ABB BCU-02 Brake Control Unit Board for ACS800 Series Frequency Converter

Product Description

BCU-02 with material code 3AUA0000110429 is a dedicated brake chopper control board independently developed by ABB Finland, specially designed for the ACS800 series high-power industrial 

variable frequency drives.

It matches the external braking resistor unit of the inverter, detects DC bus voltage in real time. When the motor is in regenerative power feedback state during deceleration, downward dragging 

or heavy load braking, the board triggers the brake IGBT chopper to consume excess regenerative energy through the braking resistor, so as to suppress DC bus overvoltage fault and ensure stable 

operation of the drive system. Equipped with hardware overcurrent and short-circuit protection circuit, fault LED status indication, PCB with conformal coating, plug-in installation inside 

ACS800 power unit cabinet. It is a common vulnerable spare part for lifting equipment, port cranes, mine hoists, centrifuges and other frequent braking load inverter systems.

Technical Specifications

Model: BCU-02, Part No.: 3AUA0000110429

Brand: ABB, Origin: Finland

Compatible Drive: ABB ACS800 series multi-drive single drive inverters

Core Function: DC bus overvoltage suppression, regenerative energy braking chopper control

Working Bus Voltage: Correspond to ACS800 380V/400V/415V power grade DC link voltage

Control Output: Drive signal for external brake power IGBT module

Protection Functions: Brake resistor overload protection, chopper short-circuit protection, internal power supply fault self-detection

Indication: Panel LED for running status and fault alarm

Power Supply: Powered by inverter internal auxiliary power supply

Operating Temperature: 0℃ ~ +55℃ continuous full-load operation

Storage Temperature: -40℃ ~ +85℃

Humidity: 5%–95% non-condensing, anti-corrosion three-proof coated circuit board

Protection Class: IP20, only installed inside frequency converter cabinet

Mounting: Standard plug-in fixed installation inside ACS800 power module compartment

Net Weight: Approx. 0.28kg

Certifications: CE, UL, industrial EMC anti-interference certification

Key Features

Accurate DC bus voltage threshold judgment, automatically activate braking energy consumption loop during motor feedback power generation, effectively avoid drive overvoltage trip fault.

Built-in multiple hardware protection mechanisms to prevent damage caused by braking resistor open circuit, short circuit and long-time overload heating.

Directly matched with the original ACS800 power unit structure, power-off one-to-one direct replacement without program modification and parameter resetting.

Intuitive front panel fault indicator light, quickly locate chopper failure, resistor abnormality and board internal faults for on-site troubleshooting.

Strong anti-electromagnetic interference ability, filter and isolation circuit adapt to harsh industrial workshop environment with large motor and rectifier harmonic interference.

Compact board layout, small occupied cabinet space, perfect coordination with ACS800 drive control program logic.

Mature and stable brake control scheme, widely applied in high-frequency braking working conditions such as hoisting, winding and tension control equipment.

Industrial-grade moisture-proof and vibration-resistant design, support 24 hours long-term uninterrupted stable operation in dusty and high-temperature control cabinets.