ABB Drives Installation and

Start-up Guide

Bus Connection
Interface Module
NBCI-02
 Bus Connection
Interface Module
NBCI-02

Installation and
Start-up Guide

3AFY 58919748 R0225

EFFECTIVE: 1.11.1999
SUPERSEDES: 14.9.1998

 1999 ABB Industry Oy. All Rights Reserved.

 Safety Instructions

Overview This chapter states the safety instructions that must be followed when
installing and operating the NBCI-02 Bus Connection Interface Module.
The material in this chapter must be studied before attempting any
work on, or with, the unit.

Warnings and Notes This manual distinguishes two sorts of safety instructions. Warnings
are used to inform of conditions which can, if proper steps are not
taken, lead to a serious fault condition, physical injury and death. Notes
are used when the reader is required to pay special attention or when
there is additional information available on the subject. Notes are less
crucial than Warnings, but should not be disregarded.

Warnings Readers are informed of situations that can result in serious physical
injury and/or serious damage to equipment with the following symbols:

Dangerous Voltage Warning: warns of situations

in which a high voltage can cause physical injury
and/or damage equipment. The text next to this
symbol describes ways to avoid the danger.
General Warning: warns of situations which can
cause physical injury and/or damage equipment by
means other than electrical. The text next to this
symbol describes ways to avoid the danger.
Electrostatic Discharge Warning: warns of
situations in which an electrostatic discharge can
damage equipment. The text next to this symbol
describes ways to avoid the danger.

Notes Readers are notified of the need for special attention or additional
information available on the subject with the following symbols:

CAUTION! Caution aims to draw special attention to a

particular issue.
Note: Note gives additional information or points out
more information available on the subject.

NBCI-02 Installation and Start-up Guide iii

Safety Instructions

General Safety WARNING! All electrical installation and maintenance work on the
Instructions drive should be carried out by qualified electricians.
The drive and adjoining equipment must be properly earthed.
Do not attempt any work on a powered drive. After switching off the
mains, always allow the intermediate circuit capacitors 5 minutes to
discharge before working on the frequency converter, the motor or the
motor cable. It is good practice to check (with a voltage indicating
instrument) that the drive is in fact discharged before beginning work.
The motor cable terminals of the drive are at a dangerously high
voltage when mains power is applied, regardless of motor operation.
There can be dangerous voltages inside the drive from external control
circuits even when the drive mains power is shut off. Exercise
appropriate care when working with the unit. Neglecting these
instructions can cause physical injury and death.

WARNING! There are several automatic reset functions in the

drive. If selected, they reset the unit and resume operation after a fault.
These functions should not be selected if other equipment is not
compatible with this kind of operation, or dangerous situations can be
caused by such action.

More Warnings and Notes are printed at appropriate instances along

the text.

iv NBCI-02 Installation and Start-up Guide

Table of Contents

Appendix A – Technical Data

Panel Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
NBCI-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Appendix B – Ambient Conditions

Ambient Conditions, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ambient Conditions, Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Ambient Conditions, Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

vi NBCI-02 Installation and Start-up Guide

 Chapter 1 – Introduction to This Guide

Overview This chapter contains a description of the Installation and Start-up

Guide for the NBCI-02 Bus Connection Interface Module.

Intended Audience The Guide is intended for the people who are responsible for installing,
commissioning and using an NBCI-02 Module with an ABB drive. The

NBCI-02 Installation and Start-up Guide 1-1

Chapter 2 – Overview

The NBCI-02 Module The NBCI-02 Bus Connection Interface Module is an optional device
for ABB drives, providing a galvanic isolation between the panel bus
and the panel link of the drive. The NBCI-02 is used to connect a drive
to the panel bus, in turn controlled by a CDP 312 Control Panel or a
Modbus controller (PLC or PC). PC connection usually requires an
RS-232/485 converter, available as NPCU-01.
The NBCI-02 is mounted onto a standard mounting rail inside or
outside the drive unit, depending on drive type and configuration. See
the drive documentation for module placement options.

