ABB Advant AC500 User manual

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V2 AC500 Hardware 1-1 System data AC500 / Issued: 05.2007
Contents
System data and system construction ........................................................................ 1-4
System data ............................................................................................................................................ 1-4
Operating and ambient conditions ............................................................................................................ 1-4
Creepage distances and clearances ....................................................................................................... 1-5
Insulation test voltages, routine test, according to EN 61131-2 ............................................................... 1-5
Power supply units ................................................................................................................................... 1-5
Electromagnetic compatibility .................................................................................................................. 1-6
Mechanical data ....................................................................................................................................... 1-7
Mounting and disassembling the Terminal Bases and the couplers ...................................... 1-8
Assembly on DIN rail ............................................................................................................................... 1-8
Assembly with screws ............................................................................................................................ 1-13
Mounting and disassembling the Terminal Units and the I/O modules ................................ 1-14
Assembly on DIN rail ............................................................................................................................. 1-14
Assembly with screws ............................................................................................................................ 1-17
Mechanical dimensions ..................................................................................................................... 1-18
Switch-gear cabinet assembly ......................................................................................................... 1-21
Insertion / Replacement of the Lithium battery .................................................................. 1-22
Insertion of the SD Memory Card ........................................................................................ 1-24
Connection system ............................................................................................................................. 1-25
Terminals for power supply and the COM1 interface (CPU Terminal Base AC500)..............................1-25
Terminals at the Terminal Units (I/O, FBP) ............................................................................................ 1-26
Connection of wires at the spring terminals ........................................................................................... 1-27
Mechanical encoding .......................................................................................................................... 1-29
General wiring recommendations ................................................................................................... 1-31
Bad wiring on power supply terminals .................................................................................................... 1-31
Bad wiring on I/O terminals..................................................................................................................... 1-31
Behaviour of the system in case of power supply interruptions and power recovering .. 1-31
I/O-Bus..................................................................................................................................................... 1-32
General .................................................................................................................................................. 1-32

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V2 AC500 Hardware 1-2 System data AC500 / Issued: 05.2007
Wiring...................................................................................................................................................... 1-32
Number of user data, bus cycle time and data security .........................................................................1-32
Replacement of modules on the I/O bus ............................................................................................... 1-33
Serial interfaces of the CPU Terminal Bases ................................................................................ 1-33
Interface standard................................................................................................................................... 1-33
Technical data......................................................................................................................................... 1-33
Serial interface COM1.......................................................................................................................... 1-33
CS31 system bus................................................................................................................... 1-35
Connection of the AC500 CPU to the CS31 system bus using COM1 of the Terminal Base ............... 1-35
Wiring...................................................................................................................................................... 1-36
Bus topology ........................................................................................................................................... 1-36
Earthing................................................................................................................................................... 1-38
Number of user data, bus cycle time and data security .........................................................................1-39
Replacement of modules on the CS31 system bus ............................................................................... 1-39
Serial interface COM2 ........................................................................................................... 1-40
FieldBusPlug / FBP .............................................................................................................................. 1-42
Wiring...................................................................................................................................................... 1-42
Bus topology ........................................................................................................................................... 1-42
Modbus.................................................................................................................................................... 1-43
General ................................................................................................................................................... 1-43
Bus topology ........................................................................................................................................... 1-43
Number of user data, bus cycle time and data security .........................................................................1-43
PROFIBUS .............................................................................................................................................. 1-44
ISO/OSI model........................................................................................................................................ 1-44
Typical Field Bus Topologies.................................................................................................................. 1-45
Overview of transferred data .................................................................................................................. 1-46
PROFIBUS DP-V0 <---> PROFIBUS DP-V1 .......................................................................................... 1-46
Wiring...................................................................................................................................................... 1-49
Bus line ............................................................................................................................................... 1-49
Cable lengths...................................................................................................................................... 1-49

