ABB S500 User guide

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V2 S500 Hardware 1-1 System Data S500 / Issued: 01.2007
System Data S500, Overview
S500 system data, assortment Page 1-3
Use of the S500 I/O modules 1-4
Diagnosis LEDs 1-5
Mounting and disassembling the Terminal Units and the I/O modules 1-13
Mechanical dimensions S500 1-17
Switch-gear cabinet assembly 1-19
Connection system 1-20
Mechanical encoding 1-24
General wiring recommendations 1-26
Behaviour of the system in case of power supply interruptions and power recovery 1-26
Block diagrams, earthing concept 1-26

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V2 S500 Hardware 1-2 System Data S500 / Issued: 01.2007

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V2 S500 Hardware 1-3 System Data S500 / Issued: 01.2007
S500 System data
The same system data as for the system AC500 apply to the system S500-FBP. Only additional details
are therefore documented here.
Assortment
Parts of the S500-FBP system are
• the FBP Interface Module DC505-FBP
• digital I/O modules
• analog I/O modules
• Terminal Units for the FBP Interface Module and the I/O modules
• accessories
The FBP Interface Module DC505-FBP serves for the data interchange between a fieldbus and the I/O
modules attached to the FBP Interface Module. The FBP interface module itself also has some digital
inputs and outputs. The fieldbus type is defined by the choice of the FieldBusPlug (see documentation
FieldBusPlug / FBP).
Subjects (overview)
Use of the S500 I/O modules ..................................................................................................................... 1-4
Diagnosis LEDs .......................................................................................................................................... 1-5
Mounting and disassembling the Terminal Units and the I/O modules ................................................... 1-13
Mechanical dimensions S500 ................................................................................................................... 1-17
Switch-gear cabinet assembly ................................................................................................................. 1-19
Connection system .................................................................................................................................. 1-20
Mechanical encoding ............................................................................................................................... 1-24
General wiring recommendations ............................................................................................................ 1-26
Behaviour of the system in case of power supply interruptions and power recovery .............................. 1-26
Block diagrams, earthing concept ............................................................................................................ 1-27

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V2 S500 Hardware 1-4 System Data S500 / Issued: 01.2007
Use of the S500 I/O modules
The S500 I/O modules either can be attached directly to an AC500 CPU (central expansion) or be
operated by the FBP Interface Module DC505-FBP (decentralized expansion).
DC532DC532PM581CM577CM572
DIN rail,
earthed
Mounting
plate,
earthed
Figure: S500 I/O modules directly attached to an AC500 CPU (central I/O expansion)
DC532DC532DC505
DIN rail,
earted
Mounting
plate,
earthed
Figure: S500 I/O modules attached to the FBP Interface Module DC505-FBP (decentralized expansion)

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V2 S500 Hardware 1-5 System Data S500 / Issued: 01.2007
Diagnosis LEDs
All S500 modules have LEDs for the display of operating statuses and error messages. They indicate:
LED Status Color LED = ON LED = OFF LED flashes
digital input yellow input = ON input = OFF --Input
analog input yellow brightness depends on the value of the
analog signal
--
digital output yellow output = ON output = OFF --Output
analog output yellow brightness depends on the value of the
analog signal
--
UP process
voltage 24 V
DC via
terminal
green voltage is present voltage is missing --
PWR supply voltage
24 V DC via
FBP
green voltage is present voltage is missing --
S-ERR Sum Error red serious error, data
exchange is
stopped, depends
on the behaviour of
the master
no error error (e.g. error
on one
channel, data
exchange is not
stopped
FBP FBP
communication
green communication
between FBP and
FBP Interface
Module is running
communication
between FBP and
FBP Interface
Module is broken
during
initialization
I/O-Bus I/O-Bus
communication
green communication
between FBP
Interface Module
and the I/O
modules is running
no communication
between FBP
Interface Module
and the I/O
modules
error on one I/O
expansion
module (e.g.
one output
short-circuited)
CH-ERR1 red
CH-ERR2 red
CH-ERR3 red
CH-ERR4
Channel Error,
error
messages in
groups (digital
or analog
inputs and
outputs
combined into
the groups 1,
2, 3, 4)
red
serious error within
the corresponding
group
no error error on one
channel of the
corresponding
group (e.g. one
output short-
circuited)
CH-ERR
*)
Module Error red error within the I/O
module
-- --
*) All of the LEDs CH-ERR1 to CH-ERR4 (as far as they exist) light up together

