ABB BCU-02 User manual

ABB industrial drives
Hardware manual
BCU-02/12/22 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 ACS880 multidrive cabinets and
modules
3AUA0000102301
Electrical planning instructions for ACS880 multidrive
cabinets and modules
3AUA0000102324
Cabinet design and construction instructions for ACS880
multidrive modules
3AUA0000107668
BCU-02/12/22 control units hardware manual 3AUA0000113605
Supply module manuals
ACS880-204 IGBT supply modules hardware manual 3AUA0000131525
ACS880 IGBT supply control program firmware manual 3AUA0000131562
ACS880-304 +A018 diode supply modules hardware manual 3AXD50000010104
ACS880 diode supply control program firmware manual 3AUA0000103295
ACS880-904 regenerative rectifier modules hardware manual 3AXD50000020457
ACS880 regenerative rectifier control program firmware
manual
3AXD50000020827
Inverter module manuals
ACS880-104 inverter modules hardware manual 3AUA0000104271
ACS880 primary control program firmware manual 3AUA0000085967
ACS880 primary control program quick start-up guide 3AUA0000098062
Manuals for application programs (Crane, Winder, etc.)
Brake module and DC/DC converter module manuals
ACS880-604 3-phase brake chopper modules hardware
manual
3AXD50000022033
ACS880 brake control program firmware manual (3-phase
brake)
3AXD50000020967
ACS880-1604 DC/DC converter modules hardware manual 3AXD50000023642
ACS880 DC/DC converter control program firmware manual 3AXD50000024671
Module package hardware manuals
ACS880-04 module packages hardware manual 3AUA0000138495
ACS880-04XT drive modules (500 to 1200 kW) hardware
manual
3AXD50000025169
ACS880-14 and -34 module packages hardware manual 3AXD50000022021
Option manuals
FSO-12 safety functions module user's manual 3AXD50000015612
FDPI-02 diagnostics and panel interface user’s manual 3AUA0000113618
3AUA0000113605 Rev C
EN
EFFECTIVE: 2015-05-29
2015 ABB Oy. All Rights Reserved.

3
Table of contents
1. BCU-02/12/22 control units
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fiber optic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
The 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Identifying different control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vertical DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Horizontal DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installing the FSO-xx safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the real-time clock battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the SD/SDHC memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacement illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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-02/12/22 control units 5
BCU-02/12/22 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 ACS880 multidrive cabinets and
modules (3AUA0000102301 [English]) or ACS880-04XT drive modules (500 to 1200 kW)
hardware manual (3AXD50000025169 [English]).
For information on the unit’s electrical installation, see Electrical planning instructions for
ACS880 multidrive cabinets and modules (3AUA0000102324 [English]) and the
appropriate drive/converter/inverter 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
FSO safety functions module user's 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 ACS880
multidrive cabinets and modules (3AUA0000102301 [English]) or ACS880-04XT
drive modules (500 to 1200 kW) hardware manual (3AXD50000025169 [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 drive/converter/inverter.

6 BCU-02/12/22 control units
Hardware description
The BCU-02, BCU-12 and BCU-22 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:
You can use a BCU-22 to replace any of the control unit types.
The control unit requires an external 24 V DC power source. It has three option slots for
I/O extensions, encoders and fieldbus adapters, an integrated Ethernet port for PC tool
communication 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 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.
BCU type No. of fiber optic connections Can be replaced with
BCU-02 2 BCU-02, BCU-12, BCU-22
BCU-12 7 BCU-12, BCU-22
BCU-22 12 BCU-22

BCU-02/12/22 control units 7
Fiber optic connections
The BCU-02 control unit has two fiber optic connections V1 and V2 for connecting to
converter modules. The control unit does not include the BPEB-05 board. The BCU-12
control unit includes one BPEB-05 board that adds five connections to it (V3…V7), while
the BCU-22 control unit includes two BPEB-05 boards and thus twelve connections
(V1…V12).
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-22 control unit. For the default I/O
connection diagrams and more information on the connections, see the appropriate
hardware manual.
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12
xINT
Module 1
xINT
Module 3
I/O
BPEB-05
BCU-x2 BIOC-01
BPEB-05
xINT
Module 2
xINT
Module 7
xINT
Module 8
xINT
Module 12

