ABB BCU-01 User manual

—
ABB INDUSTRIAL DRIVES
Hardware manual
BCU-01/11 control units

—
List of related manuals
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.
General manuals Code (English)
Safety instructions for ACS860 multidrive cabinets and
modules
3AXD50000034060
Electrical planning instructions for ACS860 multidrive
cabinets and modules
3AXD50000034058
Cabinet design and construction instructions for ACS860
multidrive modules
3AXD50000034059
BCU-01/11 control units hardware manual 3AXD50000034055
Inverter module manuals
ACS860-104 inverter modules hardware manual
3AXD50000034054
ACS860 primary control program firmware manual 3AXD50000034052
ACS860 primary control program quick start-up guide 3AXD50000034105
Option manuals
FDPI-02 diagnostics and panel interface user’s manual
3AUA0000113618
3AXD50000034055 Rev B
EN
EFFECTIVE: 2023-10-15
© 2023 ABB Oy. All rights reserved.

3
Table of contents
1. BCU-01/11 control units
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fiber optic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Identifying different control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Vertical DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horizontal DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing the real-time clock battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing the SD/SDHC memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4

BCU-01/11 control units 5
BCU-01/11 control units
Contents of the manual
This manual contains a description of the use and structure of the control unit and
its technical data. It also describes how to install and maintain the control unit.
For safety information, see
Safety instructions for ACS860 multidrive cabinets and
modules
(3AXD50000034060 [English]).
For information on the unit’s electrical installation, see
Electrical planning
instructions for ACS860 multidrive cabinets and modules
(3AXD50000034058
[English]) and the appropriate drive/converter/inverter hardware manual.
For the default I/O connection diagrams and more information on the connections,
see the appropriate drive/converter/inverter hardware manual.
For the related manuals, see
List of related manuals .
Safety
WARNING! Obey the safety instructions in Safety instructions for ACS860
multidrive cabinets and modules
(3AXD50000034060 [English]). If you
ignore them, injury or death, or damage to the equipment can occur.
Terms and abbreviations
Later in this manual, term converter substitutes for string inverter.
Hardware description
The BCU-01/11 are control units used for controlling converters via fiber optic links.
It contains 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 in a secure data card.
The control unit types have a different number of fiber optic connections:
The control unit requires an external 24 V DC power source. It has two option slots
for encoders and fieldbus adapters and a removable memory unit. For example, if
the control unit needs to be replaced, the parameter settings can be retained by
transferring the memory unit from the defective control unit to the new one.
The control unit has an on-board data logger that collects real-time data from the
converter power stages to help fault tracing and analysis. The data is stored onto
BCU type No. of fiber optic connections
BCU-01 2
BCU-11 7

6 BCU-01/11 control units
the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB
service personnel.
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 has also one option slot for connecting the RDCO DDCS communication
option board. For more information, see the appropriate hardware manual.
Fiber optic connections
BCU-01 control unit has two fiber optic connections for converter modules,
V1 and V2. BCU-11 control unit has a BPEB-05 board that provides five additional
fiber optic connections. Thus, BCU-11 has seven connections (V1…V7) in all.
The maximum lengths of the cables are:
•1 mm plastic optical fiber cables, 35 m (115 ft)
•200 μm hard-clad silica fiber cables, 100 m (328 ft).
Fiber optic pairs connected to one control unit must have the same length. With long
distances, cables of different length cause different delays, which can have an
unwanted effect on the operation.
For instructions on connecting the control unit to the converter module, see the
appropriate hardware manual
.
Layout
The following figures show the layout of the BCU-01 control unit. For the default I/O
connection diagrams and more information on the connections, see the appropriate
hardware manual.
BCU-X1

BCU-01/11 control units 7

8 BCU-01/11 control units
The label
describes the
location of the
I/O connectors
and has the
same colors as
the connectors.
Label

BCU-01/11 control units 9
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
XDIL Drive interlock connection (input signal).
Note: This input only acts as a true Drive interlock 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 Drive interlock, see the appropriate hardware
manual.
XDIL OUT Drive interlock connection (output for powering XDIL 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 =
DIOGND
Determines whether DICOM is separated from DIOGND (ie, common
reference for digital inputs floats).
Fiber optic connector
V1T…V7T,
V1R…V7R
Fiber optic connector to converter module: T = Transmitter, R = Receiver
Connector for optional module
SLOT 1 F-type adapter
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
SLOT 4 RDCO-0x DDCS communication option modules
Control panel and Ethernet connector
XETH Not in use
X13 Control panel
Memory unit and card connector
X205
MEMORY
UNIT
Converter memory unit connector
SD CARD Secure digital card holder (Data logger memory for the fiber optic links)

10 BCU-01/11 control units
The 7-segment display
The following table describes the indications of the 7-segment display on the control
unit. Multicharacter indications are displayed as repeated sequences of characters.
Checking the delivery
Check that all items listed below are present. Check that there are no signs of
damage:
•control unit with the I/O connectors
•memory unit
•SD/SDHC flash memory card (inserted in its slot)
•real-time clock battery.
Identifying different control unit types
Before installation, check that the control unit has the correct control program for
the converter hardware in question. The control program is shown in the label
attached to the memory unit.
Check also that the control unit is suitable for your equipment configuration.
Miscellaneous
+ Battery Real-time clock battery
“U” is indicated shortly before “o”.
The control program has been launched and is running.
Flashing character.
The firmware cannot be started: The memory unit is missing or corrupted.
The firmware download from a PC to the control unit is in progress.
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.
Description

BCU-01/11 control units 11
Mechanical installation
WARNING! Do not install the control unit in the immediate vicinity of
electromagnetic disturbance sources, such as relays, contactors, brake
choppers, power and motor cabling. The minimum recommended distance
from such components is 200 mm. We recommend to install metallic screening
between the control unit and the source of disturbance. This can reduce the required
distance.
WARNING! Mount the control unit so that air can pass freely through the
ventilation holes in the housing. Avoid mounting directly above heat-
generating equipment.
You can mount the control unit on a vertical or horizontal standard 35 × 7.5/15 mm
DIN rail. In vertical direction, you can mount the unit either top or bottom upwards.
When mounting the unit horizontally, the connectors must be downwards and the
connector texts the right way up.
Leave enough space for cabling, and replacing the memory unit and real-time clock
battery. See sections
Replacing the real-time clock battery , Replacing the memory
unit
and Replacing the SD/SDHC memory card on page 15 .
Installing the control unit
The control unit is grounded through the DIN rail.

12 BCU-01/11 control units
Vertical DIN rail mounting
1. Fasten the latch to the back of the control unit with four screws.
2. Clip the control unit to the rail as shown below.
1
1
2
2

BCU-01/11 control units 13
Horizontal DIN rail mounting
1. Fasten the latches to the back of the control unit with four screws.
2. Clip the control unit to the rail as shown below.
Electrical installation
WARNING! Obey the safety instructions given in Safety instructions for
ACS860 multidrive cabinets and modules
[3AXD50000034060 (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.
Connect the fiber optic cables and gate driver board wiring from the converter
module to the control unit according to the instructions given in the converter
module hardware manual.
For general electrical installation instructions, see
Electrical planning instructions
for ACS860 multidrive cabinets and modules
[3AXD50000034058 (English)].
1
1
22

14 BCU-01/11 control units
Fault tracing
LEDs
LED
BATT OK When on, the battery voltage of the real time clock is OK (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 OK.
FAULT When on, the control program indicates that the equipment is faulty. See the
appropriate firmware manual.
WRITE When on, writing to the SD card is in progress.

BCU-01/11 control units 15
Maintenance
Replacing the real-time clock battery
Replace the real-time clock battery if the BATT LED is not illuminated when the
control unit is powered. For information on the LED, see
Fault tracing on page 14 .
See A in figure
See the appropriate documentation: drive or inverter module
hardware manual.
on page 16 .
1. Undo the fastening screw and remove the battery. For the replacement battery
type, see
Real-time clock battery on page 20 .
2. Insert the new battery according to figure
See the appropriate documentation:
drive or inverter module hardware manual.
.
3. Dispose the old battery according to local disposal rules or applicable laws.
4. Set the real-time clock.
Replacing the memory unit
WARNING! Do not remove or insert the memory unit when the control unit is
powered.
See B in figure
See the appropriate documentation: drive or inverter module
hardware manual.
on page 16 .
1. To remove the memory unit, undo the fastening screw and pull the memory unit
out. See the following figure.
2. Insert the new memory unit and fasten the screw.
Replacing the SD/SDHC memory card
Note: Do not remove the SD card while the yellow WRITE LED is lit. Writing to the SD
card is in progress.
See C in figure
See the appropriate documentation: drive or inverter module
hardware manual.
on page 16 .
1. Undo the fastening screw of the clip covering the memory card and press the
card to remove it. For the card location, see the following figure. For the
replacement card type, see
Ground isolation diagram on page 19 .
2. Insert the new card in reverse order.

16 BCU-01/11 control units
Replacing the control unit
See section Installing the control unit on page 11 .
1. If the control unit has been installed vertically, remove the end bracket.
2. Remove the control unit from the rail.
3. Undo the four fastening screws with which the latch has been fastened to the
back of the control unit.
4. Pull out the detachable terminal blocks which have control cables connected.
5. Install the new control unit in reverse order.
Note: If there is a safety circuit connected to the DIL terminals (XDIL) of the control
unit, redo its acceptance test according to the instructions given in the inverter or
drive module hardware manual.
See the appropriate documentation: drive or inverter module hardware manual.
A
A
B
C

