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’