B&R ACOPOS 5A2005 Servo Drive Modules — 5A2005.02

Technical Dossier

Product Details And Specifications

B&R ACOPOS 5A2005 Series: Comprehensive Module Range and Technical Overview

The B&R ACOPOS 5A2005 series represents a core product line within Bernecker & Rainer's ACOPOS servo drive platform, deployed extensively across global heavy industry sectors including chemical processing plants, nuclear power facilities, oil refineries, and continuous-process manufacturing lines. The 5A2005 designation identifies single-axis servo drive modules rated at 5 A continuous output current, engineered for integration within B&R's ACOPOS backplane infrastructure. These units operate under the POWERLINK real-time Ethernet protocol, providing deterministic motion control with cycle times down to 400 µs. Their compact DIN-rail and panel-mount form factors, combined with direct compatibility with B&R's Automation Studio engineering environment, have made the 5A2005 series a standard specification in process industries requiring precise torque, velocity, and position control over extended operational lifespans exceeding 15 years.

The Evolution of ACOPOS 5A2005 Architecture

The ACOPOS platform was introduced by B&R in the late 1990s as a modular, network-integrated servo drive architecture designed to replace proprietary fieldbus-dependent motion controllers. The 5A2005 module family evolved through three distinct hardware generations. The first generation (circa 1998–2004) used parallel backplane communication and was compatible with B&R's proprietary CAN-based motion bus. The second generation (2004–2012) transitioned to POWERLINK Ethernet as the primary motion network, introducing the 5A2005.02 variant with enhanced firmware support for electronic camming and gearing functions. The third generation introduced extended safe motion functions (STO, SS1, SLS) compliant with IEC 62061 and EN ISO 13849-1, addressing evolving machinery safety directives in the EU and North American markets.

Compatibility constraints are a critical operational consideration: 5A2005 modules require matching ACOPOS power supply modules (e.g., 8B0P series) and are not interchangeable with the later ACOPOSmulti or ACOPOSmicro platforms without hardware and firmware migration. Facilities running legacy ACOPOS installations must maintain a stock of 5A2005-series spares, as cross-generation substitution is not supported at the backplane level.

ACOPOS 5A2005 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly deployed modules within the B&R ACOPOS 5A2005 and closely related single-axis servo drive range. Modules are classified by functional category:

Single-Axis Servo Drive Modules (5 A Class)

5A2005.02: Single-axis ACOPOS servo drive, 5 A continuous, POWERLINK interface, standard firmware
5A2005.03: Single-axis ACOPOS servo drive, 5 A continuous, extended safe motion STO/SS1 firmware
5A2005.10: Single-axis ACOPOS servo drive, 5 A, with integrated encoder evaluation (EnDat 2.1)
5A2005.11: Single-axis ACOPOS servo drive, 5 A, EnDat 2.2 / Hiperface DSL encoder support
5A2005.20: Single-axis ACOPOS servo drive, 5 A, with resolver interface option
5A2005.30: Single-axis ACOPOS servo drive, 5 A, incremental encoder (TTL/HTL) interface variant

Power Supply & Infrastructure Modules (ACOPOS Compatible)

8B0P0045HWS0.000-1: ACOPOS power supply module, 45 A DC bus, for 5A2005 backplane systems
8B0P0022HWS0.000-1: ACOPOS power supply module, 22 A DC bus, compact rail configuration
8B0C0000HWS0.000-1: ACOPOS capacitor module, DC bus buffer for multi-axis configurations

Communication & Interface Modules

8AC110.60-1: ACOPOS POWERLINK interface card, X2X Link gateway for legacy backplane integration
8AC120.60-1: ACOPOS CAN interface adapter, first-generation backplane compatibility module
8AC130.60-1: ACOPOS DeviceNet gateway module for third-party PLC integration

Encoder & Feedback Accessories

8AC001.00-1: Encoder cable set, EnDat 2.1, 5 m, for 5A2005 series motor feedback
8AC002.00-1: Resolver cable assembly, shielded, 5 m, compatible with 5A2005.20
8AC003.00-1: Motor power cable, 5 m, for ACOPOS single-axis drive series

Replacement & Maintenance Components

5A2005.02-000: Factory-refurbished 5A2005.02 unit, full functional test certification
5A2005.02-R: Repair-exchange unit, 5A2005.02, with 12-month warranty
8B0F0045HWS0.000-1: ACOPOS filter module, EMC line filter, 45 A, for 5A2005 power stage

Sourcing Hard-to-Find & Obsolete ACOPOS 5A2005 Parts

The B&R ACOPOS 5A2005 series has entered the mature-to-end-of-life phase of its product lifecycle. B&R (now part of ABB) has transitioned its primary servo drive portfolio to the ACOPOSmulti and ACOPOSmicro platforms. As a result, new production of 5A2005 modules has been discontinued, and OEM spare parts availability through standard distribution channels is increasingly constrained.

DriveKNMS maintains a dedicated inventory of 5A2005-series modules sourced through certified secondary market channels, decommissioned plant buybacks, and authorized repair partners. Our procurement process covers: factory-surplus new-in-box (NIB) units, professionally refurbished modules with full functional verification, and repair-exchange programs for units with repairable fault conditions (IGBT failure, capacitor degradation, firmware corruption). For facilities operating ACOPOS-based motion systems under long-term service agreements or with planned operational horizons beyond 2030, DriveKNMS provides lifecycle extension support including multi-year supply contracts and consignment stocking arrangements.

Quality Control for the ACOPOS 5A2005 Range

The ACOPOS 5A2005 module architecture presents specific test challenges due to its integrated backplane bus interface, POWERLINK communication stack, and multi-axis synchronization firmware. DriveKNMS applies a structured test protocol for all 5A2005 units prior to dispatch:

1. Visual and mechanical inspection: PCB condition, connector integrity, capacitor visual check, backplane edge connector pin assessment.
2. Power stage functional test: DC bus energization at rated voltage (nominally 750 V DC), IGBT switching verification, current measurement accuracy calibration.
3. Communication bus validation: POWERLINK node initialization, cycle time verification at 400 µs, X2X Link synchronization check where applicable.
4. Encoder interface test: EnDat/Hiperface/resolver signal integrity verification using reference encoder simulation.
5. Firmware version audit: Confirmation of installed firmware revision against B&R compatibility matrix for target Automation Studio version.
6. Burn-in cycle: 48-hour operational load test under simulated motion profile to screen latent component failures.

All units are shipped with a test report documenting measured parameters and pass/fail criteria against B&R factory specifications.

For sourcing inquiries, technical specifications, or volume pricing on B&R ACOPOS 5A2005 modules: