ABB industrial drives
Hardware manual
BSFC-02C charging controller
Hardware manual
BSFC-02C charging controller
2017 ABB Oy. All Rights Reserved.
3AXD50000027498 Rev A
EN
EFFECTIVE: 2017-04-10
5
Table of contents
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BSFC layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BSFC connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connections of the DC supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inverter power switch-on sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Details of the locking solenoid control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inverter power switch-off sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protecting against contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
List of components needed in power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting and removing the BSFC unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6
BSFC-02C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Introduction to the manual 7
1
Introduction to the manual
Contents of this chapter
This chapter gives the basic information on the manual.
Compatibility
The manual is compatible with the BSFC-02C charging controller.
Safety instructions
Follow all safety instructions delivered with the drive equipment.
•
Read the complete safety instructions before you install, commission, or use the drive.
The complete safety instructions are given in ACS880 multidrive cabinets and
modules safety instructions [3AUA0000102301(English)].
Note: The installation must always be designed and made according to applicable local
laws and regulations. ABB does not assume any liability whatsoever for any installation
that breaches the local laws and/or other regulations. Furthermore, if the
recommendations given by ABB are not followed, the drive system may experience
problems that the warranty does not cover.
WARNING! Perform the electrical safety precautions before starting any work on
the installation. Ignoring the precautions can cause physical injury or death, or
damage to the equipment. Only a qualified electrician is allowed to work on the
installation.
8 Introduction to the manual
1. Clearly identify the work location.
2. Disconnect the circuit to be worked on completely. After disconnection, always wait for
5 minutes to let the capacitors discharge.
3. Secure against re-connection. Lock the disconnectors and attach warning notices.
4. Provide protection against adjacent live parts.
5. Verify by measuring that there is no voltage present.
6. Carry out grounding and short-circuiting when necessary. Refer to local regulations
and EN 50110-1:2004.
Ask for a work permit. Only the nominated person in control of the electrical installation
work is allowed to issue a work permit.
Static electricity
WARNING! Circuit boards contain components sensitive to electrostatic
discharge (ESD). Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Intended audience
The manual is intended for cabinet designers, and installation, commissioning and
maintenance personnel of ACS800 and ACS880LC multidrive modules.
The reader is expected to know the standard electrical wiring practices, electronic
components, and electrical schematic symbols.
Contents of the manual
This manual consists of the following chapters:
Hardware description describes BSFC-02C unit.
Installation guides in planning the installation of the BSFC-02C unit.
Circuit diagrams contains connection diagrams.
Dimension drawings contains the dimensional drawings of the BSFC-02C unit.
Inquiries
Address any inquiries about the product to the local ABB representative, quoting the type
code and the serial number of the unit. If the local ABB representative cannot be
contacted, address inquiries to the manufacturing facility.
Hardware description 9
2
Hardware description
Contents of this chapter
This chapter shows an overview of the BSFC unit and describes the connectors, settings
and LEDs. In addition, it contains circuit diagram examples of the DC supply circuit of
ACS880 frame R8i modules, and describes switch-on and switch-off sequences of the
units.
BSFC unit overview
ACS880 frame size R8i inverter modules can be connected to the drive DC bus through a
switch/disconnector (or switch fuse). This configuration requires a charging circuit to
charge the DC capacitors of the modules in a controlled way. The DC voltage can be
directly connected to the modules only after the capacitors are charged to a sufficient
level. The BSFC is a unit that monitors the charging, and controls switch-on and switch-off
of the DC voltage.
In addition to inverter units, the BSFC can be used with other units consisting of R8i
modules, such as brake or DC/DC converter units. One BFSC unit controls the charging of
1...3 frame R8i modules.
The BSFC unit can be snapped onto a standard mounting rail.
10 Hardware description
BSFC layout
Symbol
Description
Layout
X4
X5
Switch status monitoring (Q10 and Q11).
Power supply input for BSFC and operating
voltage output for switch/disconnector locking
solenoid.
