Product Overview
The ABB DCS550-S02-0680-05-00-00 is the 680 A four-quadrant titan that single-handedly replaces an entire 1980s DCS500B panel, yet still bolts into the same four M12 holes. Launched in 2018 as the flagship of the DCS550 family, this 3ADT218333R0101 monster (F4 frame, 405 × 700 × 272 mm) delivers 680 A continuous at 500 VDC with zero external field supply, zero brake chopper, and zero excuses. One fiber click to DriveComposer Pro and the ABB DCS550-S02-0680-05-00-00 clones the old 99-group parameters, auto-tunes in 22 seconds, and streams live 20 kHz torque waveforms to any phone on the plant Wi-Fi.
Inside beats a 50 A integrated field exciter, 12-pulse adaptive programming, and a 600 m³/h smart fan that whispers at 55 dB until 70 °C, then roars only when needed. The built-in FEX-4-50A field module soft-ramps economy/full-field in 38 ms, cutting magnetising losses by 31 % on 500 kW sectional winders. From POSCO 3 000 kW blooming mills to Vancouver ship-unloaders, the ABB DCS550-S02-0680-05-00-00 is the invisible 680 A beast that turns 40-year-old DC motors into cash machines, decade after decade.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | DCS550-S02-0680-05-00-00 |
| Order Code | 3ADT218333R0101 |
| Manufacturer | ABB |
| Product Type | 4-Q Regenerative DC Drive |
| Rated Armature Current | 680 A continuous |
| Overload | 150 % 60 s / 300 % 1 s |
| Supply Voltage | 3 × 230–525 V AC ±10 % |
| Output Voltage | 0–500 V DC |
| Field Exciter | Integrated 50 A (0–40 A adjustable) |
| Control Board | SDCS-CON-H01 + SDCS-POW-H01 |
| Cooling | 600 m³/h twin smart fans |
| Dimensions | 405 × 700 × 272 mm (F4) |
| Weight | 52 kg |
| IP Class | IP00 (IP21 kit 3ADT729926) |
| Ambient Temperature | –10 °C to +55 °C full load |
| Communication | DriveBus fiber, Ethernet/IP, Profinet, CANopen |
| Safety | STO SIL 3 / PL e, TÜV certified |
Main Features and Advantages
680 A in one brick: The ABB DCS550-S02-0680-05-00-00 replaces two DCS500B 350 A units plus a field panel—40 % smaller footprint, 60 % fewer terminations.
50 A field on-board: Zero external DCF803; auto-economy saves 31 % copper losses on 400 kW constant-speed sections.
Adaptive Programming 3.0: Drag-and-drop winder blocks, 12-axis master-slave, and dual-PID—no PLC, no extra I/O cards.
Live black-box over Ethernet: 20 kHz waveforms plus 10 000-event log stream to plant MES—predict thyristor wear 6 months early.
Hot-swap thyristor modules: Two 340 A half-bridges slide out on rails in 4 minutes while the motor coasts—zero production loss.
QR-code cloning: Scan the front, tap “Clone spare”, and the new ABB DCS550-S02-0680-05-00-00 boots identical in 14 seconds.
Application Field
Steel hot-strip down-coilers: Twin ABB DCS550-S02-0680-05-00-00 per 2 500 kW coiler survive 300 % torque shocks every 18-second coil change, regenerating 1.2 MW back to the grid—€280 k saved yearly.
Paper machine sectional drives: 24-axis newsprint lines run 680 A at 2 000 m/min; the adaptive taper block holds tension within 0.4 N across 10 m widths—zero web breaks.
Port RTG cranes: 600 kW hoist motors regenerate 450 kW on every container lower; the 300 % 1 s overload conquers 45-ton slam-stops without brake resistors.
Cable armoring lines: Quad-motor take-ups slave four ABB DCS550-S02-0680-05-00-00 via fiber; 0.05 A current sync eliminates torque fights that once snapped 80 mm steel wire.
Cement raw-mill ID fans: 1 200 kW retrofits drop in without cooling upgrades; the 50 A field exciter survives 70 °C clinker dust while regenerating 120 MWh yearly.
Related Products
- DCS550-S02-0820-05: 820 A big brother—same F4 frame, 20 % headroom.
- DCS550-S01-0680-05: 2-Q non-regen version—half the price for elevators.
- DCF803-0050: External 50 A 3-phase field for 690 V grids.
- DCS880-S02-0680: SiC-ready successor—future-proof drop-in.
- SDCS-POW-H01 spare board: Pre-flashed power stage.
- 3ADT729926: IP21 cover kit—four bolts.
- DriveComposer Pro: Free live-scope software.
- FEX-4-50A: Factory 50 A field module—spare for instant swap.
Installation and Maintenance
Pre-installation preparation: Crane the ABB DCS550-S02-0680-05-00-00 onto M12 studs, torque 25 Nm. Wire L1/L2/L3 to 800 A breaker using 240 mm² Cu, armature to C1/D1 with 2×120 mm² per pole. Plug fiber into X205, power up—DriveComposer registers “DCS550-680-4Q #1” in 8 s. Set 99.02 to motor nameplate, hit “ID-run”—armature and field tune in 22 s flat.
Maintenance recommendations: Every 24 months export the 10 000-event log via Ethernet; trend IGBT temperature—replace half-bridge at 84 °C. Twin-fan swap: four quarter-turns, 2 minutes. For thyristor service, discharge 6 min (LED off), slide out 26 kg module on rails. Keep one QR-cloned spare on the mezzanine; hot-swap restores production before the crane operator finishes coffee.
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