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V2 S500 Hardware 1-6 System Data S500 / Issued: 01.2007
Display, if the FBP is not plugged
DC505 AX522 DC532 DI524 DX522
FBP not plugged
UP is present at all modules,
initialization is impossible because of missing FBP power supply
Situation:
LEDs:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4 UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DC532 DI524 DX522
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
Figure: LED displays, if the FBP is not plugged
Display examples during the initialization
Initialization of DC505-FBP without I/O modules attached
UP present, FBP plugged
Situation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2
DC505-FBP
DC505
LEDs before initialization, UP is present
LEDs during initialization (I/O-Bus + FBP)
LEDs after successful initialization (normal condition)
The module remains uninitialized, if errors occurCase A2
Case A1
Case A3
LEDs: LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
Figure: Initialization DC505-FBP without I/O modules attached

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V2 S500 Hardware 1-7 System Data S500 / Issued: 01.2007
AX522 DC532 DX522
Initialization with I/O modules present
UP is present at all modules, FBP is plugged
Situation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DC532 DX522
DC505 DX522
more than 77654321 ...
DI524
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DI524
UP CH-ERR1 CH-ERR2
DX522
LEDs before initialization, UP is present, number of I/O modules < 7
LEDs during initialization of the I/O-Bus, number of I/O modules > 7
initialization will not succeed because of too big number of I/O modules, FBP does not
get an address, no communication with the fieldbus master
LEDs during FBP initialization, number of I/O modules max. 7
LEDs after successful initialization (normal condition)
Case B1
Case B2
Case B3
Case B4
I/O modules
LEDs:
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
Figure: Initialization DC505-FBP with I/O modules attached

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V2 S500 Hardware 1-8 System Data S500 / Issued: 01.2007
AX522 DX522
Initialization with one I/O module missing
UP is present at all modules, FBP is plugged
Situation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DX522
DC505 DI524
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DI524
LEDs before initialization, UP is present
LEDs during initialization
initialization of e.g. two modules successful, FBP, however, blocks the access by
FBP-Conf_error, the red LED CONF flashes
Case C1
Case C2
LEDs:
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
Figure: Initialization with one I/O module missing

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V2 S500 Hardware 1-9 System Data S500 / Issued: 01.2007
AX522 DX522
Initialization, if more I/O modules present than have been configured
UP is present at all modules, FBP is plugged
Situation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DX522
DC505 DI524
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DI524
LEDs before initialization, UP is present
LEDs during initialization
initialization of e.g. five modules (instead of 3) successful, FBP, however, blocks
the access by FBP-Conf_err, the red LED CONF flashes, details see the
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DC532
DC532
FBP user documentation
Case D1
Case D2
LEDs:
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
Figure: Initialization, if more I/O modules present than have been configured

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V2 S500 Hardware 1-10 System Data S500 / Issued: 01.2007
Display examples for running operation
AX522 DX522
All modules OK, then UP fails at one module
UP still present at all the other modules, FBP plugged
Situation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DX522
DC505 DI524
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DI524
The module sends an error message to the master,
Case 2: UP is missing at one I/O module (DC532), error message see above
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DC532
DC532
the master has to evaluate the error (STOP or GO)
Case 1: UP is missing at DC505-FBP
All modules OK, then an FBP communication error appears
UP is present at all modules, FBP is plugged
Situation:
After 2 seconds the FBP is initialized again (see cases A2 or B3
All modules OK, then an I/O bus error appears at one I/O module
UP is present at all modules, FBP is plugged
Situation:
An I/O bus error is sent to the fieldbus master, the I/O-Bus turns to the reset status or
gets the replacement values
LEDs:
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
of the initialization processes)
Figure: Appearance of errors in running operation

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V2 S500 Hardware 1-11 System Data S500 / Issued: 01.2007
AX522 DX522
All modules OK, then one of the I/O modules is removed
UP is present at all modules, FBP is plugged
Situation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DX522
DC505 DI524
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DI524
An I/O bus error is sent to the fieldbus master, the I/O-Bus turns to the reset status or
gets the replacement values
After that, an I/O module of an other type is inserted
into the free place
Situation:
The status of the error message remains unchanged
LEDs:
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
Figure: One module was removed and then replaced by a module of an other type