1
2
3
4
5
6
L
N
PE
V1…V6
S1…S3
Fiber optic links to Inverter 1, 2 and 3.
X5
IND. CONT. EQ.
1PD8
Enable switches for charging circuit monitoring
(Inverter 1, 2 and 3).
LSOL
NSOL
RATINGS
Note: The BSFC do not allow the closing of the
DC switch/disconnector unless monitoring is
enabled for at least one inverter module.
SUPPLY VOLTAGE (X5)
230 V, 50/60Hz, 20 mA
115 V, 50/60 Hz, 40 mA
SOLENOID CONTROL
OUTPUT (X5) 115/230 V
AC, MAX 2A
EXCITATION VOLTAGE
OUTPUT (X4)
STAT 1…3
Inverter charging status LEDs (3 pcs).
Inverter “ready for start” LEDs (3 pcs).
BSFC power on LED.
15 V DC, MAX 10mA
OPER. TEMPERATURE
MAX +85 °C
U
1…3
DC
STAT
PWR
1
2
3
4
15V
AUX2
GND
GND
X4
PWR
DIS
S1
EN
UDC
STAT
TO BE USED WITH
ABB DRIVES ONLY.
MAXIMUM RATED
SYSTEM VOLTAGE
UL: 600 V AC
V1
INV1
IEC: 690 V AC
V2
DIS
EN
S2
UDC
STAT
V3
INV2
V4
DIS
S3
EN
UDC
STAT
V5
INV3
V6
Hardware description 11
BSFC connectors
Connector Signal
Description
X4
Switch status monitoring (inverter switch/disconnector (Q11), and inverter charging
switch (Q10)).
1
+15 V
AUX2
GND
GND
Supply voltage for switch status monitoring circuit (Q10 and Q11). Max. 10 mA
Digital input monitoring the switch status (Q10 and Q11).
Ground for control electronics
2
3
4
Ground for control electronics
X5
1
Power supply input & switch/disconnector locking solenoid control output
External 230/115 V AC input
L
2
N
Neutral
3
PE
Protective Earth
4
NC
LSOL
NSOL
Not connected
5
230/115 V AC control voltage for switch Q11 locking solenoid
Neutral for switch Q11 locking solenoid
6
V1
V2
V3
V4
V5
V6
INV1 EN Optical transmitter (start enable to Inverter 1)
Optical receiver (U > 80% acknowledgement from Inverter 1)
U
1
DC
DC
INV2 EN Optical transmitter (start enable to Inverter 2)
Optical receiver (U > 80% acknowledgement from Inverter 2)
U
2
DC
DC
INV3 EN Optical transmitter (start enable to Inverter 3)
Optical receiver (U > 80% acknowledgement from Inverter 3)
U
3
DC
DC
BSFC LEDs
Name
Colour
Indication
Illuminates when
INV1 STAT Yellow
INV2 STAT Yellow
INV3 STAT Yellow
Charging of Inverter 1 is in
progress, or Inverter 1 is
not in use
Switch Q11 main contacts are open (auxiliary
contact connected to connector X4 is open).
Charging of Inverter 2 is in
progress, or Inverter 2 is
not in use
See INV1 STAT.
See INV1 STAT.
Charging of Inverter 3 is in
progress, or Inverter 3 is
not in use
INV1 U
Green
Inverter 1 ready to start
Signal U 1 indicates that DC voltage of
DC
DC
Inverter 1 capacitor bank is above 80% of the
nominal.
INV2 U
INV3 U
PWR
Green
Green
Green
Inverter 2 ready to start
Inverter 3 ready to start
BSFC power on
See U 1.
DC
DC
DC
See U 1.
DC
Voltage for internal logic (5 V) is present.
