3ADW000430R0201 DCS800 Lift Magnet Supply e B

DCS800
Software Application: Supply for Electric Lifting Magnets

(mains fed and battery fed)
Title: DEABBMagBat
Version: V03.1
DCS800 (20 to 5200 A)

DCS800 Drive Manuals
Language
Public. number E D I ES F CN RU PL PT SE
DCS800 Quick Guide 3ADW000191 x x x x x x x
DCS800 Tools & Documentation CD 3ADW000211 x
DCS800 Converter module
Flyer DCS800 3ADW000190 x x x x x
Technical Catalog DCS800 3ADW000192 x x x x x x x x x
Hardware Manual DCS800 3ADW000194 x x x x x x x x
Hardware Manual DCS800 update DCF503B/DCF504B 3ADW000194Z x
Firmware Manual DCS800 3ADW000193 x x p x x x x x
Installation according to EMC 3ADW000032 x
Technical Guide 3ADW000163 x
Service Manual DCS800 3ADW000195 x x
12-Pulse Manual 3ADW000196 x
CMA-2 Board 3ADW000136 x
Flyer Hard - Parallel 3ADW000213 x
Drive Tools
DriveWindow 2.x - User's Manual 3BFE64560981 x
DriveOPC 2.x - User's Manual 3BFE00073846 x
Optical DDCS Communication Link 3AFE63988235 x
DDCS Branching Units - User’s Manual 3BFE64285513 x
DCS800 Applications
PLC Programming with C_____s C_____s_V23 x x x
61131 DCS800 target +tool description - Application Program 3ADW000199 x
DCS800 Crane Drive
DCS800 Crane Drive Manual suppl. 3AST004143 x
DCS800 Crane Drive Product note PDC5 EN x
DCS800 Winder ITC
DCS800 Winder Product note PDC2 EN x
DCS800 Winder description ITC 3ADW000308 x
Winder Questionnaire 3ADW000253Z x
DCS800-E Panel Solution
Flyer DCS800-E Panel solution 3ADW000210 x
Hardware Manual DCS800-E 3ADW000224 x
DCS800-A Enclosed Converters
Flyer DCS800-A 3ADW000213 x
Technical Catalog DCS800-A 3ADW000198 x
Installation of DCS800-A 3ADW000091 x x
DCS800-R Rebuild System
Flyer DCS800-R 3ADW000007 x x
DCS800-R Rebuild Kits 3ADW000197 x
DCS800-R Optical Rebuild Kits 3ADW000415 x
DCS800-R DCS500/DCS600 Upgrade Kits 3ADW000256 x
Extension Modules
RAIO-01 Analog IO Extension 3AFE64484567 x
RDIO-01 Digital IO Extension 3AFE64485733 x
RRIA-01 Resolver Interface Module 3AFE68570760 x
RTAC-01 Pulse Encoder Interface 3AFE64486853 x
RTAC-03 TTL Pulse Encoder Interface 3AFE68650500 x
AIMA R-slot extension 3AFE64661442 x
Door mounting kits
Door mounting DCS Control Panel (IP54, click in) 3AUA0000076085 x
Door mounting DCS Control Panel (fix mounting) 3AFE68294673 x
Door mounting DCS Control Panel (IP66, fix mounting) 3AFE68829593 x
Serial Communication
Drive specific serial communication
NETA Remote diagnostic interface 3AFE64605062 x
Fieldbus Adapter with DC Drives RPBA- (PROFIBUS) 3AFE64504215 x
Fieldbus Adapter with DC Drives RCAN-02 (CANopen)
Fieldbus Adapter with DC Drives RCNA-01 (ControlNet) 3AFE64506005 x
Fieldbus Adapter with DC Drives RDNA- (DeviceNet) 3AFE64504223 x
Fieldbus Adapter with DC Drives RMBA (MODBUS) 3AFE64498851 x
Fieldbus Adapter with DC Drives RETA (Ethernet) 3AFE64539736 x
x -> existing p -> planned
Status 01.2015
DCS800 Manuals-list e m.docx
3
Table of contents
Table of contents............................................................................................................................ 3
Electric Lifting Magnets ................................................................................................................. 4
General .......................................................................................................................................4
Diagram 1: Single Magnet in Current Control Mode ....................................................................5
Diagram 2: Multi Magnets in Voltage Control Mode and Battery Backup.....................................6
Safety instructions ......................................................................................................................... 7
Introduction to this manual ......................................................................................................... 12
DCS800 Solution for Electric Lifting Magnets ............................................................................ 13
Chapter overview ......................................................................................................................13
Functional description ...............................................................................................................14
Commissioning and engineering instructions ............................................................................25
Commissioning Parameters ......................................................................................................26
Drawings ....................................................................................................................................... 28
Appendix A – Used Standard DCS800 Parameters .................................................................... 29
Appendix B – Application Parameters ........................................................................................ 30
Group 7.....................................................................................................................................30
Group 8.....................................................................................................................................31
Group 60 ...................................................................................................................................33
Group 61 ...................................................................................................................................39
Group 62 ...................................................................................................................................41
Group 63 ...................................................................................................................................43
Group 64 ...................................................................................................................................49
Group 65 ...................................................................................................................................55
Group 69 ...................................................................................................................................63
Appendix C - Overvoltage Protection Hints ............................................................................... 64
Appendix D - Additional Technical Information ......................................................................... 66
Table of Contents
3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

4
Electric Lifting Magnets
General
Industrial electric lifting magnets (mains fed and battery fed) are used in electric and elec-
tromechanical devices and equipment with a magnetic field generated by an electrical cur-
rent creating sufficient force for lifting, holding and handling loads with ferromagnetic
properties.
They are also used as magnetic separation equipment, used to separate magnetic from
nonmagnetic material, for example separating ferrous metal from other material in scrap.
Mains-fed electric lifting magnets shall provide a tear-off force corresponding to at least 2
times the working load under the conditions specified by the customer.
A stand-by battery shall be provided to supply power in case the mains supply fails. It shall
be capable of providing the current needed to hold the working load limit for at least 10
minutes.
A protection concept always needs to be provided (please refer to Appendix D). Different
solutions are possible. The protection concept always depends on the application.
Supply for Electric Lifting Magnets

5
Diagram 1: Single Magnet in Current Control Mode

The following figure shows one magnet and a MOV directly in parallel of the magnet for
overvoltage protection. The converter operates in current control.
AC input
3-ph
I>>
K01 electronics-,
fan- supply
Current Control DCS800

+
-
+ -
MOV
For safety reasons a battery back-up is necessary, if the load must not fall down in case of
mains supply problems.

6
Diagram 2: Multi Magnets in Voltage Control Mode and Battery Backup

The following figure shows 2 magnets in parallel with MOVs directly in parallel of each
magnet and an additional MOV+resistor combination plus a freewheeling diode in parallel
of both magnets for overvoltage protection. The converter operates in voltage control.
AC input
3-ph
I>>
K01 electronics-,
fan- supply
Voltage Control DCS800

+ +
- -
+ -
Battery
DC fuses
MOV + Resistor
service switch
K02.0
Freewheeling diode Battery

K03D Battery diode K04B
fuse
K02.1 K02.2
MOV MOV
DC fuses Protection of battery, if thyristors are broken.

Note DC fuses
DC fuses will open a short circuit with the battery in case of two blown thyristors in
the DCS800 to avoid the loss of magnet supply by battery backup.

7
Safety instructions
Chapter overview
This chapter contains the safety instructions which you must follow when installing, operat-
ing and servicing the DCS800. If ignored, physical injury or death may follow, or damage
may occur to the DCS800 or the DCS800 equipment. Read the safety instructions before
you work on the unit.
To which products this chapter applies

This chapter applies to the DCS800... Size D1 to D7 and field exciter units DCF80x.
Use of warnings and notes

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

which can cause physical injury and/or damage to the
equipment.
General warning warns about conditions, other

than those caused by electricity, which can result
in physical injury and/or damage to the equip-
ment.
Electrostatic discharge warning warns of electro-
static discharge which can damage the equip-
ment.
Safety instructions

8
Installation and maintenance work

These warnings are intended for all who work on the DCS800, magnet supply ca-
ble or magnet. Ignoring the instructions can cause physical injury or death.
Only qualified electricians are allowed to install and maintain the

DCS800.
• Never work on the DCS800, magnet cable or magnet when main
power is applied.
Always ensure by measuring with a multi meter (impedance at
least 1 MΩ) that:
1. Voltage between DCS800 input phases U1, V1 and W1

and the frame is close to 0 V.
2. Voltage between terminals C+ and D- and the frame is
close to 0 V.
• Do not work on the control cables when power is applied to the
DCS800 or to the external control circuits. Externally supplied
control circuits may cause dangerous voltages inside the
DCS800 even when the main power on the DCS800 is switched
off.
• Do not make any insulation or voltage withstand tests on the
DCS800 or DCS800 modules.
• When reconnecting the magnet cable, always check that the C+
and D- cables are connected with the proper terminal.
Note:
• The magnet cable terminals on the DCS800 are at a danger-
ously high voltage when the input power is on, regardless of
whether the magnet is running or not.
• Depending on the external wiring, dangerous voltages (115 V,
220 V or 230 V) may be present on the terminals of relay outputs
SDCS-IOB-2 and RDIO.
• DCS800 with enclosure extension: Before working on the
DCS800, isolate the whole DCS800 from the supply.
Safety instructions

9
WARNING! The printed circuit boards contain components sensitive

to electrostatic discharge. Wear a grounding wrist band when han-
dling the boards. Do not touch the boards unnecessarily.
Use grounding strip:
ABB order no.: 3ADV050035P0001
Grounding
These instructions are intended for all who are responsible for the
grounding of the DCS800. Incorrect grounding can cause physical
injury, death or equipment malfunction and increase electromagnetic
interference
• Ground the DCS800, magnet and adjoining equipment to ensure

personnel safety in all circumstances, and to reduce electromag-
netic emission and pick-up.
• Make sure that grounding conductors are adequately sized as
required by safety regulations.
• In a multiple-DCS800 installation, connect each DCS800 sepa-
rately to protective earth (PE) .
• Minimize EMC emission and make a 360° high frequency
grounding of screened cable entries at the cabinet lead-through.
• Do not install a DCS800 with EMC filter on an ungrounded
power system or a high resistance-grounded (over 30 ohms)
power system.
Note:
• Power cable shields are suitable for equipment grounding con-
ductors only when adequately sized to meet safety regulations.
• As the normal leakage current of the DCS800 is higher than 3.5
mA AC or 10 mA DC (stated by EN 50178, 5.2.11.1), a fixed
protective earth connection is required.
Safety instructions