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V2 AC500 Hardware 1-3 System data AC500 / Issued: 05.2007
Ethernet................................................................................................................................................... 1-50
Wiring...................................................................................................................................................... 1-50
Bus line ............................................................................................................................................... 1-50
Cable length restrictions .................................................................................................................... 1-50
ARCNET .................................................................................................................................................. 1-51
The ARCNET system (Attached Resource Computer Network) ............................................................ 1-51
ARCNET bus topology............................................................................................................................ 1-51
The networking possibilities of Linear ARCNET ................................................................................ 1-51
Linear ARCNET, expanded by active distribution units (Active Hubs) ............................................... 1-52
Wiring...................................................................................................................................................... 1-53
General considerations for EMC-conforming assembly and
construction .................................................................................................................................... 1-54
General principles ............................................................................................................................... 1-54
Cable routing ......................................................................................................................................... 1-54
Cable shields ......................................................................................................................................... 1-55
Switch-gear cabinet ............................................................................................................................. 1-55
Reference potential .............................................................................................................................. 1-55
Equipotential bonding ........................................................................................................................ 1-56
Power consumption of an entire station ........................................................................................ 1-57

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V2 AC500 Hardware 1-4 System data AC500 / Issued: 05.2007
AC500 System data and system construction
The product family Advant Controller 500 control system is designed according to EN 61131-2 IEC
61131-2 standards. Data, different from IEC 61131, are caused by the higher requirements of Maritime
Services.
System data
Operating and ambient conditions
Voltages, according to EN 61131-2
process and supply
voltage
24 V DC (-15 %, +20 % without ripple)
absolute limits 19.2 V...30 V inclusive ripple (see remarks above)
ripple < 5 %
24 V DC
protection against
reverse polarity
10 s
line voltage 120 V AC (-15 %, +10 %)120 V AC
frequency 47 Hz..62.4 Hz / 50...60 Hz (-6 %, +4 %)
line voltage 230 V AC (-15 %, +10 %)230 V AC
frequency 47 Hz..62.4 Hz / 50...60 Hz (-6 %, +4 %)
wide-range supply
line voltage 102 V...264 V / 120 V...240 V (-15 %, +10 %)
120-240 V AC
frequency 47 Hz..62.4 Hz / 50...60 Hz (-6 %, +4 %)
Allowed interruptions of power supply, according to EN 61131-2
DC supply interruption < 10 ms,
time between 2 interruptions > 1 s, PS2
AC supply Interruption < 0.5 periods,
time between 2 interruptions > 1 s
Important: Exceeding the maximum power supply voltage (>30 V DC) for process or supply
voltages could lead to unrecoverable damage of the system. The system could be destroyed.
Temperature
operating 0 °C...+60 °C (horizontal mounting of modules)
0 °C...+40 °C (vertical mounting of modules and output
load reduced to 50 % per group)
storage -25 °C...+75 °C
transport -25 °C...+75 °C
Temperature of the Lithium battery
operating 0 °C...+60 °C
storage -20 °C...+60 °C
transport -20 °C...+60 °C
Humidity max. 95 %, without condensation
Air pressure
operating > 800 hPa / < 2000 m
storage > 660 hPa / < 3500 m

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V2 AC500 Hardware 1-5 System data AC500 / Issued: 05.2007
Creepage distances and clearances
The creepage distances and clearances meet the overvoltage category II, pollution degree 2.
Insulation test voltages, routine test, according to EN 61131-2
230 V circuits against other circuitry 2500 V surge 1.2/50 µs
120 V circuits against other circuitry 1500 V surge 1.2/50 µs
120 V to 240 V circuits against other circuitry 2500 V surge 1.2/50 µs
24 V circuits (supply, 24 V inputs/outputs), if they are
electrically isolated against other circuitry
500 V surge 1.2/50 µs
COM interfaces, electrically isolated 500 V surge 1.2/50 µs
FBP interface 500 V surge 1.2/50 µs
Ethernet 500 V surge 1.2/50 µs
ARCNET 500 V surge 1.2/50 µs
230 V circuits against other circuitry 1350 V AC 2 s
120 V circuits against other circuitry 820 V AC 2 s
120 V to 240 V circuits against other circuitry 1350 V AC 2 s
24 V circuits (supply, 24 V inputs/outputs), if they are
electrically isolated against other circuitry
350 V AC 2 s
COM interfaces, electrically isolated 350 V AC 2 s
FBP interface 350 V AC 2 s
Ethernet 350 V AC 2 s
ARCNET 350 V AC 2 s
Power supply units
For the supply of the modules, power supply units according to PELV specifications must be used.