BCU-01/11 control units 17
Technical data
Connector data
Power supply
(XPOW)
Connector pitch 5 mm, wire size 2.5 mm2
24 V (±10%) DC, 2 A
External power input. Two supplies can be connected for
redundancy.
Relay outputs RO1…RO3
(XRO1…XRO3) Connector pitch 5 mm, wire size 2.5 mm2
250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output
(XD24:2 and XD24:4)
Connector pitch 5 mm, wire size 2.5 mm2
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
(XDI:1…XDI:6) Connector pitch 5 mm, wire size 2.5 mm2
24 V logic levels: “0” < 5 V, “1” > 15 V
R
in: 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
I
max: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL
(XDI:7) Connector pitch 5 mm, wire size 2.5 mm2
24 V logic levels: “0” < 5 V, “1” > 15 V
R
in: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Digital inputs/outputs
DIO1 and DIO2
(XDIO:1…XDIO:4)
Input/output mode
selection by parameters.
DIO1 can be configured
as a frequency input
(0…16 kHz with
hardware filtering of 4
microseconds) for 24 V
level square wave signal
(sinusoidal or other
wave form cannot be
used). DIO2 can be
configured as a 24 V
level square wave
frequency output. See
the firmware manual.
Connector pitch 5 mm, wire size 2.5 mm2
As inputs:
24 V logic levels: “0” < 5 V, “1” > 15 V
R
in: 2.0 kohm
Filtering: 1 ms
As outputs:
Total output current from +24 VD is limited to 200 mA
RL
DIOx
DIOGND
+24VD

18 BCU-01/11 control units
Reference voltage for
analog inputs +VREF and
-VREF
(XAI:1andXAI:2)
Connector pitch 5 mm, wire size 2.5 mm2
10 V ±1% and –10 V ±1%, R
load 1…10 kohm
Maximum output current: 10 mA
Analog inputs AI1 and
AI2 (XAI:4 … XAI:7).
Current/voltage input
mode selection by
switches
Connector pitch 5 mm, wire size 2.5 mm2
Current input: –20…20 mA, R
in: 100 ohm
Voltage input: –10 …10 V,
R
in > 200 kohm
Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to
8ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Inaccuracy with Pt100 sensors: 10 °C (50 °F)
Analog outputs AO1 and
AO2
(XAO)
Connector pitch 5 mm, wire size 2.5 mm2
0…20 mA, R
load < 500 ohm
Frequency range: 0…500 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
Drive-to-drive link
(XD2D)
Connector pitch 5 mm, wire size 2.5 mm2
Physical layer: RS-485
Termination by switch
RS-485 connection
(X485)
Connector pitch 5 mm, wire size 2.5 mm2
Physical layer: RS-485
Drive interlock
connection (XDIL) Connector pitch 5 mm, wire size 2.5 mm2
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 DIL channel per
inverter module
EMC (immunity) according to IEC 61326-3-1
Drive interlock output
(XDIL OUT) Connector pitch 5 mm, wire size 2.5 mm2
To DIL connector of inverter module
Control panel
connection
(X13)
Connector: RJ-45
Cable length < 3 m
Ethernet connection
(XETH)
Connector: RJ-45
SDHC memory card slot
(SD CARD)
Memory card type: SDHC
Maximum memory size: 4 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.

BCU-01/11 control units 19
Ground isolation diagram
XPOW
+24VI 1
GND 2
+24VI 3
GND 4
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5
AI2+ 6
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B1
A2
BGND 3
SHIELD 4
XRO1, XRO2,
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
*
Ground
Common mode voltage
between each AI input
and AGND is +30 V
*Ground selector (DICOM=DIOGND) settings
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.

20 BCU-01/11 control units
Dimensions
Height Width Width with
connector
s
Depth Depth with
memory unit
Depth with
memory unit and
latch
mm in mm in mm in mm in mm in mm in
311 12.2
4
125 4.92 139 5.47 74 2.9 110 4.33 115 4.53
Battery
Real-time clock battery BR2032
Protection classes
Degree of protection
(IEC/EN 60529)
IP10
Overvoltage category
(IEC 60664-1)
II
Protective class
(IEC/EN 61800-5-1)
I
Protective class
(IEC 62109-1)
II
Ambient conditions
Air temperature in
operation
+0 to +70 °C (158 °F)
Materials
Housing Hot-dip zinc coated steel
Package Cardboard
Parts Name Hazard Substance
(Pb) (Hg) (Cd) (Cr6+)(PBB) (PBDE)
PCBA ×○○○○○
Metal parts ○○○○○○
Plastic parts ○○○○○○
Other Nonmetal parts ○○○○○○
Fans ○○○○○○
Cable/wires ○○○○○○
This table is made according to SJ/T 11364
○：means the content of this hazard substance in the homogeneous materials of the parts is less
than the limit requirement in GB/T 26572
×：means the content of this hazard substance in the homogeneous materials of the parts is
exceed the limit requirement of GB/T 26572
PCBA: include Printed Circuit Board and the components.
Depending on the model/type of product, it may not contain all of the above parts. It is subject to
the purchased actual product model/type.
This environmental protection period applies only when the product is used according to the
conditions required by the user manual.
To protect the environment and human health:
1. The scrapped product should be separated from domestic waste and sent to a qualified place of
disposal.
2. Recycling center should use appropriate methods to recycle/deal with the materials.
3. For more information about this product recycling, please contact local government, recycling
center or your local dealer.