10
Fiber optic cables

WARNING! Handle the fiber optic cables with care. When unplug-
ging optic cables, always grab the connector, not the cable itself. Do
not touch the ends of the fibers with bare hands as the fiber is ex-
tremely sensitive to dirt. The minimum allowed bend radius is 35 mm
(1.4 in.).
Mechanical installation
These notes are intended for all who install the DCS800. Handle the
unit carefully to avoid damage and injury.
• DCS800 sizes D4...D7: The DCS800 is heavy. Do not lift it

alone. Do not lift the unit by the front cover. Place units D4 and
D5 only on its back.
DCS800 sizes D5...D7: The DCS800 is heavy. Lift the DCS800

by the lifting lugs only. Do not tilt the unit. The unit will overturn
from a tilt of about 6 degrees.
• Make sure that dust from drilling does not enter the DCS800
when installing. Electrically conductive dust inside the unit may
cause damage or lead to malfunction.
• Ensure sufficient cooling.
• Do not fasten the DCS800 by riveting or welding.
Operation
These warnings are intended for all who plan the operation of the
DCS800 or operate the DCS800. Ignoring the instructions can cause
physical injury or death or damage the equipment.
• Before adjusting the DCS800 and putting it into service, make

sure that the magnet and all DCS800 equipment are suitable for
operation throughout the voltage range provided by the DCS800.
The DCS800 can be adjusted to operate the magnet at voltages
above and below the rated voltage.
• Do not activate automatic fault reset functions of the Standard
Application Program if dangerous situations can occur. When
activated, these functions will reset the DCS800 and resume op-
eration after a fault.
• Do not control the magnet supply with the disconnecting device
(disconnecting mains); instead, use the control panel keys
and , or commands via the I/O board of the DCS800.
Safety instructions

11
• Mains connection
You can use a disconnect switch (with fuses) in the power sup-
ply of the thyristor power converter to disconnect the electrical
components of the unit from the power supply for installation and
maintenance work. The type of disconnect used must be a dis-
connect switch as per EN 60947-3, Class B, so as to comply
with EU regulations, or a circuit-breaker type which switches off
the load circuit by means of an auxiliary contact causing the
breaker's main contacts to open. The mains disconnect must be
locked in its "OPEN" position during any installation and mainte-
nance work.
• EMERGENCY STOP buttons must be installed at each control
desk and at all other control panels requiring an emergency stop
function. Pressing the STOP button on the control panel of the
thyristor power converter will neither cause an emergency mag-
net supply stop, nor will the DCS800 be disconnected from any
dangerous potential.
To avoid unintentional operating states, or to shut the unit down
in case of any imminent danger according to the standards in the
safety instructions it is not sufficient to merely shut down the
DCS800 via signals "RUN", "DCS800 OFF" or "Emergency
Stop" respectively "control panel" or "PC tool".
• Intended use
The operating instructions cannot take into consideration every
possible case of configuration, operation or maintenance. Thus,
they mainly give such advice only, which is required by qualified
personnel for normal operation of the machines and devices in
industrial installations.
If in special cases the electrical machines and devices are in-

tended for use in non-industrial installations - which may require
stricter safety regulations (e.g. protection against contact by chil-
dren or similar) -, these additional safety measures for the instal-
lation must be provided by the customer during assembly.
Note:
• When the control location is not set to Local (L not shown in the
status row of the display), the stop key on the control panel will
not stop the DCS800. To stop the DCS800 using the control
panel, press the LOC/REM key and then the stop key .
Safety instructions

12
Introduction to this manual
Chapter overview
This chapter describes the purpose, contents and the intended use of this manual.
Before You Start

The purpose of this manual is to provide the information necessary to handle the
magnet control.
Study carefully the Safety instructions at the beginning of this manual before at-
tempting any work on or with the DCS800. Read through this manual before start-
ing-up the DCS800. The installation and commissioning instructions given in the
DCS800 Hardware Manual, DCS800 Firmware Manual and DCS800 Quick Guide
must also be read before proceeding.
This manual is based on the standard DCS800 firmware Version 3.80 or later.
What this manual contains

Electric Lifting Magnets - General information.
The Safety instructions can be found at the beginning of this manual.
Introduction to this manual, the chapter you are currently reading, introduces you
to this manual.
DCS800 Solution for Electric Lifting Magnets this chapter describes the functional-
ity functions, commissioning of the MultiFex configuration.
Appendix A – Used Standard DCS800 Parameters
Appendix B – Application Parameters
Appendix C – Overvoltage Protection Hints
Appendix D – Additional Technical Information
Introduction to this manual

13
DCS800 Solution for Electric Lifting Magnets
Chapter overview
This chapter describes the functions and commissioning of the electric lifting mag-
nets configuration.
The basic firmware contains:

1.) Magnetization mode
(Voltage and current control)
2.) Demagnetization modes
(Voltage and current control)
3.) Voltage and current
set points
4.) Magnet resistor monitoring
5.) Step by step sheet release
6.) Display:
DCS800 current output
DCS800 voltage output
7.) Transport Mode
8.) Magnet I²t-Function
(for up to 8 Magnets)
Not included:
- Charging and Discharging
of a battery
(extra hardware required)
DCS800 Solution

14
Functional description
Magnetization and Demagnetization Mode:
Voltage Control Current Control
Magnetic force can be dynamically increased and decreased using pure current
control using the full voltage range. But a longer pure current control can overheat
the magnet. Magnets in parallel prefer voltage control. This will prevent possible
overloading of the individual magnet. Depending on the requirements, a combina-
tion of current and voltage control is desirable.
The commands Cmd_MagOn, Cmd_Run, Cmd_Cur and Cmd_Demag can be set

via digital input or Magnet Control Word (7.10) and customized by parameter
group 65:
- ConfMagOn (65.01 / Magnet On)
- ConfEnbRun (65.02 / Enable Run)
- ConfEnbCC (65.04 / Current Control Selection)
- ConfDeMag (65.05 / Demagnetizing Selection)
If AutoRunSel = Enabled (60.12) then Enable RUN is activated by Magnet ON

command.
If RESEToverSTOP = Enabled (60.13) then RESET is initiated by a STOP com-

mand.
DCS800 Solution

15
Switch On Boost:
Voltage
Current
Time
Magnet switched ON with

a.) Voltage Boost in Voltage Control
b.) In Current Control
The diagram above shows how the magnet current reference can be reached as
quickly as possible after start command of the converter. Voltage or current control
can be used.
In current control the magnet current can be ramped up dynamically dependent on
the amount of input voltage.
The higher the input voltage the higher is the dynamic of the current controller.
In voltage control the magnet current can be ramped up dependent on a voltage
boost.
The voltage boost is a voltage reference value which is higher than the demanded
voltage reference to be able to ramp up the magnet current dynamically.
After reaching the magnet current reference the voltage reference is switched to
the demanded voltage reference.
The voltage boost can be at a maximum of the AC input voltage * 1.35.
Precautions have to be taken not to supply the converter with a higher input volt-
age than the specified isolation voltage of the magnet.
DCS800 Solution

16
Demagnetization or Degaussing Mode (Selection in parameter 60.15):
Voltage
Current
Time
Magnet switched
OFF through
Magnet switched OFF
Current Control Additional Reduction of changechange
of polarity
Current Additional through of
Magnet Magnets added magnetic for Demagnetiza-
Control Magnets polarity for
switched ON by switching force through tion
Magnet added by Demagnetization
connectors
switched switching reduction of
ON connectors voltage / cur-
rent
The operation mode of Demagnetization is shown on the diagram above.

The release of light weight loads is done by demagnetization.
Decreasing or alternating (positive and negative) magnet current will erase the re-
sidual force. A 4-quadrant converter which can supply current in both directions is
required for this operation.
There are requirements of erasing the remanence of magnets completely.

The operation mode which is called Degaussing by pulsing is shown in the dia-
gram above. Decreasing and alternating the magnet current will erase the residual
force.
The pulse width (T/2) of each current pulse in parameter 60.17 as well as the com-
plete degaussing time Ƭ in parameter 60.16 has to be set up to define the number
of alternating current pulses and the amplitude. The reversal time delay for the
change of the thyristor bridge has also to be considered. The degaussing proce-
dure in simplified terms can be shown with a damped harmonic oscillation curve.
DCS800 Solution

17
Voltage and current set points:
The voltage reference source can be configured in ConfRefSrc (63.17)
63.17 = Analog_Inp:
 Analog input with 0 – 10 Volt, 0 – 20 mA or 4 – 20 mA (configured by jump-
ers on SDCS-CON-4). The voltage (11.03 = AI1…AI6) can be monitored in
group 5 and adjusted in group 13. The scaling 0 to 100% is related from 0
to 99.02 in voltage and from 0 …99.03 in current control.
63.17 = PB_cont (Push buttons continuously):

 The function Push buttons continuously operates like the MotPot function in
the standard firmware and is dedicated for voltage references only.
The commands Push Button Up, Push Button Down and Push Button
Reset can be set via digital input or Magnet Control Word (7.10) and
customized by parameter group 65:
- ConfPB_UP (65.10 / Push Button Up Reference)
- ConfPB_DOWN (65.11 / Push Button Down Reference)
- ConfPB_Reset (65.12 / Push Button Reset Reference)
If PBRESEToverSTOP = Enabled (60.14) then PB-RESET is initiated by a STOP

command.
While the reference Up button is pressed, the reference will be increased continu-
ously depending on PB_RefRamp (63.18).
While the reference Down button is pressed, the reference will be decreased con-
tinuously depending on PB_RefRamp (63.18).
The unit of Parameter 63.18 is “% per second”.