NBCI-02
BUS CONNECTION
INTERFACE

X1 Modular Jack for Drive Connection

X2
Modular Jack for CDP (Control Panel) or
NPCU (PC Connection Unit) Connection


Screw Terminal Blocks
1 2 3 4
for Bus and Power Supply
Connection
5 6 7 8

2-2 NBCI-02 Installation and Start-up Guide

 Chapter 2 – Overview

Block Diagram

Compatibility The NBCI-02 is compatible with:

• ACS 600, ACN 600, ACP 600
• ACC 600*, ACF 600*
*ACC 600 and ACF 600 do not support the use of one Control Panel to control
multiple drives.
• ACS 1000
• DCS 500B.

Delivery Checklist The NBCI-02 Bus Connection Interface Module package contains:
• Bus Connection Interface Module, Type NBCI-02
• One 2-metre cable, one 0.5-metre cable, both with shielded six-pole
male modular telephone connectors (reversed/crossover
connection; black)
• Mounting rail
• This manual.

NBCI-02 Installation and Start-up Guide 2-3

Chapter 2 – Overview

Warranty and Liability The warranty for your ABB drive and options covers manufacturing
Information defects. The manufacturer carries no responsibility for damage due to
transport or unpacking.
In no event and under no circumstances shall the manufacturer be
liable for damages and failures due to misuse, abuse, improper
installation, or abnormal conditions of temperature, dust, or corrosives,
or failures due to operation above rated capacities. Nor shall the
manufacturer ever be liable for consequential and incidental damages.
The period of manufacturer’s warranty is 12 months, and not more than
18 months, from the date of delivery.
Extended warranty may be available with certified start-up. Contact
your local distributor for details.
Your local ABB Drives company or distributor may have a different
warranty period, which is specified in their sales terms, conditions, and
warranty terms.
If you have any questions concerning your ABB drive, contact your
local distributor or ABB Drives office.
The technical data and specifications are valid at the time of printing.
ABB reserves the right to subsequent alterations.

2-4 NBCI-02 Installation and Start-up Guide

 Chapter 3 – Mechanical Installation

Overview This chapter contains module mounting instructions. Depending on the

drive, the module can be installed either inside or outside the drive
housing or cabinet. See the user’s manual of the drive for module
placement options.

Mounting Outside Choose the location for the module. Note the following:
the Drive • The cabling instructions in Chapter 4 must be followed.
• The ambient conditions should be taken into account (see
Appendix B). The degree of protection of the module is IP 20.
• Observe the free space requirements for the module (see the figure
below) and the drive (see the drive documentation).
• Module earth is connected to the mounting rail by means of an
earthing clip (see the figure below). The mounting rail onto which
the option module is to be mounted must be earthed to a noiseless
earth. If the rail is not mounted on a properly earthed base, a
separate earthing conductor must be used. The conductor must be
as short as possible and its cross-sectional area must be 6 mm2 at
least. Note: No solid copper conductor may be used (stranded wire
allowed only).
Mounting instructions:
1. Switch off all dangerous voltages in the enclosure that the module
is to be mounted in.
2. Fasten the rail and ensure the proper earthing as described above.
3. Push the module onto the rail. The module can be released by
pulling the locking spring with a screwdriver (see below).

10 mm

Earthing
Clip

10 mm

NBCI-02 Installation and Start-up Guide 3-1

Chapter 3 – Mechanical Installation

Mounting Inside The work inside the drive should be carried out by a qualified
the Drive electrician only.

WARNING! Pay attention to the slowly discharging voltage of the

capacitor bank and the voltages that are connected from external
control circuits to the inputs and outputs of the drive.

WARNING! Do not touch the printed circuit boards. The integrated

circuits are extremely sensitive to electrostatic discharge.

