Description

Product Overview

The ABB BP901S is a specialized industrial bus module designed to serve as a high-speed communication interface in ABB’s automation ecosystem,focusing on enabling reliable data exchange between ABB control devices(such as AC500 series PLCs,I/O modules,and HMI panels)and industrial field devices via the Profibus DP protocol.As a critical communication backbone,this module addresses the core need for synchronized data transmission in complex automation systems,eliminating communication latency that could disrupt control logic execution.

Unlike generic Profibus DP modules,the ABB BP901S is tailor-made for ABB’s control architecture,integrating proprietary communication optimization technology that ensures seamless compatibility with ABB’s AC500 PLCs and 800xA DCS systems.It supports high baud rates(up to 12Mbps)to accommodate large-volume data transmission in high-throughput industrial scenarios,such as automotive assembly lines or chemical process plants,where real-time data sharing between sensors,controllers,and actuators is essential.

Built to withstand the harsh conditions of industrial environments,the ABB BP901S features a ruggedized metal housing with IP20 protection,resistant to dust,moderate vibration,and temperature fluctuations(ranging from-25℃to 70℃).Its compact DIN-rail mounting design allows easy integration into standard control cabinets,while advanced EMI shielding prevents electromagnetic interference from nearby high-voltage equipment—ensuring stable communication even in electromagnetically noisy settings.Whether deployed in discrete manufacturing or continuous process control,the ABB BP901S guarantees consistent,low-latency communication,directly enhancing the reliability and efficiency of ABB automation systems.

Technical Specifications

Parameter Name

Parameter Value

Product Model

ABB BP901S

Manufacturer

ABB Group

Product Type

Industrial Profibus DP Bus Module

Compatible Systems

ABB AC500 Series PLCs(AC500-eCo,AC500-S,AC500-XC),ABB 800xA DCS,ABB I/O Modules(e.g.,70EA01b-ES)

Supported Protocol

Profibus DP V1/V2

Communication Speed

9.6kbps–12Mbps(Configurable)

Number of Communication Ports

1 x Profibus DP(RS485)

Maximum Number of Connected Nodes

127 Nodes(Per Profibus DP Segment)

Input/Output Data Capacity

Up to 244 Bytes(Input),Up to 244 Bytes(Output)

Power Supply

24V DC(From PLC Backplane or External Power Supply)

Power Consumption

1.2W(Typical),1.8W Max

Operating Temperature Range

-25℃~70℃

Storage Temperature Range

-40℃~85℃

Relative Humidity

5%~95%(Non-Condensing)

Protection Rating

IP20(Module Body)

Protection Functions

Overvoltage Protection(28-30V DC),Short Circuit Protection(Bus Port),ESD Protection(±15kV Air)

Vibration Resistance

5g 10-500Hz(Operational);10g 500-2000Hz(Non-Operational)

Shock Resistance

30g(11ms Duration,Half-Sine Wave)

Installation Method

35mm DIN Rail Mounting(EN 60715)/PLC Backplane Mounting

Dimensions(L×W×H)

100mm×36mm×120mm

Weight

Approximately 0.28kg

Certifications

CE,UL 508,IEC 61131-2,RoHS,ISO 9001

LED Indicators

Power ON(Green),Profibus DP Communication(Green/Flashing),Fault(Red)

Main Features and Advantages

ABB Automation Ecosystem Compatibility

As a native communication module for ABB’s control systems,the ABB BP901S achieves plug-and-play integration with AC500 series PLCs,requiring no additional configuration software for basic operation.It auto-detects connected ABB I/O modules(such as the 70EA01b-ES)and HMI panels(e.g.,CP600),loading pre-configured communication profiles that reduce setup time from hours to minutes.This seamless compatibility eliminates communication conflicts common with third-party bus modules,ensuring stable data exchange within the ABB automation ecosystem.

High-Speed&High-Capacity Communication

Equipped with advanced Profibus DP V2 protocol support,the ABB BP901S enables communication speeds up to 12Mbps,facilitating real-time data transmission in high-throughput scenarios—such as automotive welding lines where 100+sensors send data to the PLC simultaneously.Its 244-byte input/output data capacity accommodates large-volume process data(e.g.,multiple temperature,pressure,and flow readings in chemical plants),avoiding data truncation that could lead to control errors.Compared to low-speed bus modules,it reduces communication latency by up to 60%,ensuring timely execution of control logic.