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V2 AC500 Hardware 1-6 System data AC500 / Issued: 05.2007
Electromagnetic compatibility
Immunity
against electrostatic discharge (ESD) according to EN 61000-4-2, zone B, criterion B
- electrostatic voltage in case of air discharge 8 kV
- electrostatic voltage in case of contact
discharge
4 kV, in a closed switch-gear cabinet 6 kV ¹)
ESD with communication connectors In order to prevent operating malfunctions, it is
recommended, that the operating personnel
discharge themselves prior to touching
communication connectors or perform other
suitable measures to reduce effects of
electrostatic discharges.
ESD with connectors of Terminal Bases The connectors between the Terminal Bases and
CPUs or couplers must not be touched during
operation. The same is valid for the I/O-Bus with
all modules involved.
Immunity
against the influence of radiated (CW radiated) according to EN 61000-4-3, zone B, criterion A
- test field strength 10 V/m
Immunity
against transient interference voltages (burst) according to EN 61000-4-4, zone B, criterion B
- supply voltage units (AC, DC) 2 kV
- digital inputs/outputs (24 V DC) 1 kV
- digital inputs/outputs (120/230 V AC) 2 kV
- analog inputs/outputs 1 kV
- CS31 system bus 2 kV
- serial RS-485 interfaces (COM) 2 kV
- serial RS-232 interfaces (COM) 1 kV
- ARCNET 1 kV
- FBP 1 kV
- Ethernet 1 kV
- I/O supply, DC-out 1 kV
Immunity
against the influence of line-conducted
interferences (CW conducted)
according to EN 61000-4-6, zone B, criterion A
- test voltage 3V zone B, 10 V is also met.
High energy surges according to EN 61000-4-5, zone B, criterion B
- power supply AC 2 kV CM* / 1 kV DM*
- power supply DC 1 kV CM* / 0.5 kV DM*
- AC I/O supply, add. AC-supply-out 2 kV CM* / 1 kV DM*
- DC I/O supply, add. DC-supply-out 0.5 kV CM* / 0.5 kV DM*
- Buses, shielded 1 kV CM*
- AC-I/O unshielded 2 kV CM* / 1 kV DM*
- I/O analog, I/O DC unshielded 1 kV CM* / 0.5 kV DM*
* CM = Common Mode, * DM = Differential Mode
Radiation (radio disturbance) according to EN 55011, group 1, class A
¹) High requirement for shipping classes are achieved with additional specific measures (see specific
documentation).

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V2 AC500 Hardware 1-7 System data AC500 / Issued: 05.2007
Mechanical data
Wiring method / terminals
Mounting horizontal
Degree of protection IP 20
Housing according to UL 94
Vibration resistance acc. to EN 61131-2 all three axes
2 Hz...15 Hz, continuous 3.5 mm
15 Hz...150 Hz, continuous 1 g (4 g in preparation)
Vibration resistance with SD Memory Card
inserted
15 Hz...150 Hz, continuous 1 g
Shock test all three axes
15 g, 11 ms, half-sinusoidal
Shipping specific requirements
Mounting of the modules
- DIN rail according to DIN EN 50022 35 mm, depth 7.5 mm or 15 mm
- mounting with screws screws with a diameter of 4 mm
fastening torque 1.2 Nm