Mounting instructions:
1. Stop the drive.
2. Switch off the power supply of the drive and all dangerous voltages
connected to the inputs and outputs.
3. Wait for five minutes to ensure that the capacitors in the
intermediate circuit have discharged.
4. Remove the front cover of the drive.
5. Ensure that the mains cable, motor cable and capacitor bank
(UDC+ and UDC–) are not powered.
6. Locate the position for the module (see the drive documentation).
Fasten the mounting rail to its place if not already installed.
Observe the free space requirements for the module (see the
figure above).
7. Push the module onto the rail. The module can be released by
pulling the locking spring with a screwdriver (see the figure above).

3-2 NBCI-02 Installation and Start-up Guide

 Chapter 4 – Electrical Installation

Overview This chapter contains instructions for panel bus wiring, termination and
earthing.

WARNING! Before installation, switch off the drive power supply. Wait
for five minutes to ensure that the capacitor bank of the drive is
discharged. Switch off all dangerous voltages connected from external
control circuits to the inputs and outputs of the drive.

Bus Wiring Arrange the bus cables as far away from the drive power cables as
possible. Avoid parallel runs; cables should cross at right angles. Use
bushings at cable entries.
The panel bus cable should be RS-485 compatible twin twisted pair
cable with a common screen, e.g. NK Cables JAMAK; Lappkabel
0035160 R+T; Belden 9842. (See also section Power Supply for the
Modules later in this chapter.)

Cable Earthing The panel bus cable screen may be connected to the PE terminal at
one module only. At other modules, the cable screen is to be connected
to the SHF terminal.

Bus Termination The built-in terminating resistors must be switched on if the NBCI-02
module is installed at the end of the bus. Otherwise the resistors must
be switched off. Terminating resistors prevent signal reflections from
the bus cable ends.
The termination switch is located inside the NBCI-02 module. The
module has to be opened in order to change the selection of the bus
termination switch. Follow the instructions given below.

NBCI-02 Installation and Start-up Guide 4-1

Chapter 4 – Electrical Installation

Pull the PCB outwards.

1 2 (Stoppers prevent the PCB from
Press down the 1 2 3 4
being completely removed.)
clips on top and
bottom of the
module. 5 6 7 8

Bottom View Side View

Close the module by sliding

3 4 the PCB back until the clips
lock into their recesses.

SW1
OFF ON
Set the termination
switch to the
required position.

4-2 NBCI-02 Installation and Start-up Guide

 Chapter 4 – Electrical Installation

Panel Bus
Wiring Diagram
Maximum Panel Bus Length: 1200 m*

NBCI-02 NBCI-02 NBCI-02

X4 X4 X4
1 2 3 4 1 2 3 4 1 2 3 4
B
A

DG
+24VE

5 6 7 8 5 6 7 8 5 6 7 8

External
Power Supply*

+24 V

0V *See section Power Supply for the Modules below.

Terminal Block X4
Designations

X4 Description
X1

1 A
RS-485 bus wires.
2 B

X2 3 +24VE Power supply link between all modules on the panel bus.
4 DG Twisted pair. (See also section Power Supply for the Modules.)

 5 PE Earth.
For earthing the panel bus cable screen.
Used at one module only.

6 SHF Shield (Filtered).

1 2 3 4
Cable screen AC earthing (via an RC filter).
X4 Used at all modules except one.
5 6 7 8
7 +24V 24 V d.c. ± 10% external power supply connection.
Used at one module only. The power is not to be taken from a
8 0V drive since the bus connection requires galvanic isolation.

Note: The pin designations for modular jacks X1 and X2 are given in Appendix A –
Technical Data.)

NBCI-02 Installation and Start-up Guide 4-3

Chapter 4 – Electrical Installation

Power Supply The modules on the panel bus are powered from an external 24 V d.c.
for the Modules (± 10%) power supply. The power is connected to one module on the
bus and distributed to all others via the bus cable.

Note: The power is not to be taken from a drive since the bus
connection requires galvanic isolation between the bus and the drives.

Note: At long distances between the power supply and the modules,
the voltage drop caused by the resistance of the cable has to be taken
into account. The voltage between terminals X4:3 and X4:4 of each
module should be 20 V minimum. In case the voltage is below 20 V, do
one of the following:
• Use a cable with larger conductor area
• Use a cable with extra twisted pairs; connect two or more pairs in
parallel for the power supply line
• Provide a separate power supply cable with larger conductor area
• Divide the panel bus into segments, then provide each segment with
a separate power supply.

Drive and Control The drive is connected to the NBCI-02 (modular jack X1) with a flat oval
Panel Connections telecommunications cable. (Consult the drive documentation as to the
corresponding connector inside the drive.) A similar cable is used to
connect the Control Panel to one of the alternative connection points
indicated in Figure 2-1.
The above cables must have a reversed (crossover) wiring (pin 1 to
pin 6, pin 2 to pin 5, etc.). Two such cables are supplied with the
package. Cables with a reversed wiring are also available separately as
NPLC-xxC in lengths of 0.5, 2 and 3 metres.
The cables used for connecting drives in parallel must have a straight-
through wiring (pin 1 to pin 1, pin 2 to pin 2, etc.). Cables with a
straight-through wiring are available separately as NPLC-xxS in
lengths of 0.5, 1 and 2 metres.

Note: The length for each flat oval cable should not exceed 3 metres.

Note: Do not connect the drive to modular jack X2, or the Control Panel
to modular jack X1.

4-4 NBCI-02 Installation and Start-up Guide

 Chapter 5 – Fault Tracing

The table below lists some problems that may arise during the
commissioning or use of the NBCI-02, together with the most likely
causes and remedies.

Problem Cause Remedy

Control Panel display is blank. No external 24 V d.c. power supply Check external power supply and wiring
connected to terminal block X4. (see Chapter 4).

Control Panel connected to NBCI-02 Connect Control Panel to modular jack X2.
modular jack X1.

Control Panel constantly indicates Drive not powered. Switch on drive.

a communication fault.
Incorrect bus cable wiring. Check bus cable wiring (Chapter 4).

Control Panel indicates a Interference. Check bus termination (should be ON on the

communication fault at regular modules at each panel bus end, OFF on
intervals. other modules).

Check bus cable earthing.

Check bus cable routing (parallel runs with

power and control cables should be avoided)

Drive indicates a communication Communication lost with, or not Any of the above.
fault. established with, the Control Panel

Communication lost with, or not Check communication parameter settings

established with, the Modbus (baudrate, parity, node no., etc.).
Controller.
Check bus cable wiring between control
system and NBCI-02.

Check that the bus master is communicating

at regular intervals with the drive.

NBCI-02 Installation and Start-up Guide 5-1

Chapter 5 – Fault Tracing

5-2 NBCI-02 Installation and Start-up Guide

 Appendix A – Technical Data

Panel Bus Compatible Devices: All devices compatible with the RS-485 physical
interface
Maximum Number of Stations: 31 (with CDP control); 247 (with a
Modbus controller)
Medium: Twin twisted pair RS-485 cable, common screen
• Termination: built in the NBCI-02 Module
• Specifications:

Parameter Value

Impedance 100 to 130 Ω

(f > 100 kHz)

Capacitance < 60 pF/m

Conductor Resistance < 140 Ω/km

Conductor area > 0.20 mm2 or

24 AWG

• Maximum Bus Length: 1200 m. (At long distances, cable

resistance must be taken into account. See Chapter 4.)
Topology: Multi-drop
Serial Communication Type: Asynchronous, half Duplex
Transfer Rate: ≤ 9.6 kbit/s
Protocol: Modbus RTU

