Furthermore it acts as isolating transformer.
If such a converter transformer has no screen the EMC
demands are nevertheless fulfilled in most cases, be-
cause the RF interference can hardly get via the medi-
um-voltage network and the transformer of the public
network to the loads which must be protected against
disturbances.
PE
PE
Installation hints
All metal cabinets available on the market can be
used.
The mounting plate must be made from steel with
zinc coating and without any painting. It must be
connected with the PE busbar by several bolts/
cables.
The converter, the line reactors, fuses, contactors
and the EMC filter are to be placed on the mounting
plate so that the connections are as short as possible,
especially those from the converter via the line choke
to the filter.
The cables for digital signals which are longer than
3m and all cables for analogue signals must be
screened. Each screen must be connected at both
ends by metal clamps or comparable means directly
on clean metal surfaces. In the converter cubicle this
kind of connection must be made directly on the
sheet metal close to the terminals.
The necessity of a screen for power cables depends
on the length of the cable and on the environmental
demands. If a screen is necessary then it must be
pressed by a well conducting metal clamp directly
against the mounting plate or the PE busbar of the
converter cabinet.
Screened cables to the armature and to the excitation
winding cause the lowest noise level. The armature
current cable must contain a wire for a PE connec-
tion if the copper cross section of the screen cannot
fulfil the safety demands.
If a screen is not necessary the armature
current cable must be a four-wire cable.
Two wires are needed as PE to discharge
the parasitic RF currents from the motor
to the EMC filter in the cabinet.
II F 2-28
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
II F 3-1
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
3 Overview of crane software
3.1 Basic structure of DCS 600
CraneDrive
The control hardware of DCS 600 CraneDrive consists
of 2 parts:
converter control board SDCS-CON-2
drive control board SDCS-AMC-DC 2
(AMC = Application Motor Control)
Accordingly, the software is split into 2 parts:
All control functions superimposed to the torque
reference are done inside the AMC board. In addi-
tion, all HMI (Human Machine Interface) and
communication functions are part of the AMC
board's software. Also the Start/Stop functions
('Drive Logic') are realized by the AMC board's
software. All parameters and signals of the drive are
accessed via an AMC board residing data structure
called 'AMC-table'.
All converter related functions and the handling of
standard I/O are done by the SDCS-CON-2 soft-
ware:
Armature current control
Field weakening
Motor protection
I/O handling
In general, the software functions are distributed be-
tween the SDCS-CON-2 board and the SDCS-AMC-
DC 2 board according to the following diagram:
Fig. 3.1/1: Distribution of software functions
3.2 Control modes
The Control mode selects the source of control word
and references.
Local Mode
Commissioning tool DriveWindow is connected to
DDCS channel 3 of the AMC board and can use local
mode.
Local mode is also available on the panel CDP 312.
Fieldbus Mode
Reference and control word are supplied by an overrid-
ing control system, Advant controller or a fieldbus
adapter connected to the DDCS channel 0. This con-
trol mode enables also the functionality of shared
motion control bit (two motors controlled by one
converter).
Stand-alone Mode
Reference and control signals are supplied by hardware
signals.
Master/Follower Mode
Reference and control word are supplied to the follower
drive by the master drive via DDCS channel 2.
Human Machine Interface &
Communication
SDCS-CON-2
Software 15.2xx
CraneDrive functions
Software DCAAxxxx
S
D
C
S
-
A
M
C
-
D
C

2
Drive Control
Software 15.6xx
I/O handling
Torque Control
II F 3-2
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
3.3 Start, Stop and Fault Reactions
Power up
When the electronics power supply is switched on the
drive remains in the ON_INHIBIT state until electri-
cal disconnect input (DI4) is closed. In case of a fault
the drive remains in the FAULT state.
Normal start
Status bit RDY_FOR_ON = 1 signals that no faults are
pending and that the device is ready to close the main,
fan and field contactor.
The command DRIVE ON = 1 closes fan, field and
main contactor and activates the field control.