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V2 AC500 Hardware 1-8 System data AC500 / Issued: 05.2007
Mounting and disassembling the Terminal Bases, the CPUs and the couplers
Assembly on DIN rail
Step 1: Mount DIN rail 7.5 mm or 15 mm
Step 2: Mount Terminal Base (TB521, TB521, TB541)
Figure: Assembly of the Terminal Base (TB511, TB521 or TB541)
The Terminal Base is put on the DIN rail above and then snapped-in below. The disassembly is carried
out in a reversed order.
Figure: Disassembly of the Terminal Base (TB511, TB521 or TB541)

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V2 AC500 Hardware 1-9 System data AC500 / Issued: 05.2007
Step 3: Mount I/O Terminal Unit (TU515, TU516, TU531 or TU532)
Figure: Assembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532)
The I/O Terminal Unit is snapped into the DIN rail in the same way as the Terminal Base. Once secured
to the DIN rail, slide the I/O unit to the left until it fully locks into place creating a solid mechanical and
electrical connection.
Altogether 7 I/O Terminal Units can be combined with the Terminal Base.
If both of the following conditions are fulfilled, max. 10 I/O Terminal Units can be combined with the
Terminal Base:
- PS501 as of version V1.2
- CPUs as of firmware V1.2.0
1 ... 7 (10) *)
Figure: Maximum configuration (1 Terminal Base plus 7 I/O Terminal Units)
*) If both of the following conditions are fulfilled, max. 10 I/O Terminal Units can be combined with the
Terminal Base:

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V2 AC500 Hardware 1-10 System data AC500 / Issued: 05.2007
- PS501 as of version V1.2
- CPUs as of firmware V1.2.0
Figure: Disassembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532)
A screwdriver is inserted in the indicated place to separate the Terminal Units.
Step 4: Mount the CPU
PM581
Figure: Assembly of the CPU
Press the CPU into the Terminal Base until it locks in place.

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V2 AC500 Hardware 1-11 System data AC500 / Issued: 05.2007
The disassembly is carried out in a reversed order.
1
2
1
Figure: Disassembly of the CPU
Disassembly: Press above and below, then remove the CPU.
Step 5: Mount the coupler (communication module)
Figure: Assembly of a coupler
The coupler is first inserted below, then clicked-in above.

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V2 AC500 Hardware 1-12 System data AC500 / Issued: 05.2007
The disassembly is carried out in a reversed order.
1
2
1
Figure: Disassembly of a coupler
Disassembly: Press above (and below), then swing out the coupler and remove it.
The following figure shows a Terminal Base with a CPU and two couplers inserted.
PM581CM577CM572

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V2 AC500 Hardware 1-13 System data AC500 / Issued: 05.2007
Assembly with screws
If the Terminal Base should be mounted with screws, Wall Mounting Accessories TA526 must be
inserted at the rear side first. These plastic parts prevent bending of the Terminal Base while screwing
on. TB511 needs one TA526, TB521 and TB541 need two TA526.
Holes for wall mounting
1
2
1
3
Rear view
Rear view
Front view
Figure: Fastening with screws of the Terminal Base TB521-ETH (as an example)
1 The two Wall Mounting Accessories TA526 are snapped on the rear side of the Terminal Unit like DIN
rails. The arrows point to the middle of the Terminal Base. One TA526 is turned by 180°.
2 Two accessories for wall mounting inserted
3 Terminal Base, fastened with screws
By wall mounting, the Terminal Base is earthed through the screws. It is necessary that
•the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-plated)
•the mounting plate is earthed
•the screws have a good electrical contact to the mounting plate

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V2 AC500 Hardware 1-14 System data AC500 / Issued: 05.2007
Mounting and disassembling the Terminal Units and the I/O modules
Assembly on DIN rail
Step 1: Mount DIN rail 7.5 mm or 15 mm
Step 2: Mount FBP Terminal Unit (TU505 or TU506)
Figure: Assembly of the FBP Terminal Unit (TU505 or TU506)
The FBP Terminal Unit is put on the DIN rail above and then snapped-in below. The disassembly is
carried out in a reversed order.
Figure: Disassembly of the FBP Terminal Unit (TU505 or TU506)

