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ABB BCU-02, Hardware Manual

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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.

Summary of Contents for BCU-02

Page 1: ... ABB INDUSTRIAL DRIVES BCU 02 12 22 control units Hardware manual ...

Page 2: ...000020457 ACS880 regenerative rectifier control program firmware manual 3AXD50000020827 Inverter module manuals ACS880 104 inverter modules hardware manual 3AUA0000104271 ACS880 104LC inverter modules hardware manual 3AXD50000045610 ACS880 primary control program firmware manual 3AUA0000085967 ACS880 primary control program quick start up guide 3AUA0000098062 Brake module and DC DC converter modul...

Page 3: ...BCU 02 12 22 control units Hardware manual 3AUA0000113605 Rev D EN EFFECTIVE 2019 10 15 2019 ABB Oy All Rights Reserved 3 Installation Table of contents ...

Page 4: ......

Page 5: ...lation 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 illustrat...

Page 6: ... 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 ...

Page 7: ...o describes how to install and maintain the control unit 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...

Page 8: ...ntrol unit Drive Frequency converter for controlling AC motors FSO xx FSO 12 or FSO 21 safety functions module Inverter Converts direct current and voltage to alternating current and voltage LED Light emitting diode RDCO DDCS communication module SD card Secure digital memory card SDHC card Secure digital high capacity memory card STO Safe torque off IEC EN 61800 5 2 ...

Page 9: ...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 tha...

Page 10: ...m 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 how to connect the control unit to the converter module s see...

Page 11: ...ware 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 ...

Page 12: ...12 Hardware description The label describes the location of the I O connectors and has the same colors as the connectors Label ...

Page 13: ... 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 sc...

Page 14: ... 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 LED BATT OK When on the battery voltage of the real time cloc...

Page 15: ...ry unit SD SDHC flash memory card inserted in its slot real time clock battery Make sure that there are no signs of damage to any of the items Identifying different control unit types Before you install the control unit make sure that it has the correct control program for the converter hardware in question The control program is shown on the label attached to the memory unit Make sure also that t...

Page 16: ...tance 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 c...

Page 17: ...ertical DIN rail mounting 1 Attach the latches to the back of the control unit with four screws for each latch 2 Push the control unit to the rail as shown below It makes a click 3 To prevent movement of the control unit attach it to the rail with screws a or end brackets b or both 1 2 2 3a 1 3b ...

Page 18: ... the latches to the back of the control unit with four screws for each latch 2 Push the control unit to the rail as shown below It makes a click 3 Optional To prevent movement of the control unit attach it to the rail with screws or end brackets 1 1 3 2 2 ...

Page 19: ... module 1 Install the FSO xx safety functions module onto slot 3 with four screws 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 1 3 2 ...

Page 20: ...ect 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 3AXD500000486...

Page 21: ... the control unit is powered For information on the LED see section LEDs page 14 For the replacement battery type see Battery page 29 See A in figure Replacement illustration page 23 1 Remove the screw and the clip covering the battery 2 Remove the battery 3 Insert a new battery Refer to the illustration 4 Install the screw and the clip 5 Set the real time clock 6 Discard the old battery Obey loca...

Page 22: ... card 2 Push the card to remove it 3 Install the new card in reverse order Replacing the control unit See section Installing the control unit page 17 1 If the control unit is attached to the rail with screws or end brackets remove them 2 Remove the control unit from the rail 3 Remove the latches from the back of the control unit 4 Pull out the detachable terminal blocks that have control cables co...

Page 23: ...Maintenance 23 Replacement illustration A 2 1 A A A B C ...

Page 24: ...24 Maintenance ...

Page 25: ...ze 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...

Page 26: ... 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 In...

Page 27: ... 3 m 10 ft Ethernet connection XETH Connector RJ 45 This connection is not supported by the firmware SDHC memory card slot SD CARD Memory card type SDHC 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 ...

Page 28: ...DIO 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 SGND 8 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 in...

Page 29: ...horized access interference intrusion leakage and or theft of data or information Battery Real time clock battery BR2032 Protection classes Degree of protection IEC EN 60529 IP10 Enclosure type UL 508C UL Open Type 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 70 C 32 158 F Materials Housing...

Page 30: ...30 Technical data ...

Page 31: ...Dimension drawings 31 6 Dimension drawings Contents of this chapter This chapter shows the dimensions of the control unit ...

Page 32: ...32 Dimension drawings Dimension drawing of the control unit ...

Page 33: ...ce 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...

Page 34: ...abb com drives 3AUA0000113605 Rev D EN 2019 10 15 Copyright 2019 ABB All rights reserved Specifications subject to change without notice ...

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