—

ABB INDUSTRIAL DRIVES

BCU-02, BCU-12 and BCU-22 control units

Hardware manual
BCU-02, BCU-12 and BCU-22 control
units
Hardware manual

Table of contents

3. Mechanical installation

4. Electrical installation

3AUA0000113605 Rev E
EN
Original instructions
EFFECTIVE: 2024-06-19
 Table of contents 5

Table of contents

1 Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fiber optic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Examining the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Identifying different control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installing the control unit onto a DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installing an FSO safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing I/O extension, fieldbus adapter and pulse encoder interface modules . . . 21

4 Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing the real-time clock battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replacing the SD/SDHC memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6 Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BCU ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Additional information on the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Digital interlock (DIIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
The X485 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safe torque off (XSTO, XSTO OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FSO safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SDHC memory card slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Table of contents

Other information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7 Dimension drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Dimension drawing of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Further information
 Introduction to the manual 7

1
Introduction to the manual

Contents of this chapter

This chapter gives basic information about the manual and the terms used in the
manual.

Safety
WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do electrical work.

This manual does not contain the safety instructions of the drive. It only includes the
instructions related to the scope of this manual. In addition to this manual:
• for ACS880 single drives, refer to the drive hardware manual
• for ACS880 air-cooled multidrives, refer to ACS880 multidrive cabinets and modules
safety instructions (3AUA0000102301 [English])
• for ACS880 liquid-cooled multidrives, refer to ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
8 Introduction to the manual

Terms and abbreviations

Term Description
BCU Type of control unit
Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the
brake resistor when necessary. The chopper operates when the DC link voltage
exceeds a certain maximum limit. The voltage rise is typically caused by decel-
eration (braking) of a high inertia motor.
Brake chopper module Brake chopper enclosed in a metal frame or housing. Intended for cabinet in-
stallation.
Brake unit Brake chopper modules and the necessary auxiliary equipment, such as control
electronics, fusing and cabling
CIO I/O module for controlling cooling fans
Control unit The part in which the control program runs.
Converter Converts direct current and voltage to alternating current and voltage, or vice
versa.
DC/DC-converter Charges or discharges an external energy storage (such as a battery or capa-
citor bank) from or into the DC bus
DC/DC-converter module Converter power electronics, related components and DC capacitors enclosed
in a metal frame or enclosure. Intended for cabinet installation.
DC/DC-converter unit DC/DC-converter module(s) under control of one control unit, and related
components
Drive Frequency converter for controlling AC motors
Drive module Frequency converter enclosed in a metal frame or enclosure. Intended for
cabinet installation.
FDPI Diagnostics and panel interface board
FSO-12, FSO-21 Optional functional safety modules
Inverter Converts direct current and voltage to alternating current and voltage.
Inverter module Inverter bridge, related components and drive DC link capacitors enclosed in
a metal frame or enclosure. Intended for cabinet installation.
Inverter unit Inverter module(s) under control of one control unit, and related components.
One inverter unit typically controls one motor.
Multidrive Drive for controlling several motors which are typically coupled to the same
machinery. Includes one supply unit, and one or several inverter units.
RDCO Optical DDCS communication module
SD card Secure digital memory card (maximum 4 GB)
SDHC card Secure digital high capacity memory card (4…32 GB)
STO Safe torque off (IEC/EN 61800-5-2)
Supply module Rectifier bridge and related components enclosed in a metal frame or enclos-
ure. Intended for cabinet installation.
Supply unit Supply module(s) under control of one control unit, and related components.

Later in this manual, the term converter covers the terms drive, converter, inverter
and brake chopper.
 Introduction to the manual 9

Related documents
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.

ACS880 multidrive module manuals

10
 Operation principle and hardware description 11

2
Operation principle and hardware
description

Contents of this chapter

This chapter gives information about the hardware of the control units.

Hardware description
The control unit is used for controlling converter modules via fiber optic links. The
control unit 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 on a memory card which can be analyzed by ABB service personnel.
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. If
it is necessary 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 control
unit has one option slot for connecting a RDCO DDCS communication option module.
The control unit also has a connection for a control panel.
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
X485 connection provides a connection for the optional CIO-01 I/O module.
12 Operation principle and hardware description

Fiber optic connections

The different control unit types have a different number of fiber optic connections.