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V2 AC500 Hardware 1-15 System data AC500 / Issued: 05.2007
Step 3: Mount I/O Terminal Unit (TU515, TU516, TU531 or TU532)
Figure: Assembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532)
The I/O Terminal Unit is installed on the DIN rail in the same way as the FBP Terminal Unit. Once
secured on the DIN rail, slide the I/O unit to the left until it fully locks into place creating a solid
mechanical and electrical connection.
Altogether 7 I/O Terminal Units can be combined with the FBP Terminal Unit.
12 7...
Figure: Maximum configuration (1 FBP Terminal Unit plus 7 I/O Terminal Units)
Important: Up to 7 I/O modules can be used, of which up to 4 analog I/O modules are possible.

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V2 AC500 Hardware 1-16 System data AC500 / Issued: 05.2007
Figure: Disassembly of the I/O Terminal Unit (TU515, TU516, TU531 or TU532)
A screwdriver is inserted in the indicated place to separate the Terminal Units.
Step 4: Mount the modules
DC532
Figure: Assembly of the modules
Press the electronic module into the Terminal Unit until it locks in place.

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V2 AC500 Hardware 1-17 System data AC500 / Issued: 05.2007
The disassembly is carried out in a reversed order.
1
2
1
Figure: Disassembly of the modules
Disassembly: Press obove and below, then remove the module.
Assembly with screws
If the Terminal Unit should be mounted with screws, a Wall Mounting Accessory TA526 must be inserted
at the rear side first. This plastic part prevents bending of the Terminal Unit while screwing on.
1
2
Front view
Rear view
Rear view
Holes for
wall mounting
31
Figure: Fastening with screws of the Terminal Unit TU516 (as an example)
1 The Wall Mounting Accessory TA526 is snapped on the rear side of the Terminal Unit like a DIN rail.
The arrow points to the right side.
2 Accessory for wall mounting inserted
3 Terminal Unit, fastened with screws

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V2 AC500 Hardware 1-18 System data AC500 / Issued: 05.2007
By wall mounting, the Terminal Unit is earthed through the screws. It is necessary that
•the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-plated)
•the mounting plate is earthed
•the screws have a good electrical contact to the mounting plate
Mechanical dimensions AC500
2828
59 (2.32)
70.5 (2.78)
135 (5.31)
67.5 (2.66)
(1.10)(1.10)
95.5 (3.76)
(2.27)
57.7
(1.59)
40.3 4.9 (0.19)
TB511
123.5 (4.86)TB521
179.5 (7.07)TB541
28
(1.10)
28
(1.10) 135 mm
(5.31) inches
Dimensions:
Figure: Dimensions of the AC500 CPU Terminal Bases TB511, TB521 and TB541

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V2 AC500 Hardware 1-19 System data AC500 / Issued: 05.2007
28
13 (0.51)
62 (2.44)
75 (2.95)
59 (2.32)
135 (5.31)
76 (2.99)
77 (3.03)
84.5 (3.33)
(1.10)
135 mm
(5.31) inches
Dimensions:
View on the left side
DIN rail 15 mm
DIN rail 7.5 mm
Figure: Terminal Base with coupler, view from the left side
67.5 (2.66)
TU505/506
59 (2.32)
70.5 (2.78)
TU515/516/531/532
135 (5.31)
67.5 (2.66)
(2.27)
DC505
135 mm
(5.31) inches
57.7
Dimensions:
Figure: Dimensions of the S500 Terminal Units (front view)

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V2 AC500 Hardware 1-20 System data AC500 / Issued: 05.2007
28
21 (0.83)
54 (2.13)
75 (2.95)
59 (2.32)
70.5 (2.78)
135 (5.31)
76 (2.99)
View on the left side View on the right side
77 (3.03)
84.5 (3.33)
DIN rail 15 mm
DIN rail 7.5 mm
135 mm
(5.31) inches
Dimensions:
(1.10)
Figure: Dimensions of the S500 Terminal Units (view from the left and the right side)