BCU-02/12/22 Control Units: Hardware Manual
BCU-02/12/22 Control Units: Hardware Manual
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BCU-02/12/22 control units
Hardware manual
Table of contents
3. Installation
Table of contents
2. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fiber optic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Examining the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Identifying different control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Vertical DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Horizontal DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installing the FSO-xx safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing the real-time clock battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing the SD/SDHC memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacement illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Other information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. Dimension drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dimension drawing of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Introduction to the manual 7
1
Introduction to the manual
Safety
WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and
modules safety instructions (3AUA0000102301 [English]), or ACS880 liquid-
cooled multidrive cabinets and modules safety instructions (3AXD50000048633
[English]), or ACS880-04XT drive modules (500 to 1200 kW) hardware manual
(3AXD50000025169 [English]). If you ignore the safety instructions, injury or
death can occur. If you are not a qualified electrician, do not do electrical work.
8 Introduction to the manual
Later in this manual, the term converter replaces terms drive, converter, and inverter.
Hardware description 9
2
Hardware description
Hardware description
The BCU-02, BCU-12 and BCU-22 are control units used for controlling converters via
fiber optic links. They contain integrated branching unit functionality for collecting and
storing real-time data from the converter modules to help fault tracing and analysis. The
data is stored on the SDHC memory card inserted into the SD CARD slot and can be
analyzed by ABB service personnel.
The control unit types have a different number of fiber optic connections:
BCU-22 12 BCU-22
The control unit requires an external 24 V DC power source. It has three option slots for
I/O extensions, encoders and fieldbus adapters, and a removable memory unit. For
example, if you need to replace the control unit, you can keep the parameter settings by
moving the memory unit from the defective control unit to the new one.
The drive-to-drive link (XD2D) is a daisy-chained RS-485 transmission line that allows
basic master/follower communication with one master and multiple followers. The control
unit also has one option slot for connecting a RDCO DDCS communication option board.
For more information, see the RDCO-0x DDCS communication option modules user's
manual (3AFE64492209 [English]).
10 Hardware description
I/O
BCU-x2 BIOC-01
BPEB-05 BPEB-05
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12
xINT xINT
Module 1 Module 3
xINT
Module 2
xINT
Module 7
xINT
Module 8
xINT
Module 12
For instructions on how to connect the control unit to the converter module(s), see the
applicable converter hardware manual.
Hardware description 11
Layout
The figures show the layout of the BCU-22 control unit. For the default I/O connection
diagrams and more information on the connections, see the applicable converter hardware
manual.
12 Hardware description
Description
I/O connector
XAI Analog input
XAO Analog output
XDI Digital input and digital start interlock
XDIO Digital input/output
XD2D Drive-to-drive link
XD24 +24 V output for digital input
XPOW External power input
XRO1 Relay output 1
XRO2 Relay output 2
XRO3 Relay output 3
XSTO Safe torque off connection (input signal).
Note: This input only acts as a true Safe torque off input in control units controlling a motor.
In other applications (such as a supply or brake unit), de-energizing the IN1 and/or IN2
terminal will stop the unit but does not constitute a true safety function.
For more information on Safe torque off, see the applicable converter hardware manual.
XSTO OUT Safe torque off connection (output for powering XSTO input of inverter modules).
X485 Not in use
Switch
AI1 Analog input 1 current/voltage selection
AI2 Analog input 2 current/voltage selection
D2D TERM Drive-to-drive link termination
DICOM = Determines whether DICOM is separated from DIOGND (ie, common reference for digital
DIOGND inputs floats).
Fiber optic connector
V1T…V12T, Fiber optic connector to converter module: T = Transmitter, R = Receiver
V1R…V12R
Connector for optional module
SLOT 1 F-type adapter, interface and I/O extension modules
If FDPI-02 diagnostics and panel interface is used, it has to be installed in slot 1 with two
screws.
SLOT 2 F-type adapter, interface and I/O extension modules
SLOT 3 F-type adapter, interface and I/O extension modules, FSO-xx safety functions module
SLOT 4 RDCO-0x DDCS communication option modules
Safety option connector
X12 Cable connector for the FSO-xx safety functions module.
Note: The FSO-xx safety functions module can be used only with ACS880 inverters.
For more information on the FSO-xx safety functions module, see the applicable FSO-xx
safety functions module user's manual.