63.18 = 1 %/s means that the Ref value is ramped down from 100% to 0%
within 100 seconds.
within 10 seconds.
within 1 second.
While the PB_Reset button is pressed, the reference value is set to PB_ResetRef
(63.20) or zero.
It is possible to freeze the actual reference value on power off in PB_ActValFreeze
(63.21).
It is also possible to select with PB_RefPowerOn (63.22) whether the reference
value after power on is the last frozen value PB_ActValFreeze (63.21), an internal
fixed set point PB_ResetRef (63.20) or zero.
PB_RefMax (63.24) will limit the increasing function to a maximum value and
PB_RefMin (63.23) will limit the decreasing function to a minimum value.
DCS800 Solution

18
63.17 = PB_step (Push buttons stepwise):

 The function Push buttons stepwise operates with a step range and is dedi-
cated for voltage references only.
The commands Push Button Up, Push Button Down and Push Button
Reset can be set via digital input or Magnet Control Word (7.10) and
customized by parameter group 65:
- ConfPB_UP (65.10 / Push Button Up Reference)

- ConfPB_DOWN (65.11 / Push Button Down Reference)
- ConfPB_Reset (65.12 / Push Button Reset Reference)
If PBRESEToverSTOP = Enabled (60.14) then PB-RESET is initiated by a STOP

command.
While the reference Up button is pressed, the reference will be increased incre-
mentally with the rising edge depending on a variable step range PB_RefStep
(63.19).
While the reference Down button is pressed, the reference will be decreased in-
crementally with the rising edge depending on a variable step range PB_RefStep
(63.19).
While the PB_Reset button is pressed, the reference value is set to PB_ResetRef
(63.20) or zero.
It is possible to freeze the actual reference value on power off in PB_ActValFreeze
(63.21). It is also possible to select with PB_RefPowerOn (63.22) whether the ref-
erence value after power on is the last frozen value PB_ActValFreeze (63.21), an
internal fixed set point PB_ResetRef (63.20) or zero.
PB_RefMax (63.24) will limit the increasing function to a maximum value and
PB_RefMin (63.23) will limit the decreasing function to a minimum value.
DCS800 Solution

19
63.17 = Int_Ref (Internal voltage reference values)
 There are 16 internal voltage reference values available which can be se-
lected via 4 Bits (BCD). These fixed values are dedicated for voltage refer-
ences only.
The reference value can be indexed by a table of the fixed values named
IntRef01 – IntRef16 (63.01 – 63.16) via 4 Bits (BCD).
The resulting internal reference is written to parameter 23.01.
The commands IntRefBit0, IntRefBit1, IntRefBit2 and IntRefBit3 can be set via digi-
tal input or Magnet Control Word (7.10) and customized by parameter group 65:
- ConfRefBit0 (65.06 / Internal Reference Bit 0)
 Table of selectable internal references:
Bit 3 Bit 2 Bit 1 Bit 0 Fixed Set Point
0 0 0 0 1
0 0 0 1 2
0 0 1 0 3
0 0 1 1 4
0 1 0 0 5
0 1 0 1 6
0 1 1 0 7
0 1 1 1 8
1 0 0 0 9
1 0 0 1 10
1 0 1 0 11
1 0 1 1 12
1 1 0 0 13
1 1 0 1 14
1 1 1 0 15
1 1 1 1 16
DCS800 Solution

20
The current reference source can be configured directly in parameter TorqRefA

Sel (25.10 = AI1…AI6) and doesn’t depend on the configuration of 63.17.
Analog input with 0 – 10 Volt, 0 – 20 mA or 4 – 20 mA (configured by jumpers on
SDCS-CON-4).
Step by step sheet release (Unload cranes sheet by sheet):

If the function button StepbyStepRelease is pressed the following procedure
starts:
1.) DCS800 is in voltage control or current control when the function button is
pressed.
2.) The actual current value is set as reference current value (IRef1) for internal
use.
3.) In voltage control the control mode is switched over to current control.
4.) The current reference is ramped down within UnloadRampStep (60.05) and is
always limited with StepIrefMin (60.10).
NOTE: The unit of Parameters 60.05 and 60.11 is “% per second”:

1 %/s means that IRef is ramped down from 100% to 0% within 100 seconds.
10 %/s means that IRef is ramped down from 100% to 0% within 10 seconds.
100 %/s means that IRef is ramped down from 100% to 0% within 1 second.
5.) Release the function button:

With the release of the function button the application proceeds with taking the
actual current reference (IrefRamp) and starts to ramp it up within BackRamp
Step (60.11) to increase the magnet current reference up to a secure value and
to avoid further sheets being released: IRef2 = IrefRamp + IOffset
(Parameter 60.04).
I.) If HoldTimeSel = Enabled (60.08) then for HoldTimeDelay (60.09) 2 different

procedures are possible:
a) tHold elapses, the current reference is ramped up from IRef2 to IRef1 within
BackRampStep (60.11) and the sheet release routine will be left. If voltage
control was the selected control mode then this mode will be selected again.
b) the function button is pressed again before tHold has elapsed and the
application routine proceeds with releasing sheet 2. This procedure is
repeatable until the last sheet has been released and StepIrefMin (60.10)
has not been reached.
Releasing the function button always results in entering the decision to be

taken within HoldTimeDelay (60.09) for procedure I.) a) or I.) b).
II.) If required the hold time delay procedure in I.) a) can be disabled with
HoldTimeSel (60.08 = Disabled) and the step by step sheet release mode
can only be left with a STOP command (RdyRef = FALSE). If the function
button is pressed again the application routine proceeds with releasing sheet
2. This procedure is repeatable until the last sheet has been released and
StepIrefMin (60.10) has not been reached.
DCS800 Solution

21
To ensure reliable transition of certain steps in the program routine a secure state
delay time tx (60.06) can be set.
The command StepbyStepRel can be set via digital input or Magnet Control Word
(7.10) and customized by parameter group 65:
- ConfStbyStRel (65.13 / Step by Step Release)
The following figure shows the procedure of the step by step sheet release mode:
Transport Mode (set voltage reference to the rated magnet voltage)
The command TransportMode can be set via digital input or Magnet Control Word
(7.10) and customized by parameter group 65:
- ConfgTranspMode (65.14 / Transport Mode)
TransportMode ON: Voltage control / reference value is fixed to the

rated magnet voltage**
TransportMode OFF: Output voltage is variable and the reference value

depends on the configuration set up.
The Transport Mode command has the highest priority and therefore overrides
every other command in the application.
**This reference value is selected via 7.03 Bit 10 (DirectSpeedRef) by the magnet
software application and can be monitored in parameter 23.15.
DCS800 Solution

22
Monitoring:
Display converter current and voltage output
Current actual value can be assigned to an analog output (0 – 10 Volt)

in group 15.
Voltage actual value can be assigned to an analog output (0 – 10 Volt)
in group 15.
Magnet resistance monitoring:
The magnet resistance value can be monitored. Inside a defined window separate
alarms can be enabled for an upper and a lower threshold. The alarms can be
shown in the control panel or configured for use on digital outputs.
The filtered values of voltage and current are used to calculate the magnets
resistance:
The actual resistance value ActResVal (64.12) = UA / IA
MagResMonitor (64.06 = Enabled) activates the alarms while the magnet

resistance monitoring is permanently working with the converter in RdyRef (08.01
Bit 2 = TRUE) state.
IF 8.01 Bit 2 = FALSE then the actual resistor value showed in

ActResVal (64.12) = 0.
A compare function with parameter 64.08 for the Resistance Limit Down (cold
resistance – tolerance in mΩ) and parameter 64.07 for the Resistance Limit Up
(warm resistance + tolerance in mΩ) is implemented as well as a hysteresis func-
tion (parameter 64.09 in mΩ) for debouncing. There are 2 parameters available for
assigning the warning signals (alarm events: A312 “AlarmResHot“ and parameter
64.11 = ON or A313 “AlarmResCold“ and parameter 64.10 = ON) to digital outputs
in group 14.
Converter actual current 1.06
Converter actual voltage 1.13
ActResVal 64.12
DCS800 Solution

23
Magnet I²t-Function
The overload capacity of the magnet will be calculated as square of the current
and the time in seconds.
I²t is used to calculate heat generation in the magnet to protect it from thermal
damage or failures in case of excess heat generation.
Up to 8 magnets can be monitored with I²t accumulators:

OvrlMag1Accu (64.21)
The amount of installed and used magnets in the applications has to be configured
in NumberOfMagnets (64.17).
The commands Magnet1act, Magnet2act, Magnet3act, Magnet4act, Magnet5act,

Magnet6act, Magnet7act and Magnet8act can be selected via digital inputs or
Magnet Control Word (7.10) and customized by parameter group 65:
- ConfMonMagnet1 (65.17 / Magnet 1 active)
DCS800 Solution

24
The thermal time constant τ [s] of the magnets can be configured in ThermTime-
Const (64.15). Based on that thermal time constant τ the calculation over an expo-
nential charging/discharging curve can be realized.
The square of the actual overall magnet current (1.06) is multiplied with the sample
time of the software task and divided by the number of active magnets to calculate
the individual actual overload value in each relevant I²t accumulator. The overload
values of magnet 1 to 8 are shown in OvrlMag1Accu (64.21) - OvrlMag8Accu
(64.28). The NumberOfMagnets (64.17) helps to divide the actual overall magnet
current (1.06) into the appropriate current of each selected magnet. The input sig-
nals Magnet 1 active - Magnet 8 active furthermore help to distinguish whether
an installed magnet is leading the appropriate part of the current or not.
With MagOvrlSetLev (64.13) the level for overload alarm events A314 – A321
“Magnet1Overload – Magnet8Overload” and with MagOvrlResLev (64.14) the re-
set level for the overload warning events can be configured.
Active overload warning events are also monitored in MagnetSW_Ovrl (64.16) with
Bit0 → Magnet1Ovrld
DCS800 Solution

25
Commissioning and engineering instructions

Start Up
1.) If necessary, set all parameters to default by means of ApplMacro
(99.08) = Factory and ApplRestore (99.07) = Yes. Check with MacroSel
(8.10).
2.) Enter the magnet data, the mains (supply) data and the most important
protections [ArmOvrVoltLev (30.08), [ArmOvrCurLev (30.09), Language
(99.01), Magnet Nominal Voltage (M1NomVolt / 99.02), Magnet Nominal
Current (M1NomCur / 99.03), M1BaseSpeed (99.04 = 99.02),
NomMainsVolt (99.10) and M1UsedFesxType (99.12 = NotUsed)].
Autotuning of the Current Controller

1.) Set parameter 43.01 = FieldConv to activate the converter like a field ex-
citer for autotuning.
2.) Start the Autotuning of the field current controller by means of Service-
Mode (99.06) = FieldCurAuto and set On command within 20 s.
3.) During the autotuning the main contactor will be closed, the load circuit is
measured by means of increasing the magnet current to the nominal cur-
rent (99.03) and the current control parameters are set.
4.) If the autotuning fails A121 AutotuneFail is set. For more details please re-
fer to the DCS800 manual, check Diagnosis (9.11) and repeat the autotun-
ing.
5.) Set parameter 43.01 = ArmConv (Armature Converter) again.
6.) Set reversal delay 43.14 = 50 ms, zero current time out 97.19 = 200 ms
and the firing limit mode 43.13 = Fix in 4Q operation.
Voltage Controller Set Up

1.) Voltage controller
The voltage controller setting is sufficient for almost all applications. In case
of the DCS800 the speed controller is used as voltage controller.
24.03 = 1.0 preset application value
24.09 = 200ms preset application value
It is nonetheless advisable to check the setting of the voltage controller and
optimize it if necessary. Please keep in mind that a time-limited switchover
to current control is speeding up the current change and that the filter time
UdcFilt (64.02) will affect the controlling.
2.) Controlling with a low voltage