In stand-alone control mode the ON command is
generated internally by the first rising edge of the RUN
command (direction + reference).
Status bit RDY_FOR_RUN = 1 indicates that the field
converter is active and that the drive is ready to generate
torque.
The command START OVR = 1 activates speed and
torque control.
Status bit RUNNING = 1 indicates that the drive is in
normal operation.
Normal stop
START OVR = 0 sets the speed reference to zero and
the drive decelerates by ramp.
After the actual speed has reached zero the status bit
RUNNING is reset, the armature converter sets the
firing angle to maximum. The state RDY_FOR_RUN
is entered, when the current has reached zero.
ON = 0 sets RDY_FOR_RUN = 0 and the field current
reference to zero. The field converter sets the firing
angle to maximum. The contactors open, when the
current has reached zero.
ON = 0 internally forces RUN = 0.
Electrical Disconnect (Stop category 0)
Field and armature current are removed as fast as
possible. After the current has reached I
DC
= 0 the
contactors are opened. The normal DRIVE ON com-
mand is accepted when ELEC DISC-N = 1.
Fault reaction
Depending on the actual fault the armature current
and/or field current is reduced to zero as fast as possible
with single pulses and maximum firing angle. Contac-
tors are opened when the current has reached zero.
The state TRIPPED is entered and after a successful
reset the state ON_INHIBIT.
II F 3-3
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
3.4 Crane functions
Optimal Operational Safety
Mechanical Brake: Controls and supervises the open-
ing and closing of the brake.
Fast Stop: Stops the drive as fast as possible. When
stopped, movement in the opposite direction to the
fault is possible e.g. external detection for overload or
slack rope.
Torque Proving: Ensures that the motor is able to
produce torque before brake is lifted.
Speed Monitor: Supervises actual motor speed to be
within given limits. It also detects overspeeds and zero
speed for control interlocks.
Torque Monitor: Supervises the correlation between
requested speed & actual motor speed and direction.
Fault Handling: Monitors internal faults, identifies
possible causes and presents fault history.
Outstanding Crane Drive Performance
Start and Stop: Supervising and
control logic for starting and stopping the drive,
including torque proving.
Speed Reference: Individual settings
of acceleration and deceleration ramp times. For
smooth load handling and reduction of 'shock'
loading.
Speed and Torque: Ensures a mini-
mum variation of speed independently of the load.
Torque Memory: Presetting of torque when starting
the hoist with suspended load. The risk of load drop is
thereby minimized.
Power Optimization: Automatic field weakening of
hoist drive. Ensures maximum hoist speed relative to
the load and thus optimizes cycle times.
Master Follower: Facilitates load sharing of two mo-
tors on the same shaft. Can also be used when dual-
redundancy is required.
Speed Correction: Coordination of two drives from an
external control system. Input for correction of speed
error when used in synchronized operations.
Shared Motion: One DCS 600 CraneDrive is able to
handle two different motors (of two different motions)
including the different field windings and brakes.
II F 3-4
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
3.5 Speed Control
The speed controller is located in the AMC board
software.
Speed reference
The source of the reference is depending on the oper-
ating mode.
Overriding control
system, fieldbus adapters remote mode, DDCS
via AMC board
DriveWindow local mode, DDCS via
AMC board
Panel CDP312 local mode, connector
on CON-2
Analogue inputs local I/O
Speed reference features
Speed reference limiter
Variable slope rate
Speed correction
Speed measurement
The actual speed may be calculated from:
Armature voltage
Analogue tachometer
Pulse encoder
Controller features
PID controller
Window control
Acceleration compensation
Speed and torque adaptation
Droop
Additional torque references
Torque limitation and gear backlash function (the
integral part of the controller is set to a suitable value
on limitation)
Oscillation damping (band rejection filter for speed
error)
The diagram Fig. 3.9/2 shows the functionality of the
speed reference chain as well as of the speed controller.
3.6 Torque Control
Flux and Torque Calculation
The torque control is in general an open loop control.