Type Number of fiber optic connections

BCU-02 2
BCU-12 7
BCU-22 12

The maximum length of the cables with 1 mm plastic optical fiber (POF) cable is 35 m
(115 ft).
Make sure that:
• both cables in a fiber optic pair have the same length, and
• each fiber optic pair connected to one control unit has the same length.
With long distances, cables of different lengths 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), refer
to the applicable hardware manual.
 Operation principle and hardware description 13

Layout
The figures show the layout of the control unit. For the default I/O connection diagrams
and more information on the connections, refer to the converter hardware manual.
„
Description
I/O I/O terminals (see following diagram)

SLOT 1 I/O extension, encoder interface or

fieldbus adapter module connection.
(This is the sole location for an FDPI-02
diagnostics and panel interface.)
SLOT 2 I/O extension, encoder interface or
fieldbus adapter module connection
SLOT 3 I/O extension, encoder interface, field-
bus adapter or FSO safety functions
module connection
SLOT 4 RDCO DDCS communication option
module connection

X205 Memory unit connection

BATTERY Holder for real-time clock battery
(BR2032)

AI1 Mode selector for analog input AI1 (I =

current, U = voltage)
AI2 Mode selector for analog input AI2 (I =
current, U = voltage)
D2D TERM Termination switch for drive-to-drive link
(D2D)
DICOM= Ground selection. Determines whether
DIOGND DICOM is separated from DIOGND (ie.
the common reference for the digital in-
puts floats). See the ground isolation
diagram.

7-segment display
Multicharacter indications are displayed as repeated
sequences of characters
(“U” is indicated briefly before “o”.)
Control program running
Control program startup in progress

(Flashing) Firmware cannot be started.

Memory unit missing or corrupted

Firmware download from PC to control

unit in progress

At power-up, the display may show short

indications of eg. “1”, “2”, “b” or “U”.
These are normal indications immedi-
ately after power-up. If the display ends
up showing any other value than those
described, it indicates a hardware failure.
14 Operation principle and hardware description

Description
XAI Analog inputs
XAO Analog outputs
XDI Digital inputs, Digital input interlock (DIIL)
XRO3
XD24 XPOW XDIO Digital input/outputs
XD2D Drive-to-drive link
XRO2 XD24 +24 V output (for digital inputs)
XDIO XAO
XETH Ethernet port – Not in use

XRO1 XPOW External power input

XRO1 Relay output RO1
XDI XAI XRO2 Relay output RO2
X485
XRO3 Relay output RO3
XSTO Safe torque off connection (input signals)
XSTO OUT Safe torque off connection (to inverter
XD2D XSTO XSTO
OUT modules)
X12 (On the opposite side) Connection for FSO
safety functions module (optional)
Note: The FSO safety functions module
can be used only with ACS880 inverters.
X13 Control panel, PC connection through the
control panel
X485 Not in use by default

V1T/V1R, Fiber optic connection to modules 1 and 2

V2T/V2R (VxT = transmitter, VxR = receiver)
V3T/V3R Fiber optic connection to modules 3…7
… (BCU-12 and BCU-22 only)
V7T/V7R (VxT = transmitter, VxR = receiver)
V8T/V8R Fiber optic connection to modules 8…12
… (BCU-22 only)
V12T/V12R (VxT = transmitter, VxR = receiver)

SD CARD Data logger memory card for inverter

module communication

BATT OK Real-time clock battery voltage is higher

than 2.8 V. If the LED is off when the con-
trol unit is powered, replace the battery.
FAULT The control program has generated a fault.
See the firmware manual of the supply/in-
verter unit.
PWR OK Internal voltage is sufficient
WRITE Writing to memory card in progress. Do
not remove the memory card.
 Mechanical installation 15

3
Mechanical installation
10

Contents of this chapter

This chapter gives information on the mechanical installation of the control unit and
the contents of the delivery.

Examining the delivery

Make sure that these items are included:
• control unit with the I/O connector plugs
• memory unit
• SD/SDHC flash memory card (inserted in its slot)
• real-time clock battery (BR2032).
Make sure that there are no signs of damage to the items.

￭ Identifying different control unit types

Before you install the control unit, make sure that it has the correct control program.
The control program is shown on the label attached to the memory unit.
Make sure that the control unit is correct for your equipment configuration.
16 Mechanical installation

Installing the control unit onto a DIN rail

NOTICE Do not install the control unit adjacent to electromagnetic disturbance
sources (for example, relays, contactors, brake choppers, and power cabling). The
minimum recommended distance to such components is 200 mm (7.9 in). ABB
recommends that you install metallic screening between the control unit and the
source of disturbance. This can reduce the required distance.

NOTICE Make sure that air can pass freely through the ventilation holes in the control
unit housing. Do not install the control unit directly above heat-generating equipment.
If you do not obey these instructions, the control unit can become too hot.