8 BCU-02/12/22 control units

BCU-02/12/22 control units 9
The label describes
the location of the
I/O connectors and
has the same
colors as the
connectors.
Label

10 BCU-02/12/22 control units
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 appropriate 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 =
DIOGND
Determines whether DICOM is separated from DIOGND (ie, common reference for digital
inputs floats).
Fiber optic connector
V1T…V12T,
V1R…V12R
Fiber optic connector to converter module: T = Transmitter, R = Receiver
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 FSO safety functions
module user's manual.
Control panel and Ethernet connector
XETH Ethernet port for, eg, PC communication
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)

BCU-02/12/22 control units 11
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

12 BCU-02/12/22 control units
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 17.

BCU-02/12/22 control units 13
Installing the control unit
The control unit is grounded through the DIN rail.
Vertical DIN rail mounting
1. Fasten the latch to the back of the control unit with four screws.
2. Click the control unit to the rail as shown below.
3. Secure the control unit with an end bracket.
C
11
2
2
3

14 BCU-02/12/22 control units
Horizontal DIN rail mounting
1. Fasten the latches to the back of the control unit with four screws.
2. Click the control unit to the rail as shown below.
1
1
2

BCU-02/12/22 control units 15
Installing the FSO-xx safety functions module
1. Fasten the FSO-xx safety functions module onto slot 3 with four screws.
2. Tighten the FSO-xx electronics grounding screw (0.8 N·m).
3. Connect the FSO-xx data cable to FSO-xx connector X110 and to BCU-x2 connector
X12.
For information on the electrical installation of the FSO-xx safety functions module, see the
FSO safety functions module user's manual.
1
3
2

16 BCU-02/12/22 control units
Electrical installation
WARNING! Obey the safety instructions given in Safety instructions for ACS880
multidrive cabinets and modules [3AUA0000102301 (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.
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
ACS880 multidrive cabinets and modules [3AUA0000102324 (English)] or ACS880-04XT
drive modules (500 to 1200 kW) hardware manual (3AXD50000025169 [English]).
Fault tracing
LEDs
LED
BATT OK When lit, 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 lit, internal voltage is OK.
FAULT When lit, the control program indicates that the equipment is faulty. See the appropriate
firmware manual.
WRITE When lit, writing to the SD card is in progress.

BCU-02/12/22 control units 17
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 16.
See A in figure Replacement illustration on page 18.
1. Undo the fastening screw and remove the battery. For the replacement battery type,
see Real-time clock battery on page 22.
2. Insert the new battery according to figure Replacement illustration.
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 Replacement illustration on page 18.
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 Replacement illustration on page 18.
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 21.
2. Insert the new card in reverse order.
Replacing the control unit
See section Installing the control unit on page 13.
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 STO terminals (XSTO) 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, safety
option user’s manual and/or FSO safety functions module user’s manual.

18 BCU-02/12/22 control units
Replacement illustration
A
2:1
A
A
A
B
C

BCU-02/12/22 control units 19
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
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)
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
Rin: 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
Rin: 2.0 kohm
Filtering: 1 ms
As outputs:
Total output current from +24 VD is limited to 200 mA
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%, Rload 1…10 kohm
Maximum output current: 10 mA
RL
DIOx
DIOGND
+24VD

20 BCU-02/12/22 control units
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, Rin: 100 ohm
Voltage input: –10 …10 V, Rin > 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 8 ms
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, Rload < 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
Safe torque off connection
(XSTO)
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 STO channel per inverter
module
EMC (immunity) according to IEC 61326-3-1
Safe torque off output
(XSTO OUT)
Connector pitch 5 mm, wire size 2.5 mm2
To STO 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 fulfil 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.