Related Manuals for ABB AC500 V3
Summary of Contents for ABB AC500 V3
- Page 1 SYSTEM MANUAL PLC Automation Automation Builder, programmable logic control- lers, control panels Automation Builder, AC500 V3, AC500-eCo V3, AC500-XC V3, AC500-S, CP600, CP600-eCo, CP600-Pro...
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Page 2: Table Of Contents
Table of contents Preface................................4 1.1 Guidance through the documentations..................... 4 1.2 Do I have AC500 V2 or AC500 V3?......................4 1.3 Regulations............................... 5 1.4 Older revisions of this document....................... 5 1.5 Use the "magic button" to display your current position in the table of contents........6 1.6 Structure of safety notices......................... - Page 3 Table of contents 5.13 Control panels CP600........................... 57 Wiring................................58 6.1 Grounding concept..........................58 6.2 EMC-conforming assembly and construction..................59 6.2.1 General principles........................59 6.2.2 Cable routing..........................60 6.2.3 Cable shields..........................61 6.2.4 Control cabinet......................... 61 6.2.5 Reference potential........................62 6.2.6 Equipotential bonding.......................
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Page 4: Preface
– Release notes for the latest version of the engineering suite Automation Builder 1.2 Do I have AC500 V2 or AC500 V3? This document describes AC500 V3 products. We offer different ranges of the processor modules (V2, V3). You can easily find out which ones are used in your system. -
Page 5: Regulations
Processor module type PM + PM564 AC500 V2 3 digits Processor module type PM + PM5675 AC500 V3 (this manual) 4 digits 1.3 Regulations Planning and The planning and installation of the electrical system must be carried out in compliance with the installation of applicable regulations and standards. -
Page 6: Use The "Magic Button" To Display Your Current Position In The Table Of Contents
Preface Structure of safety notices Revisions Select any of the revisions Latest revision Get a link to the latest revision This revision Get a direct link to the selected revision 1.5 Use the "magic button" to display your current position in the table of con- tents Documentation is opened in a PDF reader. - Page 7 Preface Structure of safety notices Signal words DANGER! DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. Ensure to take measures to prevent the described impending danger. WARNING! WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
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Page 8: Safety Instructions
The examples and diagrams in this manual are included solely for illustrative purposes. mation Because of the many variants and requirements associated with any particular installation, ABB cannot assume responsibility or liability for actual use based on the examples and diagrams. - Page 9 Safety instructions NOTICE! Use of suitable enclosure The devices must be mounted in a control cabinet that ensures compliance with the specified environmental conditions. Cleaning instructions Do not use cleaning agent for cleaning the device. Use a damp cloth instead. Connection plans and a user program must be created so that no dangerous situations can occur during normal operation or failure.
- Page 10 The devices must not be opened when in operation. The same applies to the network interfaces. Information on batteries CAUTION! Use only ABB approved lithium battery modules! At the end of the battery’s lifetime, always replace it only with a genuine battery module. CAUTION! Risk of explosion! Do not open, re-charge or disassemble lithium batteries.
- Page 11 Safety instructions Environment considerations Recycle exhausted batteries. Dispose of batteries in an environmentally con- scious manner in accordance with regulations issued by the local authorities. 2023/03/03 3ADR011074, 1, en_US...