If the voltage controller is required to be able to control currents smaller
than 1 A, then a base-load resistor should be connected at the DC output of
the DCS800. This is damping the voltage peaks caused by the current
chopping. But nonetheless, there is no alternative to reduce the gain of the
voltage controller in this current range.
24.04 = 0.1 preset application value
24.05 = 10% preset application value
Application Set Up
The application set up is to be done following the functional description starting
on page 15.
DCS800 Solution

26
Commissioning Parameters
Signal / Parameter name

10.01 CommandSel (command selector)
UsedMCW (7.04) selector:
Local I/O
Local I/O
1 = MainCtrlWord Magnet Supply is controlled via MainCtrlWord (7.01)
FexLink
Int. Scaling: 1 == 1 Type: C Volatile: N
-
10.02 Direction (direction of rotation used for command Demagnetization)
Binary signal for Direction is used for Demagnetization. Direction (10.02) allows to
change the direction of voltage by negating the voltage reference in remote operation:
14 = MCW Bit13 1 = Reverse (Demagnetization), 0 = Forward (Magnetization)
MCW Bit15
MainCtrlWord (7.01) bit 13
NotUsed
NotUsed
-
11.03 Ref1Sel (speed reference 1 select used for voltage reference select)
Speed reference 1 value is used for magnet supply voltage reference:
If ConfRefSrc (63.17) ` Analog_Inp then:

0 = SpeedRef2301 SpeedRef (23.01), default
If ConfRefSrc (63.17) = Analog_Inp then:

2 = AI1 analog input AI1
SpeedRef2301
SpeedRef2301
MaxAI2AI4

-
16.08 SpeedCtrlUnit (Speed control unit)
Select speed control unit for all relevant parameters:

0 = rpm all parameters in the speed loop are displayed in units of rpm
1 = Percent all parameters in the speed loop are displayed in units of percent
2 = Volt all parameters in the speed loop are displayed in units of Volt
NOTE: The speed control unit can be displayed as a voltage control unit.
Volt
rpm
rpm

-
DCS800 Solution

27
22.11 Ramp2Select (ramp 2 selector is used for command Battery selected)

Select active ramp parameters :
14 = MCW Bit11 0 = parameter set 1 is active (Magnet Supply Mode),

1 = parameter set 2 is active (Battery Mode),
MCW Bit15
Acc/Dcc1
Acc/Dcc1
-
25.10 TorqRefA Sel (torque reference A selector)
Selector for TorqRefExt (2.24):
Current reference configuration:

Reserved for Step by Step Release function. Set and reset automatically by magnet
TorqRefA2501
TorqRefA2501
software application:
0 = TorqRefA2501 TorqRefA (25.01), default
AI6
-
26.05 TorqMux (torque multiplexer used to select current control)
TorqMux (26.05) selects a binary input to change between operation modes. The choice
of the operation modes is provided by means of TorqMuxMode (26.04). Torque reference
multiplexer binary input:
15 = MCW Bit14 0 = voltage control,

1 = current control if TorqMuxMode (26.04) = Speed/Torque,
MCW Bit15
MainCtrlWord (7.01) bit 14 NotUsed
Int. Scaling: 1 == 1 Type: C Volatile: N NotUsed

-
DCS800 Solution

28
Drawings
DCS800 Solution

29
Appendix A – Used Standard DCS800 Parameters

Signal / Parameter name
7.01 MainCtrlWord (main control word, MCW)
The main control word contains all DCS800 depending commands and is written by the magnet software application:
Bit Name Value Comment
B0 On (Off1N) 1 Command Cmd_MagOn to RdyRun state.
With MainContCtrlMode (21.16) = On: Closes contactors and starts fans.
With MainContCtrlMode (21.16) = On&Run:
RdyRun flag in MainStatWord (8.01) is forced to 1
0 Command to Off state. Stopping via Off1Mode (21.02).
B1 Off2N 1 No Off2 (Emergency Off / Coast Stop)
B1 is forced to 1 by the magnet software application
B2 Off3N 1 No Off3 (E-stop)
B3 Run 1 Command Cmd_RUN (Magnet) to RdyRef state. The firing pulses are released
and the magnet supply is running with the selected reference.
0 Command to RdyRun state. Stop via StopMode (21.03).
------------------------------------------------------------------------------------------------------------------------------------------------------------------
B4 RampOutZero 1 no action / B4 is forced to 1 by the magnet software application
B5 RampHold 1 no action / B5 is forced to 1 by the magnet software application
B6 RampInZero 1 no action / B6 is forced to 1 by the magnet software application
B7 Reset 1 (Cmd_Reset) acknowledge fault indications with the positive edge

0 no action
------------------------------------------------------------------------------------------------------------------------------------------------------------------
B8 Inching1 0 no action / B8 is forced to 0 by the magnet software application
B9 Inching2 0 no action / B9 is forced to 0 by the magnet software application
B10 RemoteCmd 1 control over magnet software application enabled
B11 Cmd_BatSel 1 used by the magnet software application to control the command Cmd_BatSel.
The battery parameters are selected. To be able to switch the ramp following
parameter has to be assigned: 22.11 = MCW Bit11 (Ramp2Sel).
0 no action
------------------------------------------------------------------------------------------------------------------------------------------------------------------
B12 Cmd_BatDis 1 used by the magnet software application to control the command Cmd_BatDis
to select the discharging of the battery.
0 no action
B13 Cmd_DeMag 1 used by the magnet software application to control the command
Cmd_DeMag which is dedicated for Demagnetization. To be able to switch the
direction the following parameter has to be assigned: 10.02 = MCW Bit13 (Direction).
0 no action
B14 Cmd_Cur 1 used by the magnet software application to control the command Cmd_Cur. To be
able to switch to current mode the following parameter has to be assigned:
26.05 = MCW Bit14 (TorqMux).
0 no action
B15 auxiliary bit 0 no action / B15 is forced to 0 by the magnet software application
Int. Scaling: 1 == 1 Type: I Volatile: Y
Appendix A

30
Appendix B – Application Parameters

Index Signal / Parameter name
def.
unit
E/C
min.
max.
Group 7
Control Words
additional to standard firmware
7.10 MagMCW Incoming Magnet Main Control Word
-
-
-
Incoming control word from PLC:
DEFAULT CONFIGURATION**:
Bit Default Value Command / Selection Configuration

0 IntRefBit3 1 Internal references Bit 3
0 No action
1 PB_UP 1 Push button UP (65.10 / ConfPB_UP)
0 No action
2 PB_DOWN 1 Push button DOWN (65.11 / ConfPB_DOWN)
0 No action
3 PB_Reset 1 Push button Reset (65.12 / ConfPB_Reset)
0 No action
4 reserved 1 reserved
0 No action
0 No action
6 Cmd_BatSel 1 Battery selected (65.15 / ConfBatOn)
0 No action
7 Cmd_BatDis 1 Battery discharging (65.16 / ConfBatDisCh)
0 No action
0
0
0
0
12 Magnet5act 1 Magnet 5 I²t-Monitoring ON (65.21 /ConfMonMagnet5)
0 No action
0 No action
0 No action
0 No action
**All available commands can be customized by parameter group 65
Appendix B

31
def.
unit
E/C
min.
max.
Group 8
Status Words
additional to standard firmware
8.05 DI StatWord (incoming Magnet DI Statusword)
-
-
-
Incoming assigned DI status word to be controlled from PLC:
DEFAULT CONFIGURATION**:
Bit DigIn Name Value Command / Selection Configuration

0 DI1 IntRefBit0 1 Internal references Bit 0 (65.06 / ConfRefBit0)
0 No action
0 No action
0 No action
3 DI4 Cmd_Demag 1 Demagnetization (65.05 / ConfDeMag)
0 No action
4 DI5 Cmd_Cur 1 Current Control (65.04 / ConfEnbCC)
0 No action
5 DI6 Reset 1 Reset (65.03 / ConfReset)
0 No action
6 DI7 Cmd_MagOn 1 Magnet On (65.01 / ConfMagOn)
0 No action
7 DI8 Cmd_Run 1 Magnet RUN (65.02 / ConfEnbRun)
0 No action
8 DI9 StepbyStepRel 1 Step by Step Release (65.13 / ConfStbyStRel)
0 No action
9 DI10 TransportMode 1 Transport Mode (65.14 /ConfTranspMode)
0 No action
10 DI11 Magnet1act 1 Magnet 1 I²t-Monitoring ON(65.17 /ConfMonMagnet1)
0 No action
0 No action
0 No action
0 No action
14 … 15 reserved 1
0
**All available commands can be customized by parameter group 65
Appendix B

32
def.
unit
E/C
min.
max.
8.15 MagMSW (outgoing magnet main status word)
-
-
-
The customized main status word.
0..2 --- not connected
3 Not tripped 1 no fault
0 fault indication
4..7 --- 1 not connected
0
8 UrefUact 1 voltage reference is reached
0 actual voltage is out of hysteresis
9..15 --- 1 not connected
0
Appendix B

33
def.
unit
E/C
min.
max.
Group 60
Application
Magnet application
60.01 ParaTrans (parameter change over between group 61 and 62 allowed)
Yes
-
E
No
No
There are parameter groups existing for the different load types of magnet (group 61) and battery
(group 62), which have to be written to certain standard firmware parameters for the selected load
type. Group 61 contains of the parameters for magnet load and group 62 for battery load. With this
parameter the transfer can be released or not.
Parameter switching-over and transferring is released:

0 = No No parameters are written, neither from group 61 nor from group 62
1 = Yes Parameters are written dependent on Cmd_BatSel = MCW Bit 11
NOTE:
If 60.01 = Yes then the parameters in group 61 (Cmd_BatSel = MCW Bit 11 = FALSE) or group 62
(Cmd_BatSel = MCW Bit 11 = TRUE) write to certain standard firmware parameters.
If 60.01 = No then the standard firmware parameters are not written neither from group 61 nor from
group 62. This helps for example in auto tune processes or optimizing those standard firmware pa-
rameters during commissioning.
Internal name : P_CrtlLoc
Type: C
60.02 BridgeBlock (blocking of thyristor bridges allowed)
Yes
Yes
-
E
No
The antiparallel negative bridge of the selected mode (battery charge or discharge) will be blocked,
if this parameter 60.04 is set to Yes. Otherwise both bridges will not be blocked.
The bridge 2 will be blocked:
0 = No
1 = Yes
Internal name : P_BlockBri
Type: C
Appendix B