Control panel and Ethernet connector
XETH Ethernet port, not in use
X13 Control panel
Memory unit and card connector
X205 Converter memory unit connector
MEMORY
UNIT
SD CARD Secure digital card holder (Data logger memory for the fiber optic links)
14 Hardware description
Description
Miscellaneous
+ Battery Real-time clock battery
At the converter power-up, the 7-segment display can show short indications of, for example,
“1”, “2”, “b” or “U”. These are normal indications immediately after powering up the converter.
If the 7-segment display ends up showing other values than described above after the
power-up, it indicates a hardware failure.
LEDs
The following table gives the indications of the LEDs on the control unit.
LED
BATT OK When on, the battery voltage of the real time clock is sufficient (higher than 2.8 V).
When off,
• battery voltage is below 2.8 V,
• battery is missing, or
• control unit is not powered.
PWR OK When on, internal voltage is sufficient.
FAULT When on, the control program indicates that the equipment is faulty. See the applicable
firmware manual.
WRITE When on, writing to the SD card is in progress.
Installation 15
3
Installation
Mechanical installation
WARNING! Install the control unit so that air can pass freely through the
ventilation holes in the housing. Do not install the control unit directly above heat-
generating equipment.
You can install the control unit on a vertical or horizontal standard 35 × 7.5/15 mm DIN rail.
In vertical direction, you can install the unit either top side or bottom side up. If you install
the unit horizontally, the connectors must be downwards and the connector texts the right
way up.
Leave enough space for cabling, and also for replacing the memory unit and real-time
clock battery. See chapter Maintenance (page 21).
Installation 17
3a
3b
18 Installation
2
2
3
Installation 19
2. Tighten the FSO-xx electronics grounding screw. Tightening torque 0.8 N·m
(7.1 lbf·in).
3. Connect the FSO-xx data cable to FSO-xx connector X110 and to BCU connector
X12.
3
20 Installation
Electrical installation
WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and
modules safety instructions (3AUA0000102301 [English]), or ACS880 liquid-
cooled multidrive cabinets and modules safety instructions (3AXD50000048633
[English]), or ACS880-04XT drive modules (500 to 1200 kW) hardware manual
(3AXD50000025169 [English]). If you ignore the safety instructions, injury or
death can occur. If you are not a qualified electrician, do not do electrical work.
Connect the +24 V external power supply to the control unit connector XPOW. You can
connect a second power supply for redundancy.
Connect the fiber optic cables from the converter module to the control unit. Refer to the
instructions given in the converter module hardware manual.
Related documents
For general electrical installation instructions, see ACS880 multidrive cabinets and
modules electrical planning instructions (3AUA0000102324 [English]), or ACS880 liquid-
cooled multidrive cabinets and modules electrical planning (3AXD50000048634 [English])
and the applicable converter hardware manual, or ACS880-04XT drive modules (500 to
1200 kW) hardware manual (3AXD50000025169 [English]).
For information on the electrical installation of the FSO-xx safety functions module, see the
applicable FSO-xx safety functions module user's manual.
For the default I/O connection diagrams and more information on the connections, see the
applicable converter hardware manual.
Maintenance 21
4
Maintenance
WARNING! Do not remove or install the memory unit when the control unit is
powered.
Replacement illustration
B A
2:1
AA
C
24 Maintenance
Technical data 25
5
Technical data
Connector data
Terminal
Power supply Connector pitch 5 mm, wire size 2.5 mm2
(XPOW) 24 V (±10%) DC, 2 A
External power input. Two supplies can be connected for redundancy.
Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm2
(XRO1…XRO3) 250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output Connector pitch 5 mm, wire size 2.5 mm2
(XD24:2 and XD24:4) Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the
power taken by DIO1 and DIO2.
Digital inputs DI1…DI6 Connector pitch 5 mm, wire size 2.5 mm2
(XDI:1…XDI:6) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), NPN (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
DI6 (XDI:6) can alternatively be used as an input for a PTC thermistor.