The flux is adjusted by the field current. The reference
of the field current is generated by the superimposed
armature voltage control.
The torque is adjusted by the armature current. The
conversion from torque to current reference is done by
means of the calculated flux (based on the field current
and saturation characteristic).
Torque reference features
Torque reference A with 1st order filter and load
share
Torque reference B with torque ramp
Torque reference limiter
Torque step
A good behaviour in the field weakening requires speed
measurement by tachometer or encoder.
A simplified scheme of the torque reference chain is
given in diagram fig. 3.9/2.
3.7 HMI (Human Machine Interface)
The HMI is performed by CDP 312 control panel
or by DriveWindow.
Both tools contain:
Display of drive signals
Setting of drive parameters
Display fault and alarm messages
Control the drive in local operation
II F 3-5
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
3.8 Torque Generation
Interface between SDCS-AMC-DC 2 board and
DC control board SDCS-CON-2
The major signals exchanged each 2 ms between CON-
2 and AMC-DC 2 are:
SPEED_ACTUAL speed actual value from
CON-2
TORQ_USED_REF active torque reference to
CON-2
In addition, the calculated torque limits are read from
the CON-2 each 8 ms:
TC_TORQMAX
TC_TORQMIN
Armature voltage Control
This controller enables operation in the field weaken-
ing range. It generates the field current reference. At low
speeds the field current is constant and armature volt-
age is roughly proportional to the speed. At higher
speeds ( base speed) the field current reference is
reduced so that the armature voltage doesnt exceed its
reference.
Field Current Control
Two field exciters can be operated simultaneously for
two different motors.
The first field exciter can be operated with fixed current
reference, in field weakening or with a reduced refer-
ence for field heating.
The second field exciter has a fixed current reference
(no field weakening possible). However, it may be
reduced for field heating purposes.
A field reversal control is available for the first field
exciter.
Optitorque is a special control method where the flux
is reduced at small torque reference. This is available for
drives with and without field reversal.
Armature Current Control
The armature current reference is calculated from torque
reference and flux. Then it is processed by a ramp,
limitation and speed dependent limitation.
The actual value of the armature current is the meas-
ured mean value between two firing pulses.
The armature voltage reference is generated by a PI
controller.
The firing angle is calculated from this voltage reference
depending on the actual line voltage and the conduc-
tion time (adaptation between continuous and discon-
tinuous state of the converter current).
A simplified scheme of the armature current control is
given in diagram fig. 3.9/3.
II F 3-6
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
3.9 Software diagrams
Introduction
The designation of parameters and signals consist of a
group and an index.
X
Parameter
01.02
23.05
Signal
Group
Index
An empty box means: This signal does not
exist or can not be displayed by the CraneDrive soft-
ware.
The structure of the software is given. Changes of the
functions or pointers are realized through setting pa-
rameters.
This can be done via panel, DriveWindow (PC utility),
fieldbus or overriding control system.
Changed parameters or pointers are stored immediate-
ly in the non-volatile flash PROM.
All parameters can be transferred to the PC and be
stored on a data medium by using the PC program
DriveWindow.
On the following pages the simplified software struc-
ture is shown.
Fig. 3.9/1: Parameter/signal designation
II F 3-7
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Fig. 3.9/2: Speed reference chain
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to TORQUE REF. SELECTOR
II F 3-8
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Fig. 3.9/3: Torque control chain


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II F 3-9
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Fig. 3.9/4: Armature current control
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Limiter
II F 3-10
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
II F 4-1
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
I/O configuration example for step joystick operation
Table 4.1/1: I/O configuration step joystick
64.1 Stand-alone
64.10 Step Joystick
Inputs/outputs
Depending on the drive modes there are different
possibilities for inputs and outputs.