34
def.
unit
E/C
min.
max.
60.03 ExtMinLimit (minimal value of external limitation)
100.00
100.00
E
0
%
The value will limit a selected external current limitation. Is this external limitation not desired the
value should be set to 100%.
Internal name : P_ExtMinLimit

Int. Scaling: 100 == 1 % Type: I
Step by Step sheet release
Appendix B

35
def.
unit
E/C
min.
max.
60.04 Ioffset (current offset value for Step by Step Sheet Release )
100.00
1.00
E
0
%
This value is a current offset to ensure a secure magnetizing state after releasing one sheet. The
value can be set from 0% to 100%.
Internal name : Ioffset

60.05 UnloadRampStep (ramp time for current reference reducing in Step by Step Sheet Release)
1000
10
-
E
1
The ramp time is value which says how many % of the current reference are reduced per second
to allow the release of sheets step by step.
Internal name : UnloadRampStep

Int. Scaling: 100 == 100 % / s Type: I
10 == 10 % / s
1 == 1%/s
60.06 SecureStateDelay (time to secure status in Step by Step Sheet Release mode)
10000
100
0
ms
This delay time ensures that each and every release state is reached reliably.
Internal name : P_SecureStateDelay

Int. Scaling: 100 == 100 ms Type: I
60.07 DeDelay (ON delay time with DEMAGNETIZATION command) 3000

0
0
ms
This is a delay time for the ON command during switch over of signs and limitations before demag-
netization.
Internal name : P_DeDelay

Appendix B

36
def.
unit
E/C
min.
max.
60.08 HoldTimeSel (enable/disable delay time before leaving Step by Step Sheet Release mode)
Disabled
Enabled
Enabled
-
E
The HoldTimeDelay (60.09) and herewith the possibility to leave this operation mode to normal
mode after dropping the step by step sheet release push button can be enabled or disabled by this
parameter. The reason behind this parameter is the decision to leave the step by step sheet re-
lease mode after an elapsed hold time to a normal operation like magnetization mode or with a
STOP command (RdyRef = FALSE) of the converter.
Enabled means the user has the possibility to leave the step by step sheet release mode to a nor-
mal operation like magnetization mode after the hold time has elapsed or to continue within the
hold time to release the next sheet by pressing the step by step sheet release push button again.
Disabled means the user has the possibility to continue to release the next sheet by pressing the
step by step sheet release push button again or to leave the step by step sheet release mode with
a STOP command (RdyRef = FALSE).
The:
0 = Disabled
1 = Enabled
Internal name : HoldTimeSel
Type: C
60.09 HoldTimeDelay (delay time before leaving the Step by Step Sheet Release mode)
65535
1000
0
ms
Within the hold delay time after dropping the step by step sheet release push button the user has
the possibility to leave the step by step sheet release mode to a normal operation like magnetiza-
tion mode after the hold time has elapsed or to continue within the hold time to release the next
sheet by pressing the step by step sheet release push button again.
Internal name : P_HoldTimeDelay
60.10 StepIrefMin (minimum current reference for Step by Step Sheet Release mode)
100.00
100.00
E
0
This is the minimum current reference that can be reached while decreasing the magnet current in
Step by Step sheet release mode.
Internal name : StepIrefMin
60.11 BackRampStep (ramp time for current reference increasing after Sheet Release)
1000
10
-
E
1
The ramp time is a value which says how many % of the current reference are increased per sec-
ond after the sheet release and the elapsed hold time delay (60.08).
Internal name : BackRampStep

10 == 10 % / s
1 == 1%/s
Appendix B

37
def.
unit
E/C
min.
max.
60.12 AutoRunSel (RUN & ON command are joined together by the ON command)
Disabled
Enabled
Disabled
-
E
RUN command and ON command are joined together and selected by the ON command if this pa-
rameter is enabled. This is to be able to use just one digital input signal or one bit to start the mag-
net supply.
Magnet RUN and ON command are selected by just the Magnet ON command:
0 = Disabled
1 = Enabled
Internal name : AutoRunSel
Type: C
60.13 RESEToverSTOP (RESET command is initiated by the STOP command)
Disabled
Enabled
Disabled
-
E
The RESET command is initiated by the STOP command if this parameter is enabled. This is to be
able to reset the converter without an additional RESET command.
The RESET and the STOP command are joined together:

0 = Disabled
1 = Enabled
Internal name : RESET_over_STOP
Type: C
60.14 PBRESEToverSTOP (PB_RESET command is initiated by the STOP command)
Disabled
Enabled
Disabled
-
E
The PB_RESET command is initiated by the STOP command if this parameter is enabled. This is
to be able to reset the Push Button Reference without an additional PB_RESET command.
The PUSH BUTTON RESET and STOP command are joined together:
0 = Disabled
1 = Enabled
Internal name : PBReset_over_STOP
Type: C
60.15 DeMagMode (configuration of demagnetization mode)
Demagnetize
Degaussing
Demagnetize
-
E
With this parameter the demagnetization mode can be configured.
The demagnetization modes can be selected as follows:
0 = Demagnetize (Inversion of voltage or current reference)

1 = Degaussing (Demagnetization of magnets by pulsing
while following a damped oscillation curve)
Internal name : P_DeMagMode

Type: C
60.16 DegausTimeConst (time constant for the falling exponential-function-curve)

30000
20000
0
ms
This time constant equals the τ of the exponential-function-curve used in Degaussing mode.
Internal name : DegaussingTime
Appendix B

38
def.
unit
E/C
min.
max.
60.17 DegausPulseWidth (time constant for the pulse width)
20000
1000
0
ms
This time constant equals the pulse width of the pulses used in Degaussing mode.
Internal name : PulseWidth
60.18 CurZeroLevel (adjustable threshold level for zero current detection)
0.01
100.00
2.00
%
This threshold level is to adjust the zero current detection level used in Degaussing mode.
When the current falls below the threshold level, the pulse amplitude with the reverse sign is set.
Internal name : iIactZeroLevel
60.19 DeMagRef (Signal for actual degaussing pulse amplitude)
100
E
0
0
%
This signal shows the actual pulse amplitude in Degaussing mode.
Internal name : iDeMagRef
Int. Scaling: 1 == 1 % Type: SI
60.20 MagRefDec (Signal the falling exponential-function-curve)
100
E
0
0
%
This signal shows the actual value of the falling exponential-function-curve in Degaussing mode.
Internal name : iMagRefFiltered
Appendix B

39
def.
unit
E/C
min.
max.
Group 61
Magnet Parameter
Magnet application
61.01 LimitPosMag ( positive current limitation using magnet )
0.00
325.00
100.00
E
%
This value will be written to parameter TorqMax (20.05), if magnet is selected.
Internal name : P_LimPos_Mag
61.02 LimitNegMag ( negative current limitation using magnet )
0.00
-325.00
-100.00
E
%
This value will be written to parameter TorqMin (20.06), if magnet is selected
Internal name : P_LimNeg_Mag
61.03 UdcFiltMag (filter time constant for actual voltage using magnet)
0.00
10000
20
E
ms
This filter time constant will be written to SpeedFiltTime (50.06), if magnet is selected.
Internal name : P_UFilt_Mag
61.04 KpVMag (p-part voltage controller using magnet )
0.00
325.00
5.00
E
%
This value will be written to KpS (24.03), if magnet is selected.
Internal name : P_KpV_Mag
61.05 TiVMag (I-part voltage controller using magnet)
64000
2500
E
0
ms
This value will be written to KpS (24.09), if magnet is selected.
Internal name : P_TiV_Mag
61.06 ContCurMag (discontinuous current limit using magnet)

0.00
325.00
100.00
E
%
This value will be written to M1DiscontCurLim (43.08), if magnet is selected.
Internal name : P_ContCurMag
61.07 KpCMag (p-part current controller using magnet)

0.00
100.00
1.00
-
E
This value will be written to M1KpArmCur (43.06), if magnet is selected.
Internal name : P_KpC_Mag
Int. Scaling: 100 == 1 Type: I
Appendix B

40
def.
unit
E/C
min.
max.
61.08 TiCMag (i-part current controller using magnet)
10 000
50
E
0
ms
This value will be written to M1TiArmCur (43.07), if magnet is selected.
Internal name : P_TiC_Mag
61.09 LMag (inductance value using magnet)
0.00
640
E
0
mH
This value will be written to M1ArmL (43.09), if magnet is selected.
Internal name : P_L_Mag
61.10 RMag (resistance value using magnet)
65500
E
0
0
mOhm
This value will be written to M1ArmR (43.10), if magnet is selected.
Internal name : P_R_Mag
Int. Scaling: 1 == 1 mOhm Type: I
Appendix B

41
def.
unit
E/C
min.
max.
Group 62
Battery Parameter
Magnet application
62.01 LimitPosBat ( positive current limitation using battery )
0.00
325.00
100.00
E
%
This value will be written to parameter TorqMax (20.05), if battery is selected.
Internal name : P_LimPos_Bat
62.02 LimitNegBat ( negative current limitation using battery )
0.00
-325.00
-100.00
E
%
This value will be written to parameter TorqMin (20.06), if battery is selected
Internal name : P_LimNeg_Bat
62.03 UdcFiltBat (filter time constant for actual voltage using battery)
0.00
10000
20
E
ms
This filter time constant will be written to SpeedFiltTime (50.06), if battery is selected.
Internal name : P_UFilt_Bat
62.04 KpVBat (p-part voltage controller using battery )
0.00
325.00
5.00
E
%
This value will be written to KpS (24.03), if battery is selected.
Internal name : P_KpV_Bat
62.05 TiVBat (I-part voltage controller using battery)
64000
2 500
E
0
ms
This value will be written to KpS (24.09), if battery is selected.
Internal name : P_TiV_Bat
62.06 ContCurBat (discontinuous current limit using battery)

0.00
325.00
100.00
E
%
This value will be written to M1DiscontCurLim (43.08), if battery is selected.
Internal name : P_ContCurBat
62.07 KpCBat (p-part current controller using battery)

0.00
100.00
1.00
-
E
This value will be written to M1KpArmCur (43.06), if battery is selected.
Internal name : P_KpC_Bat
Appendix B

42
def.
unit
E/C
min.
max.
62.08 TiCBat (i-part current controller using battery)
10 000
50
E
0
ms
This value will be written to M1TiArmCur (43.07), if battery is selected.
Internal name : P_TiC_Bat
62.09 LBat (inductance value using battery)
0.00
640
E
0
mH
This value will be written to M1ArmL (43.09), if battery is selected.
Internal name : P_L_Bat
62.10 RBat (resistance value using battery)
65500
E
0
0
mOhm
This value will be written to M1ArmR (43.10), if battery is selected.
Internal name : P_R_Bat
Int. Scaling: 1 == 1 mOhm Type: I
Appendix B

