ABB AC500 Series Reference manual

System Description AC500

Scalable PLC

for Individual Automation

Introduction

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G1 Introduction to AC500 1-1 AC500 / Issued: 07.2006

Contents

Introduction

Survey - gain an overview........................................................................................................ 1-3

System structure of AC500/S500-FBP ..................................................................................................... 1-3

AC500 system overview ........................................................................................................................... 1-4

Bus systems overview .............................................................................................................................. 1-8

Documentation overview ........................................................................................................................ 1-15

Short description of the hardware........................................................................................................... 1-19

Short description of the software ............................................................................................................ 1-20

Operating and displaying ........................................................................................................................ 1-22

Services .................................................................................................................................................. 1-26

Service - Control Engineering............................................................................................................... 1-26

Repair services and replacement devices............................................................................................ 1-26

Seminars/Workshops............................................................................................................................ 1-27

Addresses ............................................................................................................................................... 1-28

Regulations concerning the appropriate and safe setup of systems and installations........................... 1-29

Getting started with AC500.................................................................................................... 1-32

Important user information...................................................................................................................... 1-32

Before starting ....................................................................................................................................... 1-33

Assembling the system........................................................................................................................... 1-36

Insertion / replacement of the Lithium battery ........................................................................................ 1-39

Insertion of the SD Memory Card ........................................................................................................... 1-41

Mounting the system............................................................................................................................... 1-42

AC500 system dimensions ..................................................................................................................... 1-48

Setting the FBP slave address ............................................................................................................... 1-50

Status display and error indication on the AC500 CPU.......................................................................... 1-52

LEDs on S500-FBP modules.................................................................................................................. 1-56

Specifications and certifications ............................................................................................................. 1-58

Getting started with S500-FBP .............................................................................................. 1-59

Important user information...................................................................................................................... 1-59

Before starting ....................................................................................................................................... 1-60

Assembling the system........................................................................................................................... 1-62

Mounting the system............................................................................................................................... 1-65

S500 system dimensions........................................................................................................................ 1-70

Setting the FBP slave address ............................................................................................................... 1-72

LEDs on S500-FBP modules.................................................................................................................. 1-73

Specifications and certifications ............................................................................................................. 1-75

Examples ................................................................................................................................ 1-76

Examples for introduction ................................................................................................................... 1-76

Getting started ........................................................................................................................................ 1-76

Examples for decentralized systems connected by network .......................................................... 1-96

Example: AC500 CPU PM581 as PROFIBUS-DP master and coupler DC505-FBP

as PROFIBUS DP slave with FieldBusPlug PDP22-FBP ........................................................ 1-96

For AC1131 experts – connection of S500-FBP I/O module to series 90.......................... 1-122

Example: AC31 Series 90 CPU as PROFIBUS-DP master and

decentralized I/O expansion using a DC505-FBP.................................................................. 1-122

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G1 Introduction to AC500 1-2 AC500 / Issued: 07.2006

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G1 Introduction to AC500 1-3 AC500 / Issued: 07.2006

Survey - gain an overview

System structure of AC500/S500-FBP

The principle system structure is shown in the following figure:

External

couplers

CPU

S500–FBP I/Os

(max. 7 modules)

DC505–FBP S500–FBP I/Os

(7 modules max.

with a maximum of

4 analog modules)

AC500

S500–FBP

(max. 4) internal

couplers

Explanation

The following electronic modules are the basic components of the AC500 system:

• CPUs of three different performance classes

• Couplers for various bus systems: Fieldbus systems PROFIBUS DP, CANopen, DeviceNet; Ethernet

couplers.

Central expansion: One CPU supports direct connection of up to seven S500 FBP system I/O devices.

Decentralized expansion: Using the DC505 FBP interface module (for fieldbus systems PROFIBUS DP,

CANopen, DeviceNet, Modbus RTU), up to seven S500 FBP system I/O devices can be connected (with

a maximum of four analog modules).

Mechanical mounting of the electronic modules is done using CPU terminal bases (for the CPU and the

couplers) and I/O terminal units (for the I/O modules), designed for snap-on mounting on a DIN rail or for

screw-mounting on a mounting panel.

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G1 Introduction to AC500 1-4 AC500 / Issued: 07.2006

AC500 system overview

AC500 is a complex state-of-the-art system providing extensive automation potential for your plant.

Figure: AC500 system

The following pages provide a summary of all devices available for the AC500 system. For detailed

information about the individual devices please refer to the respective hardware description.

