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****** Page 1 ****** ABB industrial drives Hardware manual BSFC-02C charging controller Power and productivity for a better worldTM

****** Page 2 ****** List of related manuals General manuals Code (English) Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 Electrical planning instructions for ACS880 multidrive cabinets and modules Cabinet design and construction instructions for ACS880 multidrive modules BCU-02/12/22 control units hardware manual Supply module manuals ACS880-204 IGBT supply units as modules hardware manual ACS880 IGBT supply control program firmware manual ACS880-304 +A003 diode supply modules hardware manual ACS880-304 +A018 diode supply modules hardware manual ACS880 diode supply control program firmware manual ACS880-904 regenerative rectifier modules hardware manual 3AUA0000102324 3AUA0000107668 3AUA0000113605 3AUA0000131525 3AUA0000131562 3AUA0000102452 3AXD50000011408 3AUA0000103295 3AXD50000020457 ACS880 regenerative rectifier control program firmware manual 3AXD50000020827 Inverter module manuals and guides ACS880-104 inverter modules hardware manual ACS880 primary control program firmware manual ACS880 primary control program quick start-up guide Brake module and DC/DC converter module manuals ACS880-604 1-phase brake chopper modules hardware manual ACS880-604 3-phase brake chopper modules hardware manual 3AUA0000104271 3AUA0000085967 3AUA0000098062 3AUA0000106244 3AXD50000022033 ACS880-604 (3-phase) brake control program firmware manual 3AXD50000020967 ACS880-1604 DC/DC converter modules hardware manual ACS880 DC/DC converter control program firmware manual Option manuals and guides ACS-AP-x Assistant control panels user’s manual Drive composer statt-up and maintenance PC tool user’s manual Drive (IEC 61131-3) application programming manual Installation frames for ACS880 multidrive modules hardware manual FDPl-02 diagnostics and pane/ interface user’s manual FSO-12 safety functions module user’s manual Manuals and quick guides for VO extension modules, fieldbus adapters, etc. 3AXD50000023642 3AXD50000024671 3AUA0000085685 3AUA0000094606 3AUA0000127808 3AXD50000010531 3AUA0000113618 3AXD50000015612 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.

****** Page 3 ****** Hardware manual BSFC-02C charging controller Table of contents 3. Installation 0 2017 ABB oy. All Rights Reserved. 3AXD50000027498 Rev A EN EFFECTIVE: 2017-04-10

****** Page 5 ****** Table of contents 1. Introduction to the manual Contents of this chapter Compatibility Safety instructions Static electricity Intended audience . Contents of the manual . Inquiries 2. Hardware description Contents of this chapter BSFC unit overview ….. BSFC layout BSFC connectors BSFC LEDs Connections of the DC supply circuit Inverter power switch-on sequence Miscellaneous Details of the locking solenoid control Inverter power switch-off sequence 3. Installation Contents of this chapter Planning the installation of the Placing Wire selection Protecting against contact BSFC unit List of components needed in power supply circuit Mounting and removing the Wiring the BSFC unit 4. Technical data Contents of this chapter Optical components 5. Circuit diagrams Contents of this chapter Charging circuit lxR8i Charging circuit 2xR8i 6. Dimension drawings Contents of this chapter BSFC unit 10 11 11 . 12 13 13 13 14 15 .15 15 15 16 16 16 16 17 18 19 20 21 23

****** Page 6 ****** BSFC-02C Further information Product and service inquiries . Product training Providing feedback on ABB Drives manuals Document library on the Internet 24 25 25 25 25

****** Page 7 ****** Introduction to the manual 7 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.

****** Page 8 ****** 8 Introduction to the manual 1. 2. 3. 4. 5. 6. Clearly identify the work location. Disconnect the circuit to be worked on completely. After disconnection, always wait for 5 minutes to let the capacitors discharge. Secure against re-connection. Lock the disconnectors and attach warning notices. Provide protection against adjacent live parts. Verify by measuring that there is no voltage present. 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. Technical data contains technical specifications. 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.

****** Page 9 ****** Hardware description 9 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.

****** Page 10 ****** 10 Hardware description BSFC layout Symbol Sl…S3 Description Layout VI. STAT 1 . PVVR ..3 Switch status monitoring (Q 10 and QI 1). Power supply input for BSFC and operating voltage output for switch/disconnector locking solenoid. Fiber optic links to Inverter 1, 2 and 3. Enable switches for charging circuit monitoring (Inverter 1, 2 and 3). Note: The BSFC do not allow the closing of the DC switch/disconnector unless monitoring is enabled for at least one inverter module. Inverter charging status LEDs (3 pcs). Inverter “ready for start” LEDs (3 pcs). BSFC power on LED. L I 4 5 LSOL 6 NSOL @ STAT 2 AUX2 3 GND 4 GND TO BE USED WITH ABB DRIVES ONLY. MAXIMUM RATED SYSTEM VOLTAGE ULI V AC IEC: V AC LISTED IND. CONT. EQ. RATINGS SUPPLY 230 V, 201M SOLENOID C.CNTROL OUTPUT (X5) 115030 V AC, MAX2A EXCITATIOQ VOLTAGE OUTPUT (X4) 15 V MAX IOrnA OPER, TEMPERATURE MAX +85 oc PWR @ DIS EN UDC STAT INVI DIS EN ooc STAT DIS EN INV3