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Page 12: System Overview
System overview AC500 PLC product family — 3 System overview 3.1 AC500 PLC product family AC500 program- The AC500 (Standard), AC500-eCo, AC500-S and AC500-XC scalable PLC ranges provide mable logic con- solutions for small, medium and high-end applications. Our AC500 platform offers different trollers (PLCs) performance levels and is the ideal choice for high availability, extreme environments or safety solutions. -
Page 13: Ac500/S500 System Structure
System overview AC500/S500 system structure S500 devices represent the I/O modules of the product group AC500 (Standard), whereas S500-eCo devices represent the I/O modules of the product group AC500-eCo. Both S500 and S500-eCo devices can be flexibly combined with devices of the AC500 product family. 3.2 AC500/S500 system structure The AC500 product family provides a variety of modules and pluggable components for expanding the capabilities of the processor module with additional I/Os or other communication... -
Page 14: Ac500-Eco/S500-Eco System Structure
System overview AC500-eCo/S500-eCo system structure Decentralized I/O extension Terminal unit for communication interface modules Communication interface module with up to 24 integrated I/Os I/O bus Terminal unit for I/O modules, with screw or spring connection Terminal unit for hot swap of I/O modules to exchange of I/O modules while the system is running S500 I/O modules with up to 32 channels for analog and/or digital signals Compact S500-eCo I/O modules with up to 16 channels for analog and/or digital signals... - Page 15 System overview AC500-eCo/S500-eCo system structure AC500-eCo processor module with option boards, different memory sizes, inputs and out- puts available S500-eCo I/O module, up to 10 I/O modules can be connected, also for decentralized extension Terminal blocks in different variants available Centralized I/O Processor modules with an I/O bus interface on the right side can be expanded by up to 10 I/O extension...
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Page 16: Ac500/S500: Short Description Hardware
System overview AC500/S500: Short description hardware Fig. 4: I/O modules (S500-eCo) connected to an AC500-eCo processor module via Modbus/TCP network, using a Modbus/TCP communication interface module or a processor module as client. 3.4 AC500/S500: Short description hardware Processor modules AC500 processor modules contain the CPU with the core component of the PLC. The CPU is connected with the user memory, input and output module, communication port and other units via the system bus and performs tasks by means of system programs preset in the system memory. - Page 17 System overview AC500/S500: Short description hardware AC500 communication modules are required for ● a connection to standard fieldbus systems and ● for integration into existing networks. AC500 communication modules ● enable communication on different fieldbuses. ● are mounted on the left side of the processor module on the same terminal base. ●...
- Page 18 System overview AC500/S500: Short description hardware On AC500-eCo processor modules and special AC500 (Standard) processor modules the terminal base cannot be removed. I/O modules The I/O modules are the input/output unit which connects the PLC with the process. The PLC can detect controlled object data via the input interface and the data is taken as the basis for PLC control on the controlled object.
- Page 19 System overview AC500/S500: Short description hardware Communication interface modules Communication interface modules are used to build decentralized I/O stations in decentralized systems. They contain the fieldbus interface and a set of onboard I/O channels. Additional I/O modules can be attached to build larger decentralized I/O stations. A communication interface module is mounted on a terminal unit.
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Page 20: Ac500-Eco/S500-Eco: Short Description Hardware
System overview AC500-eCo/S500-eCo: Short description hardware 3.5 AC500-eCo/S500-eCo: Short description hardware Processor modules AC500-eCo processor modules contains the CPU with the core microprocessor of the PLC. It is integrated with power supply, onboard I/Os and communication interface. Functions: ● To download user programs ●... -
Page 21: Ac500-S
System overview AC500-S I/O modules If the number of onboard I/Os provided on the processor module is insufficient for a certain use case, the PLC can be expanded with I/O modules to meet the control requirements. Memory In the PLC, the memory is mainly used for saving system programs, user programs and work data. -
Page 22: Cp600 Control Panels
System overview Automation Builder: Short description engineering software ● DX581-S ● AI581-S ● TU582-S 3.7 CP600 control panels CP600 control The CP600-eCo, CP600 and CP600-Pro control panels offer a wide range of features and panels platform functionalities for tailor-made visualization. Our CP600 platform offers different performance levels including control panels for economic applications, robust standard operator panels, high end multi-touch human machine interfaces (HMIs). - Page 23 System overview Automation Builder: Short description engineering software ● Export and import interfaces for devices, signals, applications, visualization, etc. ● Multi-user support and project compare ● Project scripting Offline simula- IEC 61131-3 commands can be simulated without a PLC being connected, including the rele- tion vant malfunctions.