12 Hardware description
Connections of the DC supply circuit
DC bus
-A11.1
BSFC-XX
SWITCH FUSE CONTROLLER
-Q11.1
-Q10.1
X1:1
IR+
X1:2
X1:3
IR-
DIS
X2:1
X2:2
X2:3
S1
S2
S3
-K11.1
A2
IR2+
IR2-
IR3+
IR3-
EN
A1
DIS
EN
X3:1
X3:2
X3:3
DIS
EN
X4:1
X4:2
X4:3
X4:4
15V
AUX2
GND
GND
=-DOOR
-P11.1
X5:1
X5:2
X5:3
X5:4
X5:5
X5:6
L
N
L
230V AC; 115V AC
N
PE
GREEN
Chg OK
LSOL
NSOL
;I1V60
;I1V50
V1
V2
STAT
UDC
INV 1
R8i module 1
V3
V4
STAT
UDC
INV 2
INV 3
V5
V6
STAT
UDC
DC supply
to R8i module
No. Description
1
2
3
4
5
6
7
8
Drive DC bus
Main DC switch disconnecter
Charging switch fuse
Charging resistors
Solenoid that locks the manual operation mechanism
Indicator lamp on the cabinet door
BSFC unit
R8i module DC input connection
Hardware description 13
Inverter power switch-on sequence
The terms and designations used in the table below refer to the diagram in section
Operation
What happens
1.
User turns charging
circuit switch Q10 to 1
(ON) position.
Charging of inverter capacitors starts through the charging resistors [R10].
Auxiliary contact 1-2 of Q10 opens. BSFC prevents starting of inverter and
closing of switch/disconnector Q11.
“INV1 STAT” and “PWR” LEDs are on.
2.
3.
Inverter capacitor bank
charges.
BSFC monitors inverter U signal through fiber optic link(s) INV1…INV3.
DC
“INV STAT” and “PWR” LEDs are on.
BSFC unit detects that
the charging is
BSFC connects operating voltage to solenoid of switch/disconnector Q11.
Solenoid releases the locking mechanism enabling operation of the
handle.
completed: U
DC
signal(s) are received
from inverters
“INV UDC” and “PWR” LEDs are on. The “charging OK” light on the
cabinet door illuminates indicating that capacitor charging is complete and
operation of the switch/disconnector Q11 is allowed.
(U > 80%
DC
acknowledgement from
Inverter(s)).
4.
5.
User turns
switch/disconnector
Q11 to 1 (on) position.
Main contacts 1-2…7-8 of switch Q11 connect inverter(s) to DC power
supply.
Auxiliary contact 13-14 of switch Q11 closes.
Auxiliary contact 21-22 of switch Q11 opens, de-energizing the solenoid
and the “charging OK” LED on the cabinet door.
“INV UDC” and “PWR” LEDs are on.
User turns switch Q10
to 0 (off) position.
BSFC receives “main switch ON, charging switch OFF” indication through
terminal AUX2.
BSFC sends an enable signal to inverter through the fiber optic link.
“INV UDC” and “PWR” LEDs on.
Miscellaneous
Details of the locking solenoid control
The closing of the DC switch/disconnector is enabled by locking solenoid when:
•
DC voltage of all inverter modules monitored by the BSFC unit exceed 80% of the
nominal value. (BSFC receives UDC signals from inverters).
•
Switch/disconnector handle is in 0 (off) position.
14 Hardware description
Inverter power switch-off sequence
The terms and designations used in the table below refer to section Connections of the DC
Operation
What happens
1.
2.
User stops the inverters.
(Do not open the
switch/disconnector while
the inverters are loaded).
User turns switch Q11
Switch Q11 disconnects inverter(s) from the DC power supply.
handle to 0 (off) position.
Contact 13-14 of Q11 switches off the AUX2 signal on the BSFC unit.
BSFC switches INV1 EN signal off disabling inverter start.
Auxiliary contact 21-22 closes energizing the solenoid of switch Q11.
Solenoid releases the locking mechanism of switch Q11. Normal
operation (on/off) of the handle is possible as long as inverter DC
voltage remains high.
“INV UDC” and “PWR” LEDs. LED “Charging OK” light on the cabinet
door illuminates.
3.
Inverter capacitor bank
discharges.
Inverter DC voltage decreases to zero gradually. When below 80% of
nominal:
• Inverters switch off U signals from BSFC unit.