43
def.
unit
E/C
min.
max.
Group 63
Reference Configuration
Magnet application
Selectable internal voltage references ConfRefSrc (63.17) = Int_Ref:

The reference value can be selected by a table of fixed values IntRef01 – IntRef16
(63.01 – 63.16).
It is possible to select between 16 fixed internal values via 4 Bits (BCD).
The selected internal reference is written to parameter 23.01.
The commands IntRefBit0, IntRefBit1, IntRefBit2 and IntRefBit3 can be set via digital in-
put or Magnet Control Word (7.10) and customized by parameter group 65:
ConfRefBit0 (65.06 / Internal Reference Bit 0), ConfRefBit1 (65.07 / Bit 1)
ConfRefBit2 (65.08 / Bit 2) and ConfRefBit3 (65.09 / Bit 3).
Bit 3 Bit 2 Bit 1 Bit 0 Internal Reference (Fixed Set Points)
0 0 0 0 1
0 0 0 1 2
0 0 1 0 3
0 0 1 1 4
0 1 0 0 5
0 1 0 1 6
0 1 1 0 7
0 1 1 1 8
1 0 0 0 9
1 0 0 1 10
1 0 1 0 11
1 0 1 1 12
1 1 0 0 13
1 1 0 1 14
1 1 1 0 15
1 1 1 1 16
Appendix B

44
def.
unit
E/C
min.
max.
63.01 IntRef01 (internal reference 1)
-100.00
100.00
E
0
%
This reference can be selected by digital inputs or the Magnet Control Word (7.10)
if ConfRefSrc (63.17) = Int_Ref. See table at the beginning of this group 63.
Internal name : P_IntRef1
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%

-100.00
100.00
E
0
%

-100.00
100.00
E
0
%
Appendix B

45
def.
unit
E/C
min.
max.
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%

-100.00
100.00
E
0
This reference can be selected by digital inputs or the Magnet Control Word (7.10) %

-100.00
100.00
E
0
%
Appendix B

46
def.
unit
E/C
min.
max.
-100.00
100.00
E
0
%
-100.00
100.00
E
0
%
Reference Configuration
Analog_Inp 0
63.17 ConfRefSrc (configuration of voltage reference source)

Analog Inp
PB step
Analog Inp
-
E
With this parameter the reference source in voltage control can be configured.
The reference source can be selected as follows:
0 = Analog_Inp ’ (11.03 = AI1…AI6)

1 = Int_Ref ’ (11.03 = SpeedRef2301)
2 = PB_cont ’ (11.03 = SpeedRef2301)
3 = PB_step ’ (11.03 = SpeedRef2301)
NOTE: Parameter 11.03 has to be set manually; see page 24: commissioning parameters!
Internal name : P_SelRefSrc

Type: C
Appendix B

47
def.
unit
E/C
min.
max.
63.18 PB_RefRamp (reference change rate per second for push button continuous function)
1000
10
%/s
E
1
This parameter is used if ConfRefSrc (63.17) = PB_cont.
The reference increases continuously with the configured reference change rate per second
while the PB_UP push button is pressed. With the push button PB_DOWN the reference
decreases continuously with the same configured reference change rate per second.
The push button source (DI or MagCW) of PB_UP can be configured in ConfPB_UP (65.10)
and the push button source of PB_DOWN can be configured in ConfPB_UP (65.11).
Internal name : PB_RefRamp

10 == 10 % / s
1 == 1%/s
63.19 PB_RefStep (reference change step for push button step function)
100.00
E
0
0
%
This parameter is used if ConfRefSrc (63.17) = PB_step.
The reference increases with the configured reference change step once the PB_UP command is
pressed. To increase the reference again with the configured reference change step the PB_UP
push button has to be pressed once again.
The reference decreases with the same configured reference change step once the PB_DOWN
push button is pressed. To decrease the reference again with the configured reference change
step the PB_DOWN push button has to be pressed once again.
The push button source (DI or MagCW) of PB_UP can be configured in ConfPB_UP (65.10)
and the push button source of PB_DOWN can be configured in ConfPB_UP (65.11).
Internal name : PB_RefStep
63.20 PB_ResetRef (reset value for push button modes)
-100.00
100.00
E
0
%
This parameter is used if ConfRefSrc (63.17) = PB_cont or ConfRefSrc (63.17) = PB_step.
When the PB_Reset command is active then the reference value is set to PB_ResetRef (63.20).
The push button source (DI or MagCW) of PB_Reset can be configured in ConfPB_Reset (65.12)
Internal name : PB_ResetRef
63.21 PB_ActValFreeze (actual push button value frozen before power down)
-100.00
100.00
E
0
%
The actual push button reference value is frozen before power down.
With PB_RefPowerON (63.22) it is possible to select PB_ActValFreeze (63.21) as initial value for
the push button modes after power on.
Internal name : PB_ActValFreeze
Appendix B

48
def.
unit
E/C
min.
max.
63.22 PB_RefPowerOn (configuration of reference value at power on in push button modes)
Zero
FreezeVal
Zero
-
E
The reference initial value for the push button modes can be selected with this parameter.
Zero means that the initial value is 0, ResetRef takes the value of parameter PB_ResetRef (63.20)
and with FreezeVal the last frozen value before power down of parameter PB_ActValFreeze
(63.21) is taken.
The reference initial value for the push button modes can be configured as follows:
0 = Zero
1 = ResetRef
2 = FreezeVal
Internal name : P_RefPowerOn
Type: C
63.23 PB_RefMin (Minimum reference for push button modes)
-100.00
100.00
E
0
%
Minimum reference limit in % for push button modes.
Internal name : PB_RefMin
63.24 PB_RefMax (Maximum reference for push button modes)
-100.00
100.00
E
0
%
Maximum reference limit in % for push button modes.
Internal name : PB_RefMax
Appendix B

49
def.
unit
E/C
min.
max.
Group 64
Monitoring
Magnet application
64.01 UacUnderV (under voltage alarm level)
0.00
150.00
80.00
%
In the DCS800 alarm A311 (M_Undervoltg) will be generated, if MainVoltActRel (1.11) is lower
than the value of this parameter. Alarm A111 (MainsLowVoltage) in sequence with Fault F512
(MainsLowVoltage) are not practicable here because disabling the converter isn’t allowed. For that
reason the limits in the parameters UNetMin1 (30.22) and UNetMin2 (30.23) must be set to the
lowest possible values and parameter UacUnderV (64.01) has to be used for under voltage alarm
monitoring.
Internal name : P_Uac_UnderV
64.02 UdcFilt (filter time constant)
10000
1000
0
ms
The actual value of signal parameter ArmVoltActRel (1.13) will be filtered using this time constant.
Internal name : P_UdcFilt
Int. Scaling: 1 == 1 ms Type: SI
64.03 UdcAct (output of filtered DC voltage) READ ONLY
-200.00
200.00
0
%
The signal parameter ArmVoltActRel (1.13) will be filtered (see 64.02), scaled (see 64.04 and
64.05) and written to UdcAct (64.03).
Internal name : P_UdcAct
64.04 UdcSca (scale factor of filtered output DC voltage)
-320.00
320.00
100.00
%
The signal parameter ArmVoltActRel (1.13) is scaled, so that the desired output voltage of AOx
(via parameter 64.03) is reached.
Internal name : P_UdcSca
64.05 UdcOffs (offset of filtered output DC voltage)

-5000
+5000
0
If necessary an offset can be added. The parameter value of 1000 means 1V at the AOx (via pa-
rameter 64.03).
Internal name : P_UdcOffs
Int. Scaling: 1 000 == 1V Type: SI
Appendix B

50
def.
unit
E/C
min.
max.
Resistance Monitoring
Converter actual current 1.06
Converter actual voltage 1.13
ActResVal 64.12
64.06 MagResMonitor (magnet resistance monitor enabled/disabled)
Disabled
Enabled
Disabled
-
E
Alarm messages A312 (ResistorHot) and A313 (ResistorCold) together with the 2 alarm indicator
bit parameters AlarmResHot (64.11) and AlarmResCold (64.10) of the magnet resistance monitor
are enabled or disabled with this parameter. The actual resistance value ActResVal (64.12) is al-
ways displayed while status bit RdfRef (8.01 Bit 2) = TRUE. If RdfRef = FALSE then ActResVal
(64.12) = 0.
The magnet resistance monitor can be configured:

0 = Disabled
1 = Enabled
Internal name : MagResMonitor
Type: C
64.07 ResLimUp (upper resistance limit for alarm A312)
m&
65535
E
0
0
ResLimUp defines the threshold level for the alarm message A312 (ResistorHot) and the alarm in-
dicator bit parameter AlarmResHot (64.11).
Internal name: ResLimUp
Int. Scaling: 1 == 1 mΩ Type: I
64.08 ResLimDown (lower resistance limit for alarm A313)

m&
65535
E
0
ResLimDown defines the threshold level for the alarm message A313 (ResistorCold) and the alarm
indicator bit parameter AlarmResCold (64.10).
Internal name: ResLimDown
64.09 ResLimHysteresis (hysteresis for both ResLimUp and ResLimDown)

m&
65535
E
0
ResLimHysteresis defines the reset value for both alarm messages A312 and A313:
Reset value alarm message A313 and AlarmResCold (64.10) ≥ ResLimDown + ResLimHysteresis
(64.08) (64.09)
Reset value alarm message A312 and AlarmResHot (64.11) ≤ ResLimUp - ResLimHysteresis.
(64.07) (64.09)
Internal name: ResLimHysteresis
Appendix B

51
def.
unit
E/C
min.
max.
64.10 AlarmResCold (indicator for alarm A313)
FALSE
TRUE
FALSE
-
E
The alarm A313 (ResistorCold) is indicated in this read only parameter:
0 = FALSE ActResVal (64.12) ≥ ResLimDown (64.08) + ResLimHysteresis (64.09)
1 = TRUE ActResVal (64.12) ≤ ResLimDown (64.08)
Internal name : AlarmResCold
Type: C
64.11 AlarmResHot (indicator for alarm A312)
FALSE
TRUE
FALSE
-
E
The alarm A312 (ResistorHot) is indicated in this read only parameter:
0 = FALSE ActResVal (64.12) ≤ ResLimUp(64.07) - ResLimHysteresis (64.09)
1 = TRUE ActResVal (64.12) ≥ ResLimUp (64.07)
Internal name : MagResHot
Type: C
64.12 ActResVal (actual resistance)
m&
65535
E
0
0
The actual resistance is a read only parameter and calculated with the actual voltage divided by
the actual current following Ohm’s law.
Internal name: ActualResistance
Magnet I²t-function
Appendix B

52
def.
unit
E/C
min.
max.
64.13 MagOvrlSetLev (magnet overload set level)
300
110
E
0
%
This parameter defines the set level for overload alarm from magnet 1 to 8.
The set level for overload alarms can be set from 0 – 300%.
Internal name : MagOvrlSetLevel
64.14 MagOvrlResLev (magnet overload reset level)
300
100
E
0
%
This parameter defines the reset level for overload alarm from magnet 1 to 8.
The reset level for overload alarms can be set from 0 – 300% but is limited
by MagOvrlSetLev (64.13).
Internal name : MagOvrlResLevel
64.15 ThermTimeConst (thermal time constant τ of the magnet)
65535
3600
E
0
s
The thermal time constant τ [s] of the magnet can be configured here. The square of the actual
overall magnet current (1.06) is multiplied with the sample time to calculate the individual actual
overload value in each I²t accumulator.
OvrlMag1Accu (64.21) - OvrlMag8Accu (64.28) of the selected magnets within an
exponential function.
 − 
t
2  −
t 
OverloadMagnetAccumulator = Iact
2
* 1− e T  *100 % = (1 . 06 ) * 1− e (64.15) 
IN 2   ( 99.03) 2  
  
Internal name: ThermTimeConst
Int. Scaling: 1 == 1 s Type: I
64.16 MagnetSW_Ovrld (status word of magnet overload alarms)

This read only parameter shows the status of all magnet overload alarms.