You can install the control unit horizontally or vertically onto a standard 35 × 7.5/15 mm
DIN rail. If the control unit is installed horizontally, make sure that the connectors
point down. If the control unit is installed vertically, the connectors can point to the
left or right.
Leave sufficient free space around the control unit for:
• cabling
• cooling
• replacing the memory unit and real-time clock battery.
The control unit is grounded through the DIN rail and the grounding screw.
1. Attach the two latches to the back of the control unit with four screws for each
latch.

2. Ground the control unit to the cabinet frame with a grounding conductor. Use a
M4×6 or M4×8 screw to attach the grounding conductor to the control unit. Refer
 Mechanical installation 17

to the figure below. The minimum cross-sectional area of the grounding conductor
is 4 mm2 (12 AWG).

3. Push the control unit to the rail as shown below. It makes a click.
10

4. Attach the control unit to the rail with screws or end brackets. This prevents
accidental movement of the control unit. If the control unit is installed horizontally,
the screws and end brackets are optional.
18 Mechanical installation
 Mechanical installation 19

Installing an FSO safety functions module

WARNING Obey the safety instructions given in If you ignore the safety
instructions, injury or death, or damage to the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.

This procedure describes the installation of an FSO safety functions module onto the
BCU control unit. As an alternative, the FSO module can be installed adjacent to the
control unit, which is the standard method for factory-installed FSO modules. For
instructions, refer to the applicable FSO module user's manual.
1. Stop the drive and do the steps in section Electrical safety precautions of the
„converter hardware manual.
2. The FSO module comes with alternative bottom plates for installation onto
different control units. For installation onto a BCU control unit, the mounting
points should be located at the long edges of the module as shown in the
illustration below. If necessary, replace the bottom plate of the FSO module.
3. Attach the FSO module onto slot 3 of the BCU control unit [A41] with four screws.
10

4. Torque the FSO module electronics grounding screw to 0.8 N·m (7.1 lbf·in).
Note: The screw tightens the connections and grounds the module. It is essential
for fulfilling the EMC requirements and for proper operation of the module.

5. Connect the FSO module data cable between FSO connector X110 and BCU
connector X12.
6. To complete the installation, refer to the instructions in the applicable FSO module
user's manual.
20 Mechanical installation

„
 Mechanical installation 21

Installing I/O extension, fieldbus adapter and pulse

encoder interface modules
WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or maintenance
work.

NOTICE Use ESD wristband when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards are sensitive to electrostatic discharge.

Pay attention to the free space required by the cabling or terminals coming to the
option modules.
1. Stop the drive and do the steps in section Electrical safety precautions of the
converter hardware manual.
2. Pull out the lock (a) with a screw driver.
Note: The location of the lock depends on the module type.

3. Install the module to a free option module slot on the control unit.
10
4. Push in the lock (a).
5. Tighten the grounding screw (b) to a torque of 0.8 N·m (7 lbf·in).
Note: The screw tightens the connections and grounds the module. It is essential
for fulfilling the EMC requirements and for proper operation of the module.

NOTICE Do not use excessive force, or leave the screw too loose. Over-tightening
can cause damage to the screw or module. A loose screw can cause an operation
failure.

6. Connect the wiring to the module. Obey the instructions given in the
documentation of the module.
If you must remove the option module after it is installed into the drive, use a suitable
tool (for example, small pliers) to carefully pull out the lock.
22
 Electrical installation 23

4
Electrical installation

Contents of this chapter

This chapter gives information on the electrical installation of the control unit. 11

Installation procedure
WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or maintenance
work.

1. Connect an external power supply to the control unit connector XPOW. For the
power supply specifications, refer to the technical data. If necessary, you can
connect a second power supply for redundancy.
2. Connect the fiber optic cables from the converter module to the control unit. Refer
to the instructions given in the converter module hardware manual.
3. Connect the control cables to the control unit. Refer to the instructions given in
the converter module hardware manual.

Related documents
For information on the electrical installation of the FSO safety functions module, refer
to the applicable FSO module user's manual.
For information on the electrical installation of an I/O extension, fieldbus adapter, or
pulse encodure interface module, refer to the documentation of the module.
For the default I/O connection diagrams and more information on the connections,
refer to the applicable converter module hardware manual.
24
 Maintenance 25

5
Maintenance

Contents of this chapter

This chapter gives instructions on how to do maintenance on the control unit.

Replacing the real-time clock battery

WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or maintenance
work.