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Page 24: Application Planning
Application planning Communication within the PLC — 4 Application planning 4.1 Processor module and I/O selection How to select modules for your automation task: In our main catalog we offer a CPU selector and several comparative tables to find the modules for your application. Reference documentation for hardware 4.2 Communication within the PLC The synchronized serial I/O bus is the I/O data bus for the I/O modules connected with the... - Page 25 Application planning Communication within the PLC WARNING! Removal/Insertion under power Removal or insertion under power is permissible only if all conditions for hot swapping are fullfilled. Ä Chapter 11.2 “Replace an I/O module with hot swap” on page 91 The devices are not designed for removal or insertion under power when the conditions for hot swap do not apply.
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Page 26: Power Supply Dimensioning
Application planning Power supply dimensioning > Calculation of the total current consumption Parameter Value Minimum bus cycle time 500 µs This value is valid for all module combinations (from 1 to 10 I/O modules) Galvanic isolation I/O bus is galvanic connected to CPU and communication interface logic ciruits. - Page 27 Application planning Power supply dimensioning > Calculation of the total current consumption Because of the high total current consumption of the digital I/O modules (from UP = 24 V DC), the supply is divided up into several electric circuits fused separately.
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Page 28: Dimensioning Of The Fuses
Application planning Power supply dimensioning > Dimensioning of the fuses I/O bus LOADx CPU/communication module part 0.110 A 0.050 A 0.085 A 0.050 A 0.050 A I/O module part Analog1 0.002 A 0.150 A Analog2 0.002 A 0.150 A 0.160 A Analog3 0.002 A 0.100 A... -
Page 29: Libraries And Software
Application planning Libraries and software 4.4 Libraries and software Additional libraries and software packages for specific use cases are available to reduce the programming effort and implement quickly your application. In our main catalog we offer an overview of the available libraries and software packages. Reference documentation for the function blocks included in the libraries 2023/03/03 3ADR011074, 1, en_US... -
Page 30: Mechanical Planning And Installation
Mechanical planning and installation Control cabinet assembly for AC500 (Standard) — 5 Mechanical planning and installation 5.1 Control cabinet assembly for AC500 (Standard) PLC enclosure NOTICE! PLC damage due to wrong enclosures Due to their construction (degree of protection IP 20 according to EN 60529) and their connection technology, the devices are suitable only for operation in enclosed control cabinets. - Page 31 Mechanical planning and installation Control cabinet assembly for AC500 (Standard) Fig. 5: Installation of AC500/S500 modules in a control cabinet Cable duct Distance from cable duct ≥20 mm Mounting plate, grounded NOTICE! Horizontal mounting is highly recommended. Vertical mounting is possible, however, derating consideration should be made to avoid problems with poor air circulation and overheating.
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Page 32: Control Cabinet Assembly For Ac500-Eco
Mechanical planning and installation Control cabinet assembly for AC500-eCo When vertically mounted, always place an end-stop terminal block on the bottom and on the top of the modules to properly secure the modules. With high vibration applications and horizontal mounting, we also recommend to place end-stop terminals at the right and left side of the device to properly secure the modules. -
Page 33: Mounting And Demounting - General Information
Mechanical planning and installation Mounting and demounting - general information Fig. 6: Installation of AC500-eCo V3 CPU/S500 modules in a control cabinet Cable duct Distance from cable duct ≥20 mm Mounting plate, grounded NOTICE! Horizontal mounting is highly recommended. Vertical mounting is possible, however, derating consideration should be made to avoid problems with poor air circulation and overheating. -
Page 34: Optimized Mounting Of The Option Boards
Mechanical planning and installation Mounting and demounting - general information > Optimized mounting of the option boards All devices are grounded through the DIN rail to chassis ground. Use zinc plated yellow-chromate steel DIN rail to assure proper grounding. The use of other DIN rail materials (e.g. -
Page 35: Mounting And Demounting The Terminal Base
Mechanical planning and installation Mounting and demounting the terminal base 5.4 Mounting and demounting the terminal base Mounting and demounting on DIN rail Mount DIN rail 7.5 mm or 15 mm. Mount the terminal base/function module terminal base: ð The terminal base is put on the DIN rail above and then snapped-in below. The demounting is carried out in a reversed order. - Page 36 Mechanical planning and installation Mounting and demounting the terminal base Fig. 7: Terminal bases, Fastening with screws Fig. 8: Function module terminal bases, Fastening with screws By wall mounting, the terminal base is grounded through the screws. It is neces- sary that –...