0 Magnet 1 Overload 1 Magnet 1 I²t set level reached
0
0
0
0
0
0
0
0
8 - 15 reserved
Appendix B

53
def.
unit
E/C
min.
max.
64.17 NumberOfMagnets (number of connected magnets in the system)
-
E
1
8
1
This value is very important for the calculation of the separated I²t accumulators. The I²t calculation
needs to know how many magnets are supplied by the rated current value in parameter 99.03.
With the number of active magnets it is now possible to calculate how much current of the com-
plete nominal converter current is related as nominal current of one connected magnet.
Example: 99.03 = 100 A; 64.17 = 4 and 2 of 4 magnets are actually active and connected to the
converter. With the magnet lift supply in operation actually parameter 1.06 = 5000 (50 A). The ac-
tual current of each magnet is 25 A (parameter 99.03 : 4) which is equal to the magnet rated cur-
rent. This means that both active magnets get an input value of 100% into their separate I²t calcu-
lation.
Internal name : NumberOfMagnets
Type: Byte
64.18 MagCurSim (magnet current simulation)
300.00
E
0
0
%
This parameter is to simulate magnet current for I²t accumulator testing and it is active with
values > 0.
Internal name : MagCurSim
64.19
64.21 OvrlMag1Accu (magnet 1 overload accumulator)
300
100
E
0
%
OvrlMag1Accu is in operation if the Magnet1act command is set.
If the Magnet1act command is not set or reset then OvrlMag1Accu is already 0 or calculated by
cooling curve of the exponential function.
Magnet1act can be set via digital input or Magnet Control Word (7.10) and customized by parame-
ter ConfMonMagnet1 (65.17).
Internal name : OverloadMagnet1Accu
300
100
E
0
%

300
100
E
0

Appendix B

54
def.
unit
E/C
min.
max.
300
100
E
0
%
300
100
E
0
%
300
100
E
0
%

300
100
E
0
%

300
100
E
0

Appendix B

55
def.
unit
E/C
min.
max.
Group 65
Configuration Interface
Magnet application
All signals can be configured to either DIx or MagCW (7.10)
65.01 ConfMagOn (configuration of MAGNET ON command)
Binary signal for Cmd_MagOn (written to 7.01 Bit 0):
0 = NotUsed Cmd_MagOn OFF

1 = On Cmd_MagOn by rising edge (0 → 1)
2 = DI1 Cmd_MagOn by rising edge (0 → 1), 0 = Cmd_MagOn OFF
8 = DI7 Cmd_MagOn by rising edge (0 → 1), 0 = Cmd_MagOn OFF, default
10 = DI9 Cmd_MagOn by rising edge (0 → 1), 0 = Cmd_MagOn OFF, only available with
digital extension board
16 = MagMCW Bit0 Cmd_MagOn by rising edge (0 → 1), 0 = Cmd_MagOn OFF,
MagCtrlWord (7.10) bit 0
Appendix B

56
def.
unit
E/C
min.
max.

Internal name : ConfMagOn
65.02 ConfEnbRun (configuration of enable MAGNET RUN command)
NotUsed
MagMCW Bit15
-
E
DI8
Binary signal for Cmd_Run (written to 7.01 Bit 3):
0 … 31
NOTE: Please refer to parameter 65.01 for the complete configuration list
9 = DI8 Start by rising edge (0 → 1), 0 = Stop, default

Internal name : ConfEnbRun
65.03 ConfReset (configuration of RESET command)
NotUsed
MagMCW Bit15
-
E
DI6
Binary signal for Cmd_Reset (written to 7.01 Bit 7):
0 … 31
7 = DI6 Start by rising edge (0 → 1), 0 = Stop, default

Internal name : ConfReset
Appendix B

57
def.
unit
E/C
min.
max.
65.04 ConfEnbCC (configuration of ENABLE CURRENT CONTROL command)
NotUsed
MagMCW Bit15
-
E
DI5
Binary signal for Cmd_Cur (written to 7.01 Bit 14):
0 = NotUsed Cmd_Cur is not active

1 = On Cmd_Cur is active
2 = DI1 1 = Cmd_Cur is active, 0 = Cmd_Cur is not active
6 = DI5 1 = Cmd_Cur is active, 0 = Cmd_Cur is not active, default
10 = DI9 1 = Cmd_Cur is active, 0 = Cmd_Cur is not active, only available with digital
extension board
extension board
extension board
extension board
extension board
extension board
16 = MagMCW Bit0 1 = Cmd_Cur is active, 0 = Cmd_Cur is not active,
Appendix B

58
def.
unit
E/C
min.
max.
Internal name : ConfEnbCC
65.05 ConfDeMag (configuration of DEMAGNETIZATION command)
NotUsed
MagMCW Bit15
-
E
DI4
Binary signal for Cmd_DeMag (written to 7.01 Bit 13):
0 … 31
5 = DI4 1 = Cmd_DeMag is active, 0 = Cmd_DeMag is not active, default

Internal name : ConfDeMag
65.06 ConfRefBit0 (configuration of Bit0 selection command for internal references)
NotUsed
MagMCW Bit15
-
E
DI1
Binary signal for IntRefBit0:
0 … 31
2 = DI1 1 = IntRefBit0 is active, 0 = IntRefBit0 is not active, default

Internal name : ConfRefBit0
NotUsed
MagMCW Bit15
-
E
DI2
Binary signal for Cmd_IntRefBit1:
0 … 31

NotUsed
MagMCW Bit15
-
E
DI3
0 … 31

Appendix B

59
def.
unit
E/C
min.
max.
NotUsed
MagMCW Bit15
MagMCW Bit0
-
E
0 … 31
16 = MagMCW_Bit0 1 = IntRefBit3 is active, 0 = IntRefBit3 is not active, default

65.10 ConfPB_UP (configuration of PUSH BUTTON UP command)
NotUsed
MagMCW Bit15
MagMCW Bit1
-
E
Binary signal for PB_UP:
0 … 31
17 = MagMCW_Bit1 1 = PB_UP is active, 0 = PB_UP is not active, default

Internal name : ConfPB_UP
65.11 ConfPB_DOWN (configuration of PUSH BUTTON DOWN command)
NotUsed
MagMCW Bit15
MagMCW Bit2
-
E
Binary signal for PB_DOWN:
0 … 31
18 = MagMCW_Bit2 1 = PB_DOWN is active, 0 = PB_DOWN is not active, default

Internal name : ConfPB_DOWN
65.12 ConfPB_Reset (configuration of push button RESET command)
NotUsed
MagMCW Bit15
MagMCW Bit3
-
E
Binary signal for PB_Reset:
0 … 31
19 = MagMCW_Bit3 1 = PB_Reset is active, 0 = PB_Reset is not active, default

Internal name : ConfPB_Reset
65.13 ConfStbyStRel (configuration of enable STEP BY STEP SHEET RELEASE command)
NotUsed
MagMCW Bit15
-
E
DI9
Binary signal for StepbyStepRel:
0 … 31
10 = DI9 1 = StepbyStepRel is active, 0 = StepbyStepRel is not active, default

Internal name : ConfStbyStRel
Appendix B

60
def.
unit
E/C
min.
max.
65.14 ConfTranspMode (configuration of enable TRANSPORT MODE command)
NotUsed
MagMCW Bit15
DI10
-
E
Binary signal for TransportMode:
0 … 31
11 = DI10 1 = TransportMode is active, 0 = TransportMode is not active, default

Internal name : ConfTranspMode
65.15 ConfBatOn (configuration of BATTERY ON command)
NotUsed
MagMCW Bit15
MagMCW Bit6
-
E
Binary signal for Cmd_BatSel (written to 7.01 Bit 11):
0 … 31
22 = MagMCW_Bit6 1 = Cmd_BatSel is active, 0 = Cmd_BatSel is not active, default

Internal name : ConfBatOn
65.16 ConfBatDisCh (configuration of BATTERY DISCHARGE command)
NotUsed
MagMCW Bit15
MagMCW Bit7
-
E
Binary signal for Cmd_BatDis (written to 7.01 Bit 12):
0 … 31
23 = MagMCW_Bit7 1 = Cmd_BatDis is active, 0 = Cmd_BatDis is not active, default

Internal name : ConfBatDisCh
65.17 ConfMonMagnet1 (configuration of enable MAGNET 1 I²t-MONITORING command) NotUsed
MagMCW Bit15
DI11
-
E
Binary signal for Magnet1act:
0 … 31
12 = DI11 1 = Magnet1act is active, 0 = Magnet1act is not active, default

Internal name : ConfMonMagnet1
65.18 ConfMonMagnet2 (configuration of enable MAGNET 2 I²t-MONITORING command)
NotUsed
MagMCW Bit15
DI12
-
E
0 … 31

Appendix B

61
def.
unit
E/C
min.
max.
NotUsed
MagMCW Bit15
DI13
-
E
0 … 31

NotUsed
MagMCW Bit15
DI14
-
E
0 … 31

NotUsed
MagMCW Bit15
MagMCW Bit12
-
E
0 … 31
28 = MagMCW_Bit12 1 = Magnet5act is active, 0 = Magnet5act is not active, default