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V2 S500 Hardware 1-12 System Data S500 / Issued: 01.2007
AX522 DX522
Internal error on the processor card of the FBP Interface ModuleSituation:
PWR FBP S-ERR I/O-Bus UP CH-ERR1 CH-ERR2 UP CH-ERR2 CH-ERR4 UP CH-ERR1 CH-ERR2
DC505-FBP AX522 DX522
DC505 DI524
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DI524
No function at all, the I/O-Bus turns to the reset status or gets the replacement values
UP CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4
DC532
DC532
All modules OK, but there is an overload or short-circuit at oneSituation:
Everything is still running, but an error message is sent to the fieldbus master
output of the FBP Interface Module DC505-FBP
All modules OK, but there is an overload or short-circuit at oneSituation:
output of an I/O expansion module
Internal error on the I/O card of the FBP Interface ModuleSituation:
UP is present at all modules,
FBP is plugged
Internal error on the I/O card of an I/O expansion moduleSituation:
All modules OK, but there is a broken wire at an analog outputSituation:
A wrong parameter was sent to a moduleSituation:
An error message is sent to the fieldbus master
LEDs:
LED OFF
green LED ON
green LED flashes
red LED ON
red LED flashes
No function at all, the I/O-Bus turns to the reset status or gets the replacement values
No function at all, the I/O-Bus turns to the reset status or gets the replacement values
Everything is still running, but an error message is sent to the fieldbus master
Everything is still running, but an error message is sent to the fieldbus master
Figure: Displays in case of different errors

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V2 S500 Hardware 1-13 System Data S500 / Issued: 01.2007
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 S500 Hardware 1-14 System Data S500 / Issued: 01.2007
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 S500 Hardware 1-15 System Data S500 / Issued: 01.2007
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 S500 Hardware 1-16 System Data S500 / Issued: 01.2007
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 S500 Hardware 1-17 System Data S500 / Issued: 01.2007
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 S500
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 Terminal Units (front view)

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V2 S500 Hardware 1-18 System Data S500 / Issued: 01.2007
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 Terminal Units and modules (lateral views)
TB521-ETH
2828
59 (2.32)
70.5 (2.78)
135 (5.31)
67.5 (2.66)
(1.10)(1.10)
123.5 (4.86)
(2.27)
57.7
(1.59)
40.3
135 mm
(5.31) inches
Dimensions:
4.9 (0.19)
Figure: Dimensions of the AC500 CPU Terminal Base TB521-ETH (for comparison)

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V2 S500 Hardware 1-19 System Data S500 / Issued: 01.2007
Switch-gear cabinet assembly
Basically, it is recommended to mount the modules on an earthed mounting plate, independent of the
mounting location.
DC532DC532DC505
DC532DC532DC505
DIN rail,
earthed
Mounting
plate,
earthed
DIN rail,
earted
Mounting
plate,
earthed
Cable duct
20 mm minimum distance between
the modules and the cable duct
Figure: Installation of AC500/S500 modules in a switch-gear cabinet

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V2 S500 Hardware 1-20 System Data S500 / Issued: 01.2007
Important: Horizontal mounting is highly recommended. Vertical mounting is possible, however,
derating consideration should be made to avoid problems with poor air circulation and the potential for
excessive temperatures (see also the AC500 system data, operating and ambient conditions, for
reduction of ambient temperature).
Note: By vertical mounting, always place an end-stop terminal block at the bottom and on the top
of the module to properly secure the modules.
By high-vibration applications, we also recommend to place end-stop terminals at the right and the left
side of the device to properly secure the modules:
e.g. type BADL, P/N: 1SNA 399 903 R0200
Connection system
Terminals for power supply and the COM1 interface (CPU Terminal Base AC500)
L+
M
L+
M
FE
1
2
3
4
5
6
7
8
9
COM1
Figure: Terminals for power supply and the COM1 interface (CPU Terminal Base AC500)
Terminal type: Screw-type terminal
Number of cores per terminal Conductor type Cross section
1 solid 0.08 mm² to 1.5 mm²
1 flexible 0.08 mm² to 1.5 mm²
1 with wire end ferrule (without plastic
sleeve)
flexible 0.25 mm² to 1.5 mm²
1 with wire end ferrule (with plastic
sleeve)
flexible 0.25 mm² to 0.5 mm²
1 (TWIN wire end ferrule) flexible 0.5 mm²
2 (with the same cross section) solid 0.08 mm² to 0.5 mm²
2 (with the same cross section) flexible 0.08 mm² to 0.75 mm²
2 (with the same cross section) in
wire end ferrule, without plastic sleeve
flexible 0.25 mm² to 0.34 mm²