DC
• BSFC switches off the operating voltage to solenoid of switch Q11.
Locking mechanism activates preventing operation of switch into on
position.
“INV UDC” and “PWR” LEDs are on.
Installation 15
3
Installation
Contents of this chapter
This chapter instructs how to install the BSFC unit into a user-defined cabinet.
Planning the installation of the BSFC unit
Placing
Install the BSFC unit in a heated indoor environment. Ensure the temperature meets the
the requirements of the hardware manual of the inverter modules.
Do not install the BSFC unit far from the inverters. The fiber optic cable(s) between the unit
and inverter(s) must not exceed four meters in length.
WARNING! No condensation is allowed. There are connectors that are connected
to drive main circuit potential.
Wire selection
16 Installation
Protecting against contact
WARNING! Protect the BSFC unit against accidental contact. There are
connectors that are connected to drive main circuit potential.
List of components needed in power supply circuit
Component
Acquire…
Switch/disconnector kit(DC
switch/disconnector, BSFC
unit, charging switch,
…from ABB.
charging resistors)
DC fuses for inverter
Charging circuit fuses
…from ABB or according to the ABB specification.
…from ABB or according to the ABB specification.
…from ABB or according to the ABB specification.
Pair of fibre optic cables for
BSFC – inverter connection
Main DC supply
cables/busbars
… according to the ABB specification.
Charging circuit cables,
BSFC power supply
cables,switch/disconnector
control cables
… from any source according to the ABB specification.
Always use the cables recommended by ABB or equivalent. The cables are
connected to drive main circuit.
Mounting and removing the BSFC unit
1. Mount the unit by snapping the feet onto a 35 mm EN50022 mounting rail (1a).
2. Remove the unit by bending the feet outwards lightly (2) and lifting the unit
simultaneously (3).
Mounting
Removing
1b
3
2
1a
2
Wiring the BSFC unit
Technical data 17
4
Technical data
Contents of this chapter
This chapter contains the technical specifications of the BSFC unit.
Power supply input
(X5)
Operating voltage 115…230 V AC +10/%, 50/60 Hz
Current consumption 40/80 mA typical (230/115 V AC)
Protection by Microfuse 2 A, slow
6-position detachable screw terminal block (FCI OQ0601500000G), wire size max.
2
2.5 mm .
Solenoid control
output (X5)
Control voltage 115 or 230 V AC, +10/-15%
Control current max. 2 A for 3.5 s or max. 4 A for 20 ms
Protection by Microfuse 2 A, slow (common with power supply input)
2
6-position detachable screw terminal block, wire size max. 2.5 mm
Switch feedback input Voltage output 15 V DC max. 10 mA
(X4)
4-position detachable screw terminal block (FCI OQ0471500000G), wire size max.
2.5 mm
2
Optical links (V1…V6) Avago Versatile Link series 5 MBd optical transmitters & receivers
Max. optical cable (POF) length 5 m
18 Technical data
Standards applied
Safety requirements: EN 50178 Electronic equipment for use in power installations
IEC 61800-5-1 Semiconductor power converters for adjustable frequency drive
systems
UL 508 C Industrial Control Equipment
EMC emission: EN/IEC 6100-6-4:2007 Emission standard for industrial
environments
EMC immunity: EN/IEC 61000-6-2:2005 Immunity for industrial environments
Operating temperature Free air circulation: +0...+50 °C (+32 ... +122 °F)
Forced convection cooling: Max. +70 °C, min. air flow 2 m/s
Dimensions
(L × W × D)
247 × 79 × 66.5 mm (9.72” x 3.11” x 2.62”)
Mounting
On 35 mm mounting rail EN 50022, vertical or horizontal
UL approved (UL Listed according to UL 508 C)
Conformal coating as standard
Other features
Optical components
Handle fiber optic cables with care. When unplugging optic cables, always grab the
connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the
fiber is extremely sensitive to dirt. The specifications of the optic cable are as follows:
•
•
•
•
•
•
•
Storage temperature: -55...+85 °C (-67…+185 °F)
Installation temperature: -20...+70 °C (-4…+158 °F)
Maximum short-term tensile force: 50 N (11.2 lbf)
Minimum short-term bend radius: 25 mm (1.0”)
Minimum long-term bend radius: 35 mm (1.4”)
Maximum long-term tensile load: 1 N (3.6 ozf)
Flexing: Max. 1000 cycles
ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from
Avago Technologies’ Versatile Link range. Please note that the optical component type is
not directly related to the actual communication speed.