NotUsed
MagMCW Bit15
MagMCW Bit13
-
E
0 … 31

NotUsed
MagMCW Bit15
MagMCW Bit14
-
E
0 … 31

Appendix B

62
def.
unit
E/C
min.
max.
NotUsed
MagMCW Bit15
MagMCW Bit15
-
E
0 … 31

Appendix B

63
Group 69
Fault-Alarm-Text
Magnet application
Index Signal / Parameter Name
unit
E/C
min.
max.
Def.
69.01 Faults (parameter for all user fault texts)
Faulttext 1
Faulttext 1
Faulttext X
-
E
reserved
Internal name : Txt_Faults
Type: C
69.02 Alarms (parameter for all user alarm texts)
Magnet8Ovrld
ParSwiBlock
ParSwiBlock
-
E
The alarm texts implemented are:
Name Description Message

Alarm 310: ParSwiBlock → A310
Alarm 311: M_Undervoltg → A311
Alarm 312: ResistorHot → A312
Alarm 313: ResistorCold → A313
Alarm 314: Magnet1Ovrld → A314
Alarm 316: Magnet3Ovrld, → A316
Internal name : Txt_Alarms
Type: C
69.03 Notices (parameter for all user notice texts) Noticetext 1
Noticetext 1
Noticetext X
-
E
reserved
Internal name : Txt_Notice
Type: C
Appendix B

64
Appendix C - Overvoltage Protection Hints

Reduction of switch-off overvoltage and spark quenching
A magnet is a large inductance which means that great attention must be paid to the pro-
tection concept. A DC electromagnet has an inductance that causes, especially with larger
magnets, high negative switch-off voltages. This might lead on to disruption of the electric
isolation and destruction of sensible electronic components of the customers electronic
control interface.
The following measures have to be taken into account to damp the voltage spikes. But a
damping of the switch-off peak is always a compromise between the fall time of the arma-
ture and the lifetime of the electronic and switches in the periphery.
OV1 (possibilities) + Overvoltage reduction

 Resistor - Losses due to heating
 MOV + resistor + OV reduction
 RC snubber + Voltage limitation at switching contacts
 DCF506 + product existing / - no battery back-up possible
Diode + contact + prevent OV through current bridge 1

- contact must be opened through current
bridge 2
Appendix C

65
MOV directly in parallel of each magnet

(Metal Oxid Varistor)
Damping through ohmic Resistor

A parallel resistor limits the switch-off voltage. Thus the fall time of the armature current
and the electric energy demand increases. The switch-off voltage decreases if the parallel
resistor is reduced.
Damping through Diodes and Zener Diodes
To prevent trouble it is recommended to use a diode for decoupling.
With closed contactors current bridge 2 should be blocked. When selecting the diodes
make sure that these diodes are able to block the operation voltage and that they are able
to stand the rated current of the connected electromagnet for a short time in forward direc-
tion. The fall of the armature current in this circuit is delayed as well. In these circuits di-
odes with Avalanche-conduction are very reliable.
Damping through varistors (voltage dependent resistors)

To damp switch-off voltages also varistors are used. The electric energy demand increases
only slightly and the fall time of the armature current is not delayed significantly. Thus the
switch-off voltage is damped substantially.
Spark Quenching
The high switch-off voltage especially of larger DC electromagnets causes electric arcs at
the used switches and thus burning down contacts and electro migration if no spark
quenching components are installed. The most common method for spark quenching is re-
alized through a varistor and a RC element.
With the varistor the switch-off voltage is damped onto the peak voltage of the used capaci-
tor. The RC element connected in parallel to the switching contact causes that the occur-
ring voltage at the contact does not exceed the minimum voltage needed for an electric arc.
Thus an electric arc is surely avoided.
Appendix C

66
Appendix D - Additional Technical Information

1. Determination of Magnet Inductance
To determine the needed number of additional single firing pulses (reversal delay) and
dimension of the overvoltage protection on the DC side of the DCS800 for high inductance
loads the inductance of the magnet is needed.
To determine the load inductance using a trace monitor do the following:
Evaluate the linear part at the beginning of the curve.
Formal connectedness:
Take following differential equation: U – i * R – L * di / dt = 0
For the linear part of the current slope is valid: (U – i * R) * Δt / Δi = L
Example with Uact [%] and Iact [%] taken as measured

percentage values of the output voltage and current from a trace curve:
Ua = Usupply * 1.35 * Uact [%], with Uact [%] = 0.655 => 65.5% →
Ua = 280 * 1.35 * 0.655 = 248 V
ia = IN * Iact [%] with IN = 105 A and Iact [%] = 0,2831 => 28,31% →
ia = 105 * 0.2831 = 29.7 A
Because of the linear current slope from i = 0 to i after Δt the (i after Δt) / 2 can be taken for
i of the i * R decrease.
R was measured to 2.3 Ω at the end of the magnetization process when the current has
reached finally a linear behavior.
With Uact [%] = 0.37 => 37 % and Iact [%] = 0.579 => 57.9 %;
R = (280 * 1.35 * 0.37) / (105 * 0.579) = 2.30 Ω
.
With Δt = 1 s ’ L = (248 – 29.7 / 2 * 2.30) * 1 / 29.7 = 7.20 H
2. Number of single firing pulses / Calculation of the Reversal Delay Time

Despite a maximum firing angle (full opposite voltage value for current reduction in the in-
ductance) due to the high inductance loads it takes a long time until the current has been
reduced down to zero. Especially in 4-Q operation it is essential that the current is zero and
the active thyristor is safely blocked before the change of the torque direction (firing of the
antiparallel bridge for current reversal) is initiated. If the antiparallel thyristor bridge is fired
before the previous is safely blocked circulating currents will blow fuses.
Lift magnets normally have inductance values from 10 H or above. This makes it essential
after status signal zero current is active to fire a determinate number of single firing pulses
until the current has reached zero.
Beside the determination of the number of single firing pulses a calculated verification is
needed. Most of all to consider an operational existing power supply under voltage or with
rated currents > 60 A the resolution of the current actual-value acquisition applied to the
holding current of the thyristors (approx. 100 mA).
Calculation example:
U = L * Δi / Δt; Δt = L * Δi / U
U = DCS800 output voltage at power supply under voltage level
and α: U = P99.10 * (1+ P30.23 / 100) * 1.35 * cos(α)
Δi = 1 % of the converter DC current in parameter 97.02
From zero current detection (1 % of 97.02) additional single firing pulses are applied.
Δt = minimum time of single firing pulses,
1 Impulse = 3.33 ms at 50 Hz, resp. 2.78 ms at 60 Hz
Appendix D

67
Example:
L = 1 H, P99.10 = 400 V (nominal AC mains voltage);
U = P99.10 * (1+ P30.23 / 100) * 1.35 * cos (𝛼𝛼)
P30.23 = -30 % (mains voltage minimum), ∆i = P97.02 * 0.01
P97.02 = 1200 A (converter rated DC current), ArmAlphaMax = 150° (P20.14)
∆t = 1 * 12 / [400 * (1 + (-30) / 100) * 1.35 * 0.866] = 0.037 s
Minimum number of additional single firing impulses at
50 Hz = 37 ms / 3.33 ms = 12
20 % allowance = 12 * 1.2 = 14.4 → The reversal delay time should be set to
43.14 = 50 ms (RevDly), the 97.19 = 200 ms (ZeroCurTimeOut).
3. Dimensioning of Overvoltage Protection

The magnetic conservation of energy within the magnet field windings for dimensioning
of the overvoltage protection can be calculated with the inductance value of the magnet
windings:
I 2mag U mag 2*W

W = L* R mag = L=
2 I mag I 2mag
W magnetic energy in watt-seconds [Ws]

L inductance value of the magnet field windings in Henry [H]
Imag rated magnet current in Ampere (see nameplate magnet) [A]
Rmag resistance in Ohm [Ω]
Umag rated magnet voltage in Volt (see nameplate magnet) [V]
The time constant 𝝉𝝉F of a possible needed freewheeling circuit can be calculated to
L
TF =
R
L inductance value of the magnet field windings [H]
R resulting resistance of magnet field windings, cabling,
dropping resistor (if needed) [Ω]
𝝉𝝉F time constant [s]
Damping Resistor Rs (Dimensioning of B6C bridge):
1.35 xU L [V ]
R S [Ω ] ≤
0.5[ A ]
U 2Nmag [V ]
PV [W ] = 2...3*
Rs [Ω ]
UL line to line voltage on the AC connection of the converter [V]
PV power loss of Rs [W]
UNmag magnet rated voltage [V]
Appendix D

Ident. No.: 3ADW000430 R0201 Rev B

01_2015
ABB Automation Products

Wallstadter-Straße 59
68526 Ladenburg • Germany
Tel:
Fax:
+49 (0) 6203-71-76 08
+49 (0) 6203-71-76 09
*430R0201A5040000*
*430R0201A5040000*
www.abb.com/motors&drives

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DCS800

Software Application: Supply for Electric Lifting Magnets

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Electric Lifting Magnets

Supply for Electric Lifting Magnets

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Diagram 1: Single Magnet in Current Control Mode

Current Control DCS800

Supply for Electric Lifting Magnets

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Diagram 2: Multi Magnets in Voltage Control Mode and Battery Backup

Voltage Control DCS800

Freewheeling diode Battery

DC fuses Protection of battery, if thyristors are broken.

Supply for Electric Lifting Magnets

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

To which products this chapter applies

Use of warnings and notes

Dangerous voltage warning warns of high voltage

General warning warns about conditions, other

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Installation and maintenance work

Only qualified electricians are allowed to install and maintain the

1. Voltage between DCS800 input phases U1, V1 and W1

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

WARNING! The printed circuit boards contain components sensitive

Use grounding strip:

ABB order no.: 3ADV050035P0001

• Ground the DCS800, magnet and adjoining equipment to ensure

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Fiber optic cables

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

DCS800 sizes D5...D7: The DCS800 is heavy. Lift the DCS800

• Before adjusting the DCS800 and putting it into service, make

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

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

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Introduction to this manual

Before You Start

What this manual contains

The Safety instructions can be found at the beginning of this manual.

Appendix A – Used Standard DCS800 Parameters

Appendix B – Application Parameters

Appendix C – Overvoltage Protection Hints

Appendix D – Additional Technical Information

Introduction to this manual

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

DCS800 Solution for Electric Lifting Magnets

The basic firmware contains:

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Magnetization and Demagnetization Mode:

Voltage Control Current Control

The commands Cmd_MagOn, Cmd_Run, Cmd_Cur and Cmd_Demag can be set

If AutoRunSel = Enabled (60.12) then Enable RUN is activated by Magnet ON

If RESEToverSTOP = Enabled (60.13) then RESET is initiated by a STOP com-

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b

Magnet switched ON with

3ADW000430R0201 DCS800 Lift Magnet Supply Manual e b