****** Page 11 ****** Hardware description BSFC connectors 11 Connector Signal 1 2 3 4 1 2 3 4 5 6 VI +15 V AUX2 GND GND NC LSOL NSOL INVI EN INV2 EN INV3 EN Description Switch status monitoring (inverter switch/disconnector (QI 1), and inverter charging switch (QI Supply voltage for switch status monitoring circuit (QIO and QI 1). Max. 10 mA Digital input monitoring the switch status (QI 0 and Qll Ground for control electronics Ground for control electronics Power supply input & switch/disconnector locking solenoid control output External 230/115 V AC input Neutral Protective Earth Not connected 230/115 V AC control voltage for switch QI 1 locking solenoid Neutral for switch Qll locking solenoid Optical transmitter (start enable to Inverter 1) Optical receiver (UDC > 80% acknowledgement from Inverter 1) Optical transmitter (start enable to Inverter 2) Optical receiver (UDC > 80% acknowledgement from Inverter 2) Optical transmitter (start enable to Inverter 3) Optical receiver (UDC > 80% acknowledgement from Inverter 3) BSFC LEDs Name INVI STAT INV2 STAT INV3 STAT INVI INV2 UDC INV3 p VVR Colour Yellow Yellow Yellow Green Green Green Green Indication Charging of Inverter 1 is in progress, or Inverter 1 is not in use Charging of Inverter 2 is in progress, or Inverter 2 is not in use Charging of Inverter 3 is in progress, or Inverter 3 is not in use Inverter 1 ready to start Inverter 2 ready to start Inverter 3 ready to start BSFC power on Illuminates when Switch QI 1 main contacts are open (auxiliary contact connected to connector X4 is open). See INVI STAT. See INVI STAT. Signal UDCI indicates that DC voltage of Inverter 1 capacitor bank is above 80% of the nominal. See . See . Voltage for internal logic (5 V) is present.

****** Page 12 ****** 12 Hardware description Connections of the DC supply circuit 230V AC; 115V AC 3 -QIO.I 4 DC bus -KI 1.1 5 =-DOOR -pl 1.1 GREEN Chg 0K 6 O 2 -QI 1.1 O 1 8 7 -A11.1 BSFC-XX SWITCH FUSE CONTROLLER .1 ;11V60 ;11V50 X3:1 X3:2 X3:3 X4:1 X4:2 X4:3 X5:2 X5:3 X5:4 X5:5 X5:6 VI IR2+ IR2- IR3- 15V DIS EN DIS EN DIS EN R8i module 1 AUX2 GND GND LSOL NSOL @ STAT INV 1 @ STAT INV 2 @ STAT DC supply to R8i module No. 1 2 3 4 5 6 7 8 Description 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

****** Page 13 ****** Hardware description Inverter power switch-on sequence The terms and designations used in the table below refer to the diagram in section Connections of the DC supply circuit. 13 1. 2. 3. 4. 5. Operation User turns charging circuit switch QIO to 1 (ON) position. Inverter capacitor bank charges. BSFC unit detects that the charging is completed: UDC signal(s) are received from inverters (UDC > 80% acknowledgement from Inverter(s)). User turns switch/disconnector QI 1 to 1 (on) position. User turns switch QI 0 to 0 (off) position. What happens Charging of inverter capacitors starts through the charging resistors [RI O]. Auxiliary contact 1-2 of QI 0 opens. BSFC prevents starting of inverter and closing of switch/disconnector QI 1 . “INVI STAT” and “PWR” LEDs are on. BSFC monitors inverter UDC signal through fiber optic link(s) INVI INV3. “INV STAT” and UPWR” LEDs are on. BSFC connects operating voltage to solenoid of switch/disconnector QI 1 . Solenoid releases the locking mechanism enabling operation of the handle. “INV UDC” and “PWR” LEDs are on. The “charging 0K” light on the cabinet door illuminates indicating that capacitor charging is complete and operation of the switch/disconnector Q 11 is allowed. Main contacts 1-2…7-8 of switch QI 1 connect inverter(s) to DC power supply. Auxiliary contact 13-14 of switch Q 11 closes. Auxiliary contact 21-22 of switch QI 1 opens, de-energizing the solenoid and the “charging 0K” LED on the cabinet door. “INV UDO’ and “PWR’I LEDs are on. 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 O (off) position.