Digital Inputs
Input Signal use Description
SDCS-IOE-1
DI 9 DI 9
configurable
Fast STOP N
Overload
Slow down N
.....
see Group 10
DI 10 DI 10
DI 11 DI 11
DI 12 DI 12
DI 13 DI 13 Step ref 1
DI 14 DI 14 Step ref 2
DI 15 DI 15 Step ref 3
Stop & Limit
switches
Digital Outputs
Output Signal use Description
DO 1 FANS_ON fix Command fan contactor ON
DO 2 FIELD_EX_ON fix Comm. Field exciter cont. ON
DO 3 MAIN_CONT_ON fix Comm. Main contactor ON
DO 4 DIG_OUT 4 default Brake lift
DO 5 DIG_OUT 5 default Watchdog N
DO 6 DIG_OUT 6
configurable
Ready
Running
Fault ...
see Group 14
DO 7 DIG_OUT 7
DO 8 DIG_OUT 8
Digital Inputs
Input Signal use Description
SDCS-CON-2
DI 1 ACK_C_FAN fix Converter fan acknowledge
DI 2 DI 2 configurable Zero position
DI 3 ACK_M_CONT fix Main contactor acknowledge
DI 4 DI 4 fix Electrical disconnect
DI 5 DI 5 fix Funct. depends on SW rel.
DI 6 DI 6 configurable Brake acknowledge
DI 7 DI 7 fix Start Direction A
DI 8 DI 8 fix Start Direction b
4 Connection examples
4.1 Control connections
II F 4-2
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
I/O configuration example for pot joystick operation
Table 4.1/2: I/O configuration pot joystick
64.1 Stand-alone
64.10 Joystick
Inputs/outputs
Depending on the drive modes there are different
possibilities for inputs and outputs.
Stop & Limit
switches
Digital Outputs
Output Signal use Description
DO 1 FANS_ON fix Command fan contactor ON
DO 2 FIELD_EX_ON fix Comm. Field exciter cont. ON
DO 3 MAIN_CONT_ON fix Comm. Main contactor ON
DO 4 DIG_OUT 4 default Brake lift
DO 5 DIG_OUT 5 default Watchdog N
DO 6 DIG_OUT 6
configurable
Ready
Running
Fault ...
see Group 14
DO 7 DIG_OUT 7
DO 8 DIG_OUT 8
Digital Inputs
Input Signal use Description
SDCS-IOE-1
DI 9 DI 9
configurable
Fast STOP N
Overload
Slow down N
.....
see Group 10
DI 10 DI 10
DI 11 DI 11
DI 12 DI 12
DI 13 DI 13
DI 14 DI 14
DI 15 DI 15
Analogue Inputs
Input Signal use Description
SDCS-CON-2
AI 1 SPEED_REF fix Speed reference
0 V
+10 V
Digital Inputs
Input Signal use Description
SDCS-CON-2
DI 1 ACK_C_FAN fix Converter fan acknowledge
DI 2 DI 2 configurable Zero position
DI 3 ACK_M_CONT fix Main contactor acknowledge
DI 4 DI 4 fix Electrical disconnect
DI 5 DI 5 fix Funct. depends on SW rel.
DI 6 DI 6 configurable Brake acknowledge
DI 7 DI 7 fix Start Direction A
DI 8 DI 8 fix Start Direction b
II F 4-3
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
I/O configuration example for radio control operation
Table 4.1/3: I/O configuration radio joystick
64.1 Stand-alone
64.10 Radio Joystick
Inputs/outputs
Depending on the drive modes there are different
possibilities for inputs and outputs.
Stop & Limit
switches
Digital Outputs
Output Signal use Description
DO 1 FANS_ON fix Command fan contactor ON
DO 2 FIELD_EX_ON fix Comm. Field exciter cont. ON
DO 3 MAIN_CONT_ON fix Comm. Main contactor ON
DO 4 DIG_OUT 4 default Brake lift
DO 5 DIG_OUT 5 default Watchdog N
DO 6 DIG_OUT 6
configurable
Ready
Running
Fault ...