NBCI-02 Installation and Start-up Guide A-1

Appendix A – Technical Data

NBCI-02 Enclosure: Plastic, dimensions 100 × 22.5 × 115 mm (H × W × D);

degree of protection IP 20
Mounting: Onto a standard mounting rail
Current Consumption: 20 mA at 24 V d.c.
Connectors:
• Modular jack (X1) for connection to the drive
• Modular jack (X2) for connection to the CDP Control Panel
(or NPCU PC Connection Unit)

X1 X2

1 +24V 1 Not connected

2 GND 2 Not connected

1
3 A’ 3 B
6
4 B’ 4 A

5 Not connected 5 DG

6 TRANS 6 +24VE

• Two Combicon MSTBT 2,5/4-ST (4-pole, cross-section 2.5

mm 2 max.) screw terminal blocks for panel bus and power
supply connection:

X4 Description

1 A
RS-485 bus wires.
2 B

3 +24VE Power supply link between all modules on the panel bus.
4 DG Twisted pair. (See also section Power Supply for the Modules.)

5 PE Earth.
For earthing the panel bus cable screen.
Used at one module only.

6 SHF Shield (Filtered).

Cable screen AC earthing (via an RC filter).
Used at all modules except one.

7 +24V 24 V d.c. ± 10% external power supply connection.

Used at one module only. The power is not to be taken from a
8 0V drive since the bus connection requires galvanic isolation.

General:
• All materials are UL/CSA approved
• Complies with EMC Standards EN 50081-2 and EN 50082-2

A-2 NBCI-02 Installation and Start-up Guide

 Appendix B – Ambient Conditions

Ambient Conditions, Ambient operating conditions refer to the conditions the module is
Operation subjected to when installed for stationary use.
Air Temperature: 0 to +50 °C
Relative Humidity: 5 to 95 %, no condensation allowed. Maximum
allowed relative humidity is 60 % in the presence of corrosive gases.
Contamination Levels:
Chemical gases: IEC 721-3-3, Class 3C2
Solid particles: IEC 721-3-3, Class 3S2
Installation Site Altitude: 0 to 2000 m. If installation site is above
2000 m, contact local ABB representative.
Vibration: Max 0.3 mm (2 to 9 Hz), max 1 m/s2 (9 to 200 Hz)
sinusoidal (IEC 68-2-6)
Shock: Max 70 m/s2, 22 ms (IEC 68-2-27)

Ambient Conditions, Ambient storage conditions refer to the conditions the module is
Storage subjected to during storage in the protective package.
Temperature: -40 to +70 °C.
Relative Humidity: Less than 95 %, no condensation allowed
Atmospheric Pressure: 70 to 106 kPa
Vibration: Max 0.3 mm (2 to 9 Hz), max 1 m/s2 (9 to 200 Hz)
sinusoidal (IEC 68-2-6)
Shock: Max 100 m/s2, 11 ms (IEC 68-2-27)

Ambient Conditions, Ambient transportation conditions refer to the conditions the module is
Transportation subjected to during transportation in the protective package.
Temperature: -40 to +70 °C
Relative Humidity: Less than 95 %, no condensation allowed.
Atmospheric Pressure: 60 to 106 kPa
Vibration: Max 3.5 mm (2 to 9 Hz), max 15 m/s2 (9 to 200 Hz)
sinusoidal (IEC 68-2-6)
Shock: Max 100 m/s2, 11 ms (IEC 68-2-27)
Bump: Max 300 m/s2, 6 ms (IEC 68-2-29)
Free Fall: 250 mm

NBCI-02 Installation and Start-up Guide B-1

Appendix B – Ambient Conditions

B-2 NBCI-02 Installation and Start-up Guide

 SUPERSEDES: 14.9.1998
3AFY 58919748 R0225
EFFECTIVE: 1.11.1999
NBCI-02/EN

ABB Industry Oy
Drives
P.O. Box 184
FIN-00381 Helsinki
FINLAND
Telephone: +358 10 222 000
Telefax: +358 10 222 2681
Internet: http://www.abb.com/automation