Note: The optical components (transmitter and receiver) on a fiber optic link must be of the
same type.
Plastic optical fiber (POF) cables can be used with both 5 MBd and 10 MBd optical
components. 10 MBd components also enable the use of Hard Clad Silica (HCS®) cables,
which allow longer connection distances thanks to their lower attenuation. HCS® cables
cannot be used with 5 MBd optical components.
20 Circuit diagrams
Charging circuit 1xR8i
4 1
3 3
4 2
3 4
2 1
2 2
6 : 3 1 ; X
5 : 3 1 ; X
4 : 3 1 ; X
3 : 3 1 ; X
2 K
2 K
1 3
1 4
4
3
1
1
2
D C U - + =
D C U - + =
2
1
2
D C U - - =
D C U - - =
=-R1.1
2
1
1
3
3
=-R2.1
2
=-R3.1
2
1
1
3
3
=-R4.1
2
2 H
3 D
1 : 1 1 0 Q ; .
2 : 1 1 0 Q ; .
1
2
7
5
3
1
8
6
4
2
X 1
X 2
6 : 3 1 ; X
5 : 3 1 ; X
4 : 3 1 ; X
3 : 3 1 ; X
E
E
1 5
7 D
: 1 . 1 0 1 Q ;
1 4
E P 1 .
1
= -
E
1 P
Circuit diagrams 21
Charging circuit 2xR8i
4 1
3 3
4 2
3 4
2 1
2 2
6 : 3 1 ; X
5 : 3 1 ; X
4 : 3 1 ; X
3 : 3 1 ; X
2 K
2 K
2
D C U - + =
2
D C U - - =
1 3
1 4
8
7
5
3
1
1
D C U - + =
6
4
2
1
D C U - - =
=-R1.1
2
1
1
1
3
3
3
=-R2.1
2
=-R3.1
2
=-R4.1
2
1
1
1
3
3
3
=-R5.1
2
=-R6.1
2
2 H
3 D
1 : 1 1 0 Q ; .
2 : 1 1 0 Q ; .
1
2
7
5
3
1
8
6
4
2
X 1
X 2
6 : 3 1 ; X
5 : 3 1 ; X
4 : 3 1 ; X
3 : 3 1 ; X
E
E
1 5
7 D
: 1 . 1 0 1 Q ;
1 5
E P 1 .
1
= -
E
1 P
22 Circuit diagrams
24 Dimension drawings
BSFC-02C
1
2
3
L
N
PE
X5
4
IND. CONT. EQ.
1PD8
5
6
LSOL
NSOL
RATINGS
SUPPLY VOLTAGE (X5)
230 V, 50/60Hz, 20 mA
115 V, 50/60 Hz, 40 mA
SOLENOID CONTROL
OUTPUT (X5) 115/230 V
AC, MAX 2A
EXCITATION VOLTAGE
OUTPUT (X4)
15 V DC, MAX 10mA
OPER. TEMPERATURE
MAX +85 °C
STAT
1
2
15V
AUX2
GND
GND
X4
3
PWR
DIS
4
S1
EN
UDC
STAT
TO BE USED WITH
ABB DRIVES ONLY.
MAXIMUM RATED
SYSTEM VOLTAGE
UL: 600 V AC
V1
INV1
IEC: 690 V AC
V2
DIS
EN
S2
UDC
STAT
V3
INV2
V4
DIS
S3
EN
UDC
STAT
V5
INV3
V6
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
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