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G1 Introduction to AC500 1-5 AC500 / Issued: 07.2006

Overview of available CPUs

Type Order number Description

PM571 1SAP 130 100 R0100 PM571, CPU 64kB, 24 V DC, Memory Card Slot, 2x RS-

232/485 (Programming, MODBUS/CS31), 1x FBP, Display

PM571-ETH 1SAP 130 100 R0170 PM571-ETH, CPU 64kB, 24 V DC, Memory Card Slot, 2x

RS-232/485 (Programming, MODBUS/CS31), 1x FBP,

Display, integrated Ethernet TCP/IP

PM581 1SAP 140 100 R0100 PM581, CPU 256kB, 24 V DC, Memory Card Slot, 2x RS-

232/485 (Programming, MODBUS/CS31), 1x FBP, Display

PM581-

ARCNET

1SAP 140 100 R0160 PM581-ARCNET, CPU, memory 256 kB, 24 V DC,

Memory Card Slot, interfaces 2 x RS-232/485

(programming, Modbus/CS31), 1 x FBP, Display,

integrated coupler ARCNET

PM581-ETH 1SAP 140 100 R0170 PM581-ETH, CPU 256kB, 24 V DC, Memory Card Slot, 2x

RS-232/485 (Programming, MODBUS/CS31), 1x FBP,

Display, with integrated Ethernet TCP/IP coupler

PM582 1SAP 140 200 R0100 PM582, CPU, memory 512 kB, 24 V DC, Memory Card

Slot, interfaces 2 x RS-232/485 (programming,

Modbus/CS31), 1 x FBP, Display

PM582-ETH 1SAP 140 200 R0170 PM582-ETH, CPU, memory 512 kB, 24 V DC, Memory

Card Slot, interfaces 2 x RS-232/485

(programming, Modbus/CS31), 1 x FBP, Display,

integrated coupler Ethernet TCP/IP

PM591 1SAP 150 100 R0100 PM591, CPU 4MB, 24 V DC, Memory Card slot, 2x RS-

232/485 (Programming, MODBUS/CS31), 1x FBP, Display

PM591-

ARCNET

1SAP 150 100 R0160 PM591-ARCNET, CPU, memory 4 MB, 24 V DC, Memory

Card Slot, interfaces 2 x RS-232/485 (programming,

Modbus/CS31), 1 x FBP, Display, integrated coupler

ARCNET

PM591-ETH 1SAP 150 100 R0170 PM591-ETH, CPU 4MB, 24 V DC, Memory Card Slot, 2x

RS-232/485 (Programming, MODBUS/CS31), 1x FBP,

Display, with integrated Ethernet TCP/IP Coupler

Overview of available couplers

Type Order number Description

CM572-DP 1SAP 170 200 R0001 CM572-DP, Communication Module PROFIBUS DP

Master 12 Mb/s

CM575-DN 1SAP 170 500 R0001 CM575-DN, Communication Module DeviceNet Master

CM577-ETH 1SAP 170 700 R0001 CM577-ETH, Communication Module, Ethernet TCP/IP,

with integrated 2-port switch

CM578-CN

1SAP 170 800 R0001 CM578-CN, Communication Module, CANopen Master

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G1 Introduction to AC500 1-6 AC500 / Issued: 07.2006

Overview of available CPU terminal bases

Type Order number Description

TB511-

ARCNET

1SAP111 100 R0160 TB511-ARCNET, CPU Terminal Base AC500, 1x CPU

Slot, 1x Coupler Slot, ARCNET COAX Connector

TB511-ETH 1SAP 111 100 R0170 TB511-ETH, CPU Terminal Base AC500, 1x CPU Slot, 1x

Coupler Slot, Ethernet RJ45 Connector

TB521-

ARCNET

1SAP 112 100 R0160 TB521-ARCNET, Terminal Base AC500, 1x CPU Slot, 2x

Coupler Slots, ARCNET COAX Connector

TB521-ETH 1SAP 112 100 R0170 TB521-ETH, CPU Terminal Base AC500, 1x CPU Slot, 2x

Coupler Slots, Ethernet RJ45 Connector

TB541-ETH 1SAP 114 100 R0170 TB541-ETH, CPU Terminal Base AC500, 1x CPU Slot, 4x

Coupler Slots, Ethernet RJ45 Connector

Overview of available I/O modules

Type Order Number Description

DI524 1SAP 240 000 R0001 DI524, Digital Input Module, 32 DI, 24 V DC, 1-wire

DC522 1SAP 240 600 R0001 DC522, Digital input/output module, 16 DC, 24 V DC / 0.5

A, 2-wire

DC523 1SAP 240 500 R0001 DC523, Digital input/output module, 24 DC, 24 V DC / 0.5

A, 1-wire

DC532 1SAP 240 100 R0001 DC532, Digital Input/Output Module, 16 DI / 16 DC, 24 V

DC / 0.5 A, 1-wire

DX522 1SAP 245 200 R0001 DX522, Digital Input/Output Module, 8 DI 24 V DC, 8 DO

Relay, 2-wire

DX531 1SAP 245 000 R0001 DX531, Digital Input/Output Module, 8 DI, 230 V AC, 4 DO

Relay, 2-wire

AI523 1SAP 250 300 R0001 AI523, Analog input module, 16 AI, U/I/Pt100, 12 Bit + sign,

2-wires

AO523 1SAP 250 200 R0001 AO523, Analog output module, 16 AO, U/I, 12 Bit + sign, 2-

wires

AX521 1SAP 250 100 R0001 AX521, Analog input/output module, 4 AI / 4 AO, U/I/Pt100,