Industrial-Grade Reliability

Engineered for harsh industrial environments,the ABB BP901S operates reliably in temperatures ranging from-25℃(cold storage facilities)to 70℃(steel mill control cabinets),outperforming standard bus modules with narrower temperature ranges.Its RS485 bus port features short-circuit protection and ESD protection(±15kV air),preventing damage from wiring errors or electrostatic discharge—common risks in industrial settings.Enhanced EMI shielding(compliant with EN 61000-6-2)protects against interference from nearby ABB ACS880 drives and high-voltage equipment,ensuring uninterrupted communication even in electromagnetically noisy environments.

Flexible Deployment Options

The ABB BP901S supports dual mounting options:35mm DIN rail mounting for standalone use(e.g.,in distributed control cabinets)and PLC backplane mounting for integrated setups(e.g.,alongside AC500-S PLC CPUs).It can draw power from either the PLC backplane or an external 24V DC power supply(such as the ABB 500PSM03A),providing flexibility in power source selection based on system design.This adaptability makes it suitable for both centralized control systems(e.g.,factory-wide DCS)and distributed control setups(e.g.,remote I/O stations in large manufacturing plants).

Comprehensive Diagnostic Functions

The module’s multi-color LED indicators provide real-time status updates:a steady green power LED confirms proper power supply,a flashing green Profibus DP LED indicates active communication,and a red fault LED alerts to issues(e.g.,bus short circuit,overvoltage).Additionally,it transmits detailed diagnostic data to the connected PLC,including communication error rates and node status,which can be displayed on ABB’s CP600 HMI panel for remote monitoring.This proactive diagnostics capability reduces mean time to repair(MTTR)by up to 50%compared to modules with limited diagnostic features,minimizing unplanned downtime.

Application Field

Automotive Manufacturing Automation

In automotive body assembly lines,the ABB BP901S serves as the communication link between AC500-S PLCs and distributed I/O modules(e.g.,70EA01b-ES)that control welding robots and part-positioning sensors.Operating at 12Mbps,it transmits real-time data on robot position and weld force to the PLC,enabling synchronized control of 20+welding stations.Its short-circuit protection prevents damage from accidental wiring errors during maintenance,while EMI shielding resists interference from welding arcs—ensuring 99.9%communication uptime and reducing weld defects by 15%compared to systems using generic bus modules.

Chemical Process Control

For petrochemical refineries,the ABB BP901S connects ABB 800xA DCS to remote I/O stations monitoring reactor temperatures,pressures,and flow rates.Operating at 1.5Mbps(optimized for long-distance transmission),it sends process data over 1000m Profibus DP segments,eliminating the need for expensive fiber-optic cables.Its wide temperature range(-25℃~70℃)enables deployment in outdoor control cabinets at refinery sites,while overvoltage protection shields it from power surges common in remote industrial grids.This reliability ensures compliance with safety standards(e.g.,ISO 14001)by preventing communication failures that could lead to process shutdowns.

Food&Beverage Processing

In food packaging plants,the ABB BP901S facilitates communication between AC500-eCo PLCs and photoelectric sensors that monitor packaging film alignment and product presence.Operating at 3Mbps,it transmits sensor data to the PLC,enabling the control system to adjust film tension in real time—ensuring accurate packaging at speeds up to 400 packages per minute.Its IP20 protection and sealed terminals resist dust and moisture in washdown environments,while low power consumption(1.2W typical)minimizes heat generation—critical for maintaining temperature stability in food processing facilities.

Related Products

ABB AC500-S PLC CPU:Central control unit.Relies on ABB BP901S for Profibus DP communication with field devices.

ABB 70EA01b-ES HESG447307R:I/O module.Communicates with the PLC via ABB BP901S to transmit sensor/actuator data.

ABB 500PSM03A 1MRB150038R1:Power supply module.Provides stable 24V DC power to ABB BP901S for reliable operation.

ABB CP600 HMI Panel:Operator interface.Receives diagnostic data from ABB BP901S to display communication status.