Replace the real-time clock battery if the BATT OK LED is off when the control unit is
powered.
1. Stop the drive and do the steps in section Electrical safety precautions of the
converter hardware manual.
2. Remove the fastening screw.
3. Replace the battery with a new BR2032 battery.
26 Maintenance

4. If necessary, set the real-time clock.

5. Discard the old battery according to local disposal rules or applicable laws.

Replacing the memory unit

If you replace the control unit, move the memory unit from the old control unit to the
new control unit to keep the existing parameter settings.

WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or maintenance
work.

NOTICE Do not remove or insert the memory unit when the control unit is powered.

1. Stop the drive and do the steps in section Electrical safety precautions of the
converter hardware manual.
2. Make sure that the control unit is not powered.
3. Remove the fastening screw and pull the memory unit out.
4. Install a memory unit in reverse order.
 Maintenance 27

Replacing the SD/SDHC memory card

WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or maintenance
work.

Do not remove the SD card while the yellow WRITE LED is on. Writing to the SD card
is in progress. For the replacement card type, see the technical data.
1. Stop the drive and do the steps in section Electrical safety precautions of the
converter hardware manual.
2. Remove the screw and the clip covering the memory card.
3. Push the card to remove it.
4. Install the new card in reverse order.

Replacing the control unit

WARNING Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or maintenance
work.

Replace the control unit as follows:

1. Stop the drive and do the steps in section Electrical safety precautions of the
converter hardware manual.
2. Disconnect the fiber optic cables.
3. Disconnect the control cables. You can pull out the detachable terminal blocks
that have control cables connected.
4. If the control unit is attached to the rail with screws or end brackets, remove them.
5. Remove the control unit from the rail.
28 Maintenance

6. Disconnect the grounding conductor from the control unit.

7. Remove the latches from the back of the control unit.
8. Install the new control unit. Refer to section Installing the control unit onto a DIN
rail (page 16).
9. Connect the control cables to the new control unit.
10. Connect the fiber optic cables to the new control unit.
11. Move the memory unit from the old control to the new control unit. Refer to section
Replacing the memory unit (page 26).
If there is a safety circuit connected to the XSTO terminals of the control unit, do the
validation test of the safety function after you replace the control unit. Refer to the
drive or inverter module hardware manual, safety option user’s manual, and/or the
related FSO safety functions module user’s manual.
 Technical data 29

6
Technical data

Contents of this chapter

This chapter contains the technical data for the control units.

Connector data
The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5
… 2.5 mm2 (22…12 AWG). Connector pitch is 5 mm.
The maximum tightening torque for screw terminals is 0.45 N·m (4 lbf·in).

Power supply (XPOW) 24 V DC (±10%), 2 A

External power input.
Two supplies can be connected to the BCU control unit for
redundancy.
Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A
(XRO1…XRO3) Protected by varistors
+24 V output (XD24:5 and XD24:7) 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 24 V logic levels: “0” < 5 V, “1” > 15 V
(XDI:1…XDI:6) Rin: 2.0 kohm (DI1…DI5)
Input type: NPN/PNP (DI1…DI5), PNP (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL (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
30 Technical data

Digital inputs/outputs DIO1 and DIO2 As inputs: 24 V logic levels: "0" < 5 V, "1" > 15 V. Rin: 2.0 kohm.
(XDIO:1 and XDIO:2) Filtering: 1 ms.
Input/output mode selection by As outputs: Total output current from +24VD is limited to 200 mA
parameters.
+24VD
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
DIOx
other wave form cannot be used).
In some control programs, DIO2 can be RL
configured as a 24 V level square wave
frequency output. Refer to the
firmware manual, parameter group 11. DIOGND

Reference voltage for analog inputs 10 V ±1% and -10 V ±1%, Rload 1…10 kohm
+VREF and -VREF (XAI:1 and XAI:2) Maximum output current: 10 mA
Analog inputs AI1 and AI2 Current input: -20…20 mA, Rin = 100 ohm
(XAI:4 … XAI:7). Voltage input: -10…10 V, Rin > 200 kohm
Current/voltage input mode selection Differential inputs, common mode range ±30 V
by switches
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Analog outputs AO1 and AO2 (XAO) 0…20 mA, Rload < 500 ohm
Frequency range: 0…500 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
XD2D connector Physical layer: RS-485
Transmission rate: 8 Mbit/s
Cable type: Shielded twisted-pair cable with a twisted pair for
data and a wire or another pair for signal ground (nominal
impedance 100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
Termination by switch
RS-485 connection (X485) Physical layer: RS-485
Cable type: Shielded twisted-pair cable with a twisted pair for
data and a wire or another pair for signal ground (nominal
impedance 100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
Safe torque off connection (XSTO) Input voltage range: -3…30 V DC
Logic levels: "0" < 5 V, "1" > 17 V.
Note: Both circuits must be closed to enable start and operation
(IN1 and IN2 must be connected to OUT). This applies to all
control units (including drive, inverter, supply, brake, DC/DC
converter etc. control units), but SIL/PL classified Safe torque
off functionality is only achieved through the XSTO connector
of the drive/inverter control unit.
Current consumption: 66 mA (continuous) per STO channel per
drive/inverter module
EMC (immunity) according to IEC 61326-3-1 and IEC 61800-5-2
Safe torque off output (XSTO OUT) To STO connector of inverter module.
Control panel connection (X13) Connector: RJ-45
Cable length < 100 m (328 ft)
 Technical data 31