12 Bit + sign, 2-wires

AX522

1SAP 250 000 R0001 AX522, Analog Input/Output Module, 8 AI / 8 AO,

U/I/Pt100, 12 Bit + sign, 2-wire

Overview of available terminal units

Type Order Number Description

TU515 1SAP 212 200 R0001 TU515, I/O Terminal Unit, 24 V DC, Screw Terminals

TU516 1SAP 212 000 R0001 TU516, I/O Terminal Unit, 24 V DC, Spring Terminals

TU531 1SAP 217 200 R0001 TU531, I/O Terminal Unit, 230 V AC, Relay, Screw

Terminals

TU532 1SAP 217 000 R0001 TU532, I/O Terminal Unit, 230 V AC, Relay, Spring

Terminals

TU551-CS31 1SAP 210 600 R0001 TU551-CS31, Bus-I/O Terminal Unit, 24 V DC, Screw

Terminals

TU552-CS31 1SAP 210 400 R0001 TU552-CS31, Bus-I/O Terminal Unit, 24 V DC, Spring

Terminals

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G1 Introduction to AC500 1-7 AC500 / Issued: 07.2006

Overview of available FBP interface modules

Type Order Number Description

DC505-FBP 1SAP 220 000 R0001 DC505-FBP, FBP-Interface Module, 8 DI / 8 DC, 24 V DC /

0,5 A, 1-wire

DC551-CS31 1SAP 220 500 R0001

DC551-CS31, Digital Input/Output-Bus Module, 8DI / 16DC

24 V DC / 0,5 A, 1-wire

Overview of available FBP terminal units

Type Order Number Description

TU505 1SAP 210 200 R0001 TU505, FBP Terminal Unit, Screw Terminals

TU506 1SAP 210 000 R0001 TU506, FBP Terminal Unit, Spring Terminals

Overview of available FieldBusPlugs and accessories

Type Order number Description

PDP22-FBP.025 1SAJ 2401 00 R1003 PDP22-FBP.025 PROFIBUS DP-V0/V1-FBP 0.25 m,

modular (FieldBusPlug)

PDP22-FBP.050 1SAJ 2401 00 R1005 PDP22-FBP.050 PROFIBUS DP-V0/V1-FBP 0.5 m,

modular (FieldBusPlug)

PDP22-FBP.100 1SAJ 2401 00 R1010 PDP22-FBP.100 PROFIBUS DP-V0/V1-FBP 1 m,

modular (FieldBusPlug)

PDP22-FBP.200 1SAJ 2401 00 R1020 PDP22-FBP.200 PROFIBUS DP-V0/V1-FBP 2 m,

modular (FieldBusPlug)

PDP22-FBP.500 1SAJ 2401 00 R1050 PDP22-FBP.500 PROFIBUS DP-V0/V1-FBP 5 m,

modular (FieldBusPlug)

PDV11-FBP.0 1SAJ 924 008 R0001 Feeding connector 24 V DC, Code B-A

PDV12-FBP.0 1SAJ 924 011 R0001 Feeding connector 24 V DC, Code A-A

PDA11-FBP.050 1SAJ 924 009 R0005 Adapter M12-Dsub9-M12, cable length 0.50 m

PDA12-FBP.050 1SAJ 924 010 R0005 Adapter M12-Dsub9-M12, cable length 2 x 0.50 m

PDR11-FBP.150 1SAJ 924 007 R0001 Terminating resistor 150 Ohm

Overview of available accessories

Type Order Number Description

TA521 1SAP 180 300 R0001 TA521, Lithium Battery

MC502 1SAP 180 100 R0001 MC502, SD Memory Card 128 MB

TK501 1SAP 180 200 R0001 TK501, Programming Cable, D-Sub / D-Sub

TK502 1SAP 180 200 R0101 TK502, Programming Cable, Terminal Block / D-Sub

TA523 1SAP 180 500 R0001 TA523, Pluggable Marker Holder (10 pcs)

TA524 1SAP 180 600 R0001 TA524, Dummy Coupler Module

TA525 1SAP 180 700 R0001 TA525, Set of 10 white Plastic Markers

TA526 1SAP 180 700 R2001 TA526, Wall mounting accessory, 10 pcs

PS501-PROG 1SAP 190 100 R0001 PS501-PROG, Control Builder AC500, Programming

Software German / English / French (CD-ROM incl.

Online Help and PDF Docs)

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G1 Introduction to AC500 1-8 AC500 / Issued: 07.2006

Bus systems overview

Bus System Short information / Web Links / Block Libraries

ARCNET www.arcnet.com ARCNET Trade Association, USA; -> Literature -> Other Puplications

-> ARCNET Tutorial and Product Guide

CANopen www.can-cia.org

DeviceNet www.odva.org -> DEVICENET

Ethernet www.ethermanage.com

The Ethernet Library -> see ‘Function Block Libraries AC500’

Modbus www.modbus.org

PROFIBUS www.profibus.com -> Web Based Training

The PROFIBUS DP Library -> see ‘Function Block Libraries AC500’

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