see Group 14
DO 7 DIG_OUT 7
DO 8 DIG_OUT 8
Digital Inputs
Input Signal use Description
SDCS-IOE-1
DI 9 DI 9
configurable
Fast STOP N
Overload
Slow down N
.....
see Group 10
DI 10 DI 10
DI 11 DI 11
DI 12 DI 12
DI 13 DI 13
DI 14 DI 14
DI 15 DI 15
Analogue Inputs
Input Signal use Description
SDCS-CON-2
AI 1 SPEED_REF fix Speed reference
0 V
+10 V
Digital Inputs
Input Signal use Description
SDCS-CON-2
DI 1 ACK_C_FAN fix Converter fan acknowledge
DI 2 DI 2 configurable
DI 3 ACK_M_CONT fix Main contactor acknowledge
DI 4 DI 4 fix Electrical disconnect
DI 5 DI 5 fix Funct. depends on SW rel.
DI 6 DI 6 configurable Brake acknowledge
DI 7 DI 7 fix Start Direction A
DI 8 DI 8 fix Start Direction b
II F 4-4
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
I/O configuration example for fieldbus operation (Fieldbus Mode)
Table 4.1/4: I/O configuration fieldbus or overriding
control system
64.1 Not Stand-alone
98.2 Fieldbus or overriding control system
Speed reference
Data set 1 word 2
Actual Speed
Data set 2 word 2
PLC
F
i
e
d
b
u
s
Command Word
Data set 1 word 1
Bit number Signal Description
0 = Bit 0, LSB COMTEST REC Comtest receive bit
1 DRIVE ON Drive ON from
overriding control
2 HIGH SPEED High speed select
3 START OVR Start from overriding
control
4 RAMP HOLD Ramp holding signal
5 SEPARATE Separate ctrl select
signal (M/F ctrl)
6 TORQ CTRL Torquecontrol select
signal
7 LOAD MEAS SEL Load measurement
select (enable LOAD
MEAS REF)
8 RESET OVR Reset from overriding
control
9 FAST STOP 1 Fast stop 1
10 FAST STOP 11 Fast stop 11 type select
11 PGM SYNC Program synchrization
of pos meas.
12 HW SYNC Hardware
synchronization inhibit
13 RESET SYNC
READY
Reset synchronization
ready
14 USER MACRO
CHANGE
Shared motion
Motor1/Motor2 change
request
15 = Bit 15,
MSB
not used
Status Word
Data set 2 word 1
Bit number Signal Description
0 = Bit 0, LSB RDY FOR ON Ready for on
1 ELEC DISC-N Electrical disconnect,
DI4
2 RDY FOR RUN Ready for run
3 RUNNING Running
4 ZERO SPEED Zero speed
5 REM LOC Remote / local
(1=Remote)
6 TORQ PROV OK Torque proving OK
7 USER 1 OR 2 Motor 1 or 2 active
8 FAULT Fault
9 WARNING Warning
10 LIMIT Drive in torque limit
11 SYNC Sync input (e.g. DI7)
12 SYNC RDY Synchronization ready
13 BRAKE LONG FTIME Brake long falling time
indication
14 COMTEST TRA Communication test
transmit bit
15 = Bit 15,
MSB
SNAG LOAD Snag load indication
Digital Inputs
Input Signal use Description
SDCS-CON-2
DI 1 ACK_C_FAN fix Converter fan acknowledge
DI 2 DI 2 configurable
DI 3 ACK_M_CONT fix Main contactor acknowledge
DI 4 DI 4 fix Electrical disconnect
DI 5 DI 5 fix Funct. depends on SW rel.
DI 6 DI 6 configurable Brake acknowledge Motor 1
DI 7 DI 7 configurable
DI 8 DI 8 configurable Brake Acknowledge Motor 2 *
Digital Outputs
Output Signal use Description
DO 1 FANS_ON fix Command fan contactor ON
DO 2 FIELD_EX_ON fix Comm. Field exciter cont. ON
DO 3 MAIN_CONT_ON fix Comm. Main contactor ON
DO 4 DIG_OUT 4 default Brake lift Motor 1
DO 5 DIG_OUT 5 default Watchdog N
DO 6 DIG_OUT 6
configurable
Brake lift Motor 2 *
Ready
Running
Fault ...
see Group 14
DO 7 DIG_OUT 7
DO 8 DIG_OUT 8 * for shared motion application
Inputs/outputs
Depending on the drive modes there are different
possibilities for inputs and outputs.
II F 4-5
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
DCS 600
CraneDrive
Control word
Torque reference
Status word
DCS 600
CraneDrive
Control word
Torque reference
Status word
PLC
Master/Follower
The Master is speed controlled and the Follower is
normally torque controlled.
This feature is useful for:
Hoist drive - operation on one drum
use Follower torque controlled
Travel drive - weak mechanical connection
use Follower window controlled
Redundancy purpose
use emergency parameter set handled by user
macro
Master/Follower is normally a load sharing application.
It is designed for applications running two DCS 600
CraneDrives being coupled by a motor shaft via gears,
rails, etc.
The Master/Follower application is controlling the
load distribution between the two drives. The Master is
sending control signals and references (e.g. speed or
torque) through the Master/Follower link to the Fol-
lower. The Master is also reading back status informa-
tion from the Follower to ensure a safe operation.
The Master/Follower application can be used for both
hoist and travel motions, as well as in fieldbus mode
and stand-alone mode.
Fig 4.1/1: Master Follower
Fig 4.1/2: Master Follower with PLC control
II F 4-6
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
Fig. 4.2/1: DCS 600 CraneDrive wiring diagram
4.2 Wiring diagram
A
I
T
A
C
A
I
1
A
I
2
A
I
3
A
I
4
D
I
1
D
I
2
D
I
3
D
I
4
D
I
5
D
I
6
D
I
7
D
I
8
_
_
_
_
_
+
+
+
+
+
T
T
X
3
:
1
2
3
4
5
6
7
8
9
1
0
X
6
:
1
2
3
4
5
6
7
8
X
4
:
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
X
5
:
+
_
K
1
K
B
2
K
5
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II F 4-7
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
II F 4-8
3ADW000139R0401_DCS600_CraneDrive_System description_e_d
ABB Automation Products GmbH
Postfach 1180
68619 Lampertheim GERMANY
Telefon +49(0) 62 06 5 03-0
Telefax +49(0) 62 06 5 03-6 09
www.abb.com/dc
3
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*139R0401A4100000*
*139R0401A4100000*
DCS 400
DCS 500B / DCS 600
DCS 400 / DCS 500
Easy Drive
DCA 500 / DCA 600
DCE 400 plus
The drive module for standard applications
Integrated field supply (max. 20 A)
Accurate speed and torque control
Extremely small and compact design
Very easy installation and commissioning
Express delivery
Power range: 10...500 kW (13...670 HP)
The drive module for demanding
applications
Free programming of software
6- and 12-pulse configuration up to 10 MW/
13,000 HP and more
Plain text display
Power range: 10...5000 kW (13...6700 HP)
Highly integrated panel
Extremly small and compact design
Contains:
DCS 400 module
AC fuses
Auxiliary transformer
Motor fan starter with protection
Main contactor
Power range: 20...130 kW (26...174 HP)
The complete standard cabinet solution
Pre-engineered
Easy installation and commissioning
Protection class: IP 21
Plain text display
Short delivery time
Power range: 50...1350 kW (65...1800 HP)
For complex, completely engineered Drive
System in common cabinet design
Flexible and modular hardware structure
6- and 12-pulse configuration up to 18 MW/
23,000 HP and more
Pre-programmed applications:
Metals, Cranes, P&P application, Mining
Power range: 10...18000 kW (13...23000 HP)
DC Drives Product Portfolio
Since we aim to always meet the latest state-of-the-art
standards with our products, we are sure you will
understand when we reserve the right to alter particulars
of design, figures, sizes, weights, etc. for our equipment
as specified in this brochure.