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: 4 GB
Battery Real-time clock battery type: BR2032
The terminals of the control unit 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.
32 Technical data

￭ BCU 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
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
SGND 8

*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.

**The maximum common mode voltage between each AI input and AGND is +30 V
 Technical data 33

Additional information on the connections

￭ Power supply for the control unit (XPOW)
Refer to the control unit connector data for the current and voltage ratings of the
power supply.
Connect an additional external power supply to the free +24 V and GND terminals of
the XPOW terminal block if:
• the control unit must be kept operational during input power breaks, for example,
because of continuous fieldbus communication
• immediate restart is necessary after a power break (that is, no control unit
power-up delay is permitted).

￭ Digital interlock (DIIL)

Digital interlock input (DIIL) terminal is originally intended for interlock signals that
stop the drive/unit when necessary. In the ACS880 primary control program, DIIL
terminal is the source for the run enable signal by default. The inverter unit or drive
cannot start, or it stops when there is no DIIL signal. In other control programs (and
units), the default use of the DIIL terminal varies. Refer to firmware manual for more
information.
Note: This input is not SIL or PL classified.

￭ The XD2D connector

The XD2D connector has an RS-485 connection that can be used for
• basic master/follower communication with one master drive/unit and multiple
followers
• fieldbus control through the embedded fieldbus interface (EFB)
• drive-to-drive (D2D) communication implemented by application programming.
Refer to the firmware manual for the availability of these features and related
parameter settings.
Terminate the bus on the units at the ends of the drive-to-drive link. Disable bus
termination on the intermediate units.
Use a shielded twisted-pair cable for data, and another pair or a wire for signal ground
(nominal impedance 100…165 ohm, for example Belden 9842). For the best immunity,
use high quality cable. Keep the cable as short as possible. Avoid unnecessary loops
and parallel runs near power cables such as motor cables.
34 Technical data

The following diagram shows the wiring between control units.

XD2D

XD2D

XD2D
B 1
A 2
BGND 3
SHIELD 4

B 1
A 2
BGND 3
SHIELD 4

B 1
A 2
BGND 3
SHIELD 4
Termination ON Termination OFF Termination ON

￭ The X485 connector

The X485 provides a connection for the optional CIO-01 I/O module. For more
information, refer to CIO-01 I/O module for distributed I/O bus control user’s manual
(3AXD50000126880 [English]).

￭ Safe torque off (XSTO, XSTO OUT)

The XSTO input only acts as a true Safe torque off input on the inverter control unit.
De-energizing the STO input terminals of other control units (supply, DC/DC converter,
or brake unit) stops the unit but does not constitute a SIL/PL classified safety function.

￭ FSO safety functions module connection (X12)

In drives or inverter units with a compatible control program, an optional FSO safety
functions module can be connected to the X12 connector. The control program in
supply, brake, and DC/DC converter units does not support the FSO safety functions
module.
For more information on the FSO safety functions module, refer to the applicable FSO
module user's manual.
Note: Inverter modules and control units that have a sticker with the text “No FSO
support” are not compatible with the FSO safety functions module.

￭ SDHC memory card slot

The control unit has an on-board data logger that collects real-time data from the
power modules 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.
 Technical data 35

Other information
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 opera- 0…70 °C (32…158 °F)
tion
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
For other standards, refer to the applicable hardware and functional safety manuals.
Markings
cULus The control unit is cULus Listed.

Cyber security 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.
36
 Dimension drawings 37

7
Dimension drawings

Contents of this chapter

This chapter shows the dimensions of the control unit.
38 Dimension drawings

Dimension drawing of the control unit

—
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 www.abb.com/contact-centers.

Product training
For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB manuals

Your comments on our manuals are welcome. Navigate to forms.abb.com/form-26567.

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.

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3AUA0000113605E

3AUA0000113605 Rev E (EN) 2024-06-19

© Copyright 2024 ABB. All rights reserved.

Specifications subject to change without notice.