****** Page 14 ****** 14 Hardware description Inverter power switch-off sequence The terms and designations used in the table below refer to section Connections of the DC supply circuit. 1. 2. 3. Operation User stops the inverters. (Do not open the switch/disconnector while the inverters are loaded). User turns switch QI 1 handle to 0 (off) position. Inverter capacitor bank discharges. What happens Switch Q 11 disconnects inverter(s) from the DC power supply. Contact 13-14 of Q 11 switches off the AUX2 signal on the BSFC unit. BSFC switches INVI EN signal off disabling inverter start. Auxiliary contact 21-22 closes energizing the solenoid of switch Qll . Solenoid releases the locking mechanism of switch Q 11. Normal operation (on/off) of the handle is possible as long as inverter DC voltage remains high. “INV UDC” and “PWR” LEDs. LED “Charging 0K” light on the cabinet door illuminates. Inverter DC voltage decreases to zero gradually. When below 80% of nominal: • Inverters switch off UDC signals from BSFC unit. • BSFC switches off the operating voltage to solenoid of switch Q 11. Locking mechanism activates preventing operation of switch into on position. “INV UDO’ and UPWR” LEDs are on

****** Page 15 ****** Installation 15 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 requirement given in chapter Technical data. Also ensure that the ambient conditions meet 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 See chapter Circuit diagrams on page 19.

****** Page 16 ****** 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 Switch/disconnector kit (DC switch/disconnector, BSFC unit, charging switch, charging resistors) DC fuses for inverter Charging circuit fuses Pair of fibre optic cables for BSFC inverter connection Main DC supply cables/busbars Charging circuit cables, Acquire… . from ABB. …from ABB or according to the ABB specification. . .from ABB or according to the ABB specification. . from ABB or according to the ABB specification. according to the ABB specification. from any source according to the ABB specification. BSFC power supply Charging circuit wire specification, see chapter Circuit diagrams on page 19. cables, switch/disconnector Always use the cables recommended by ABB or equivalent. The cables are control cables 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 (1 a). 2. Remove the unit by bending the feet outwards lightly (2) and lifting the unit simultaneously (3). Mounting 1b Wiring the BSFC unit Removing la Connect the wiring according to the diagrams in chapter Circuit diagrams on page 19.

****** Page 17 ****** Technical data Technical data Contents of this chapter This chapter contains the technical specifications of the BSFC unit. 17 Power supply input Solenoid control output (X5) Switch feedback input Optical links (VI …V6) Operating voltage 115…230 V AC 0/0/0, 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 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 Voltage output 15 V DC max. 10 mA 4-position detachable screw terminal block (FCI OQ0471500000G), wire size max. 2 2.5 mm Avago Versatile Link series 5 MBd optical transmitters & receivers Max. optical cable (POF) length 5 m

****** Page 18 ****** 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 oc (+32 …. +122 OF) Dimensions Mounting Other features Forced convection cooling: Max. +70 oc, min. air flow 2 m/s 247 x 79 x 66.5 mm (9.72″ x 3.11″ x 2.62″) On 35 mm mounting rail EN 50022, vertical or horizontal UL approved (UL Listed according to UL 508 C) Conformal coating as standard 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 oc (-67…+185 OF) Installation temperature: -20…+70 oc (-4…+158 OF) 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.

****** Page 19 ****** Circuit diagrams 19 Circuit diagrams Contents of this chapter This chapter shows the connections between the switch/disconnector, the charging controller and one or two inverters. The BSFC unit is supplied from 115…230 V AC power source.

****** Page 20 ****** 20 Circuit diagrams Charging circuit lxR8i zz 88 Saä Ii7

****** Page 21 ****** Circuit diagrams 21 Charging circuit 2xR8i ili ii ili -an—I 08 E 3.dV1-•

****** Page 22 ****** 22 Circuit diagrams

****** Page 23 ****** Dimension drawings 23 Dimension drawings Contents of this chapter This chapter contains dimension drawings of BSFC-02C charging controller.

****** Page 24 ****** 24 Dimension drawings BSFC-02C 79 1 3 4 5 LSOL 6 NSOL STAT 1 15V 2 AUX2 3 GND 4 GND TO BE USED WITH ABB DRIVES ONLY. MAXIMUM RATED SYSTEM VOLTAGE IEC: 6m V AC LISTED IND. CONT. EQ. IPD8 RATINGS SUPPLY VOLTAGE 230 V, 20 mA 11SVi50/60Hz40mA SOLENOID CONTROL OUTPUT 115/230 V EXCITATI(»• VOLTAGE OUTPUT DC, mmx OPER TEMPERATURE MAX •C PWR @ DIS EN STAT INVI DIS EN STAT@ @ INV2 DIS EN INV3

****** Page 25 ****** 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 service contacts can be found by navigating to abb.com/searchchannels. Product training For information on ABB product training, navigate to new.abb.com/service/training Providing feedback on ABB Drives manuals Your comments on our manuals are welcome. Navigate to new.abb.com/drives/manuals-feedback-form. Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at abb.com/drives/documents.

****** Page 26 ****** Contact us abb.com/drives abb.com/drivespartners 3AXD50000027498 Rev A (EN) 2017-04-10 Power and productivity for a better worldTM


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