“0” > 4 kohm, “1” < 1.5 kohm
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
26 Technical data
Start interlock input DIIL Connector pitch 5 mm, wire size 2.5 mm2
(XDI:7) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Digital inputs/outputs DIO1 Connector pitch 5 mm, wire size 2.5 mm2
and DIO2 As inputs:
(XDIO:1…XDIO:4) 24 V logic levels: “0” < 5 V, “1” > 15 V
Input/output mode selection Rin: 2.0 kohm
by parameters. DIO1 can be Filtering: 1 ms
configured as a frequency
As outputs:
input (0…16 kHz with
hardware filtering of 4 Total output current from +24 VD is limited to 200 mA
microseconds) for 24 V level
square wave signal +24VD
(sinusoidal or other wave form
cannot be used). DIO2 can be
configured as a 24 V level
square wave frequency DIOx
output. See the firmware
manual. RL
DIOGND
Reference voltage for Connector pitch 5 mm, wire size 2.5 mm2
analog inputs +VREF and - 10 V ±1% and –10 V ±1%, Rload 1 … 10 kohm
VREF Maximum output current: 10 mA
(XAI:1 and XAI:2)
Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm2
(XAI:4 … XAI:7). Current input: –20…20 mA, Rin: 100 ohm
Current/voltage input mode Voltage input: –10…10 V, Rin > 200 kohm
selection by switches Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to 8 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Inaccuracy with Pt100 sensors: 10 °C (18 °F)
Analog outputs AO1 and Connector pitch 5 mm, wire size 2.5 mm2
AO2 0…20 mA, Rload < 500 ohm
(XAO) Frequency range: 0 … 500 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm2
(XD2D) Physical layer: RS-485
Termination by switch
RS-485 connection Connector pitch 5 mm, wire size 2.5 mm2
(X485) Physical layer: RS-485
Safe torque off connection Connector pitch 5 mm, wire size 2.5 mm2
(XSTO) Input voltage range: -3…30 V DC
Logic levels: “0” < 5 V, “1” > 17 V
For the unit to start, both connections must be “1”
Current consumption: 66 mA (continuous) per STO channel per inverter
module
EMC (immunity) according to IEC 61326-3-1
Technical data 27
Safe torque off output Connector pitch 5 mm, wire size 2.5 mm2
(XSTO OUT) To STO connector of inverter module
Control panel connection Connector: RJ-45
(X13) Cable length < 3 m (10 ft)
Ethernet connection Connector: RJ-45
(XETH) This connection is not supported by the firmware.
SDHC memory card slot Memory card type: SDHC
(SD CARD) Maximum memory size: 8 GB
The terminals on the board fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV
requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
28 Technical data
XPOW
+24VI 1
GND 2
+24VI 3
GND 4
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 Common mode voltage between
AI2+ 6 each AI input and AGND is
AI2- 7 +30 V
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
SHIELD 4
XRO1, XRO2, XRO3
NC 11
COM 12
NO 13
NC 21
COM 22
NO 23
NC 31
COM 32
NO 33
XD24
+24VD 5
DICOM 6
+24VD 7
DIOGND 8
XDIO
DIO1 1
DIO2 2
DIOGND 3
DIOGND 4
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
DIIL 7
XSTO
OUT 1
SGND 2
IN1 3
IN2 4
XSTO OUT
IN1 5
SGND 6
IN2 7
Ground
SGND 8
DICOM=DIOGND: ON
All digital inputs share a common ground (DICOM connected to DIOGND). This is the default setting.
DICOM=DIOGND: OFF
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND).
Isolation voltage 50 V.
Technical data 29
Other information
Battery
Real-time clock battery BR2032
Protection classes
Degree of protection IP10
(IEC/EN 60529)
Enclosure type (UL 508C) UL Open Type
Overvoltage category II
(IEC 60664-1)
Protective class I
(IEC/EN 61800-5-1)
Protective class II
(IEC 62109-1)
Ambient conditions
Air temperature in 0…70 °C (32…158 °F)
operation
Materials
Housing Hot-dip zinc coated steel, cover painted
Label Polycarbonate
Package Cardboard
Applicable standards
EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety
requirements – electrical, thermal and energy
EN 61800-3:2004 Adjustable speed electrical power drive systems. Part 3: EMC requirements
and specific test methods
IEC/EN 62109-1:2010 Safety of power converters for use in photovoltaic power systems Part 1:
General requirements
UL508C:2002 UL Standard for Safety, Power Conversion Equipment, third edition
Note: For other standards, see the applicable hardware and functional safety manuals.
Markings
cULus The control unit is cULus Listed.
Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and data via
a network interface. It is Customer's sole responsibility to provide and continuously ensure
a secure connection between the product and Customer network or any other network (as
the case may be). Customer shall establish and maintain any appropriate measures (such
as but not limited to the installation of firewalls, application of authentication measures,
encryption of data, installation of anti-virus programs, etc) to protect the product, the
network, its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB and its
affiliates are not liable for damages and/or losses related to such security breaches, any
unauthorized access, interference, intrusion, leakage and/or theft of data or information.
30 Technical data
Dimension drawings 31
6
Dimension drawings
Product training
For information on ABB product training, navigate to new.abb.com/service/training.