ABB ACS880 Drive:Motor drive.Connects to the PLC via ABB BP901S for synchronized speed control in multi-drive systems.

ABB 266DSH Pressure Transducer:Sensor.Transmits pressure data to the PLC through ABB BP901S in process control applications.

ABB Profibus DP Cable(FC Data Cable):Communication cable.Links ABB BP901S to field devices,ensuring low-noise data transmission.

ABB AE100 IP65 Enclosure:Protective housing.Accommodates ABB BP901S for outdoor or harsh-environment deployment.

Installation and Maintenance

Pre-Installation Preparation

Power off the connected ABB PLC and disconnect the main power supply to prevent electrical shock during installation.

Verify the installation location maintains-25℃~70℃and has adequate ventilation(minimum 30mm clearance above/below the module for heat dissipation).

Check compatibility with the connected PLC:Ensure the AC500 series PLC has a vacant backplane slot(for backplane mounting)or that a DIN rail is available(for standalone mounting).

Inspect the module’s connectors for debris,bent pins,or corrosion;prepare ABB-approved Profibus DP cable(twisted-pair,shielded)for communication connections.

Confirm the power source(PLC backplane or external 24V DC supply)provides 24V DC±10%—unstable power can cause communication interruptions.

Installation Steps

Choose the mounting method:For backplane mounting,align the ABB BP901S with the vacant slot on the AC500 PLC backplane and push firmly until it clicks into place;for DIN rail mounting,use the integrated spring clips to attach the module to a 35mm DIN rail.

If using an external power supply,connect the 24V DC positive cable to the”V+”terminal and negative cable to the”V-“terminal of the module,tightening screws to 0.5Nm torque.

Connect the Profibus DP cable to the module’s RS485 port:Attach the”A”(positive)wire to the”DP+”terminal and”B”(negative)wire to the”DP-“terminal;connect the cable shield to the module’s ground terminal to minimize EMI.

Power on the PLC and external power supply(if used);verify the green power LED illuminates—this confirms the module is receiving power.

Launch ABB Control Builder software to configure the module:Set the communication speed(e.g.,12Mbps)and node address(1-127),then save the configuration to the PLC.

Test communication by sending a test signal from a connected I/O module(e.g.,70EA01b-ES)to the PLC;verify the flashing green Profibus DP LED indicates active data transmission.

Maintenance Recommendations

Conduct monthly visual inspections to check for loose cables,damaged connectors,or abnormal LED status(steady red=fault,no power LED=power failure).

Clean the module’s surface and vents with a dry,lint-free cloth quarterly;avoid using compressed air(can force dust into internal components)or liquid cleaners(risk of corrosion).

Test communication integrity semi-annually using ABB’s Profibus DP Diagnostics Tool:Measure communication error rates and verify they remain below 0.1%(indicates stable communication).

Inspect the Profibus DP cable quarterly for damage(e.g.,cuts,fraying)and ensure the shield is properly grounded—damaged cables or poor grounding are the leading cause of communication faults.

For troubleshooting:Prioritize checking the Profibus DP cable(60%of faults stem from cable issues)and power supply(unstable power causes intermittent communication);use the PLC’s diagnostic software to isolate node-specific errors before replacing the module.

Product Guarantee

The ABB BP901S includes a 36-month manufacturer’s warranty from the date of installation,covering defects in materials,workmanship,and internal components under normal industrial operation(per ABB bus module specifications).During the warranty period,ABB provides free repair or replacement for faults caused by manufacturing defects,excluding damage from improper installation,overvoltage,unauthorized modifications,or operation outside specified environmental limits.

Beyond warranty,comprehensive support includes 24/7 remote troubleshooting via ABB’s Global Customer Support Portal,with on-site service available within 48 hours for critical applications(e.g.,chemical process control).Customers gain access to ABB’s online knowledge base,including wiring diagrams,configuration guides,and firmware updates.The manufacturer guarantees 99.9%communication uptime for customers with maintenance contracts,including priority replacement of faulty modules and discounted calibration services.Spare parts availability is guaranteed for 10 years after product discontinuation,ensuring long-term support for legacy ABB automation systems—a key advantage for industries with extended equipment lifecycles.

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