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Page 37: Mounting And Demounting The Ac500 Processor Module
Mechanical planning and installation Mounting and demounting the AC500 processor module 5.5 Mounting and demounting the AC500 processor module After mounting the terminal base on the DIN rail, mount the processor module. Press the processor module into the terminal base until it locks in place. The demounting is carried out in a reversed order. -
Page 38: Mounting And Demounting The Terminal Unit
Mechanical planning and installation Mounting and demounting the terminal unit 5.6 Mounting and demounting the terminal unit Mounting on DIN rail Mount DIN rail 7.5 mm or 15 mm. Mount the terminal unit. The terminal unit is snapped into the DIN rail in the same way as the Terminal Base. Once secured to the DIN rail, slide the terminal unit to the left until it fully locks into place creating a solid mechanical and connection. -
Page 39: Mounting And Demounting The Communication Module
Mechanical planning and installation Mounting and demounting the communication module Fig. 9: Fastening with screws By wall mounting, the terminal unit is grounded through the screws. It is neces- sary that – the screws have a conductive surface (e.g. steel zinc-plated or brass nickel- plated) –... - Page 40 Mechanical planning and installation Mounting and demounting the communication module NOTICE! Risk of damaging the PLC modules! Overvoltages and short circuits might damage the PLC modules. – Make sure that all voltage sources (supply voltage and process supply voltage) are switched off before you begin with operations on the system. –...
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Page 41: Mounting And Demounting The I/O Module
Mechanical planning and installation Mounting and demounting the I/O module 5.8 Mounting and demounting the I/O module After mounting the terminal unit, mount the I/O modules. Press the I/O module into the terminal unit until it locks in place. The demounting is carried out in a reversed order. Press above and below, then remove the module. -
Page 42: Mounting And Demounting The Ac500-Eco Processor Module
Mechanical planning and installation Mounting and demounting the AC500-eCo processor module > Mounting a processor module on a DIN rail 5.9 Mounting and demounting the AC500-eCo processor module 5.9.1 Mounting a processor module on a DIN rail NOTICE! Risk of function faults! The processor module is grounded via DIN rail. -
Page 43: Demounting A Processor Module Mounted On A Din Rail
Mechanical planning and installation Mounting and demounting the AC500-eCo processor module > Demounting a processor module mounted on a DIN rail 5.9.2 Demounting a processor module mounted on a DIN rail Remove I/O modules if connected. While pressing down processor module pull it away from DIN rail. 2023/03/03 3ADR011074, 1, en_US... -
Page 44: Mounting A Processor Module On A Metal Plate
Mechanical planning and installation Mounting and demounting the AC500-eCo processor module > Mounting a processor module on a metal plate 5.9.3 Mounting a processor module on a metal plate NOTICE! Risk of function faults! Missing electrical contact by isolating screws or washers! Use metal screws on the metal plate. -
Page 45: Demounting A Processor Module Mounted On A Metal Plate
Mechanical planning and installation Mounting and demounting the AC500-eCo processor module > Demounting a processor module mounted on a metal plate 5.9.4 Demounting a processor module mounted on a metal plate Remove I/O modules if connected. Remove the 2 screws. 2023/03/03 3ADR011074, 1, en_US... -
Page 46: Mounting Of Ta5301-Cfa
Mechanical planning and installation Mounting and demounting the S500-eCo I/O module 5.9.5 Mounting of TA5301-CFA TA5301-CFA cable fixing accessory 2 openings on the PM50x2 processor module Insert the TA5301-CFA cable fixing accessory into the two openings on the PM50x2 processor module marked white in the figure. 5.10 Mounting and demounting the S500-eCo I/O module S500-eCo I/O modules can be mounted either on a DIN rail or with screws on a metal plate. - Page 47 Mechanical planning and installation Mounting and demounting the S500-eCo I/O module Attach I/O module by hand to an other module. The serial I/O bus is connected automati- cally. Demounting I/O modules mounted on a DIN rail Remove I/O module by hand if connected. 2023/03/03 3ADR011074, 1, en_US...
- Page 48 Mechanical planning and installation Mounting and demounting the S500-eCo I/O module While pressing down I/O module pull it away from DIN rail. Mounting I/O modules on a NOTICE! metal plate Risk of function faults! Missing electrical contact by isolating screws or washers! Use metal screws on the metal plate.
- Page 49 Mechanical planning and installation Mounting and demounting the S500-eCo I/O module Attach the I/O module by hand to an other module. The serial I/O bus is connected automatically. Fasten the I/O module with two screws (diameter: 4 mm) to the metal plate. 2023/03/03 3ADR011074, 1, en_US...
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Page 50: Accessories For Ac500 (Standard)
Mechanical planning and installation Accessories for AC500 (Standard) Demounting I/O modules mounted on a metal plate Remove the 2 screws. Remove the I/O module from the connected module by hand. 5.11 Accessories for AC500 (Standard) This section only describes accessories that are frequently used for system assembly, connec- tion and construction. -
Page 51: Inserting And Removing A Memory Card
Mechanical planning and installation Accessories for AC500 (Standard) > Inserting and removing a memory card 5.11.1 Inserting and removing a memory card NOTICE! Removal of the memory card Do not remove the memory card during access. Otherwise the memory card and/or files on it might get corrupted and/or normal PLC operation might be disturbed. -
Page 52: Accessories For Ac500-Eco
Mechanical planning and installation Accessories for AC500-eCo > Mounting and demounting the option boards To remove the memory card, push on the memory card until it moves forward. By this, the memory card is unlocked and can be removed. 5.12 Accessories for AC500-eCo This section only describes accessories that are frequently used for system assembly, connec- tion and construction. - Page 53 Mechanical planning and installation Accessories for AC500-eCo > Mounting and demounting the option boards Press the option board TA51xx (or TA5300-CVR) into the slot of the processor module PM50x2 until it locks in place. The option board must click into the slot of the processor module. 5.12.1.3 Removing the option board Push the option board on the side to release the lock.
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Page 54: Mounting And Demounting Of The Terminal Blocks For Onboard I/Os
Mechanical planning and installation Accessories for AC500-eCo > Mounting and demounting of the terminal blocks for onboard I/Os 5.12.2 Mounting and demounting of the terminal blocks for onboard I/Os Intended pur- Removable terminal blocks are used for power supply and for I/O connectors on AC500-eCo V3 pose processor modules PM50x2. - Page 55 CAUTION! Risk of injury and damaging the module when using unapproved terminal blocks! Only use terminal blocks approved by ABB to avoid injury and damage to the module. Terminal block set for PM50x2 Processor modules PM50x2 CPU are not delivered with terminal blocks.
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Page 56: Inserting And Removing A Memory Card
Mechanical planning and installation Accessories for AC500-eCo > Inserting and removing a memory card Disassembly 5.12.3 Inserting and removing a memory card NOTICE! Removal of the memory card Do not remove the memory card during access. Otherwise the memory card and/or files on it might get corrupted and/or normal PLC operation might be disturbed. -
Page 57: Control Panels Cp600
Mechanical planning and installation Control panels CP600 AC500-eCo V3 Micro memory card slot cover Micro memory card Micro memory card slot Open the micro memory card slot cover by turning it upwards. Micro memory card can be removed from the micro memory card slot by gripping and pulling with two fingers. -
Page 58: Wiring
Wiring Grounding concept — 6 Wiring 6.1 Grounding concept NOTICE! PLC damage due to missing grounding – Make sure to ground the devices. – The grounding (switch cabinet grounding) is supplied both by the mains connection (or 24 V supply voltage) and via the DIN rail. The DIN rail must be connected to ground before power is supplied to the device. -
Page 59: Emc-Conforming Assembly And Construction
Wiring EMC-conforming assembly and construction > General principles Block diagram: Analog I/O modules I/O Terminal Unit TU515/TU516 I/O-Bus AX522 Analog I/O interface I/O-Bus rail CH-ERRx Inputs Outputs Power + – + – – + – supply I+ I– I+ I– O+ O–... -
Page 60: Cable Routing
Wiring EMC-conforming assembly and construction > Cable routing There are three important principles to be especially considered: – Keep all connections as short as possible (in particular the grounding con- ductors) – Use large conductor cross sections (in particular for the grounding conduc- tors) –... -
Page 61: Cable Shields
Wiring EMC-conforming assembly and construction > Control cabinet ● Route signal cables and data cables separately from the power cables. – Separate cable ducts or cable bundles. – The distance should be 20 cm or greater. ● Lay signal and data cables close to earthed surfaces. 6.2.3 Cable shields ●... -
Page 62: Reference Potential
Wiring EMC-conforming assembly and construction > Equipotential bonding For supplying Use the mains socket which is located inside the control cabinet. the PC Ä Chapter 5.1 “Control cabinet assembly for AC500 (Standard)” on page 30 6.2.5 Reference potential ● Provide a uniform reference potential in the entire installation and ground all electrical appliances if possible. -
Page 63: Connection And Wiring
Wiring Connection and wiring Fig. 12: AC500, equipotential bonding Cabinet 1 Cabinet 2 Power supply for the CPU Fuse for the CPU power Power supply for the I/Os Fuse for the I/O power For fuses for the contacts of the relay outputs 0V rail Grounding of the 0V rail 10 Cabinet grounding... -
Page 64: Ac500
After recovery of the power supply of the affected I/O module it will continue normal operation and inputs and outputs will be updated. As power supply for the AC500 system, the ABB power supplies series CP can be used. 6.3.1.2 Power supply for processor modules The supply voltage of 24 V DC is connected to a removable 5-pin terminal block. - Page 65 Wiring Connection and wiring > AC500 Pin assignment Pin Assignment Label Function Description +24 V DC Positive pin of the power supply voltage +24 V DC Positive pin of the power supply voltage Negative pin of the power supply voltage Terminal block Terminal block removed...
- Page 66 Wiring Connection and wiring > AC500 Fig. 14: Connect the wire to the spring terminal (steps 4 ... 7) Side view (open terminal drawn for illustration) The top view shows the openings for wire and screwdriver Insert screwdriver (2.5 x 0.4 to 3.5 x 0.5 mm) at an angle, screwdriver must be at least 15 mm free of insulation at the tip While erecting the screwdriver, insert it until the stop (requires a little strength) Screwdriver inserted - terminal open...
- Page 67 Wiring Connection and wiring > AC500 Conductor Screwdriver Fig. 16: Disconnect wire from the spring terminal (steps 4 ... 6) Terminal with wire connected Insert screwdriver (2.5 x 0.4 ... 3.5 x 0.5 mm) at an angle, screwdriver must be at least 15 mm free of insulation at the tip While erecting the screwdriver, insert it until the stop (requires a little strength) - terminal is now open...
- Page 68 Wiring Connection and wiring > AC500 Terminal type: Number of cores Conductor type Cross section Stripped conductor Spring terminal per terminal solid 0.2 mm² ... 2.5 mm² 10 mm flexible 0.2 mm² ... 2.5 mm² 10 mm 1 with wire-end fer- flexible 0.25 mm²...
- Page 69 Wiring Connection and wiring > AC500 collisions even for the smallest possible frame size of 64 bytes (512 bits). But this is only guaranteed if the first bit of the frame arrives at the most distant subscriber within the collision domain before the last bit has left the transmitting station.
- Page 70 Wiring Connection and wiring > AC500 Pair 2 Pair 3 Pair 3 Pair 1 Pair 4 Pair 2 Pair 1 Pair 4 T568A T568B Fig. 19: Pin assignment of RJ45 sockets 6.3.1.5.3 Cable types Crossover cable Particular use Crossover cables are needed only for a direct Ethernet connection without crossover functionality.
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Page 71: Ac500-Eco
Wiring Connection and wiring > AC500-eCo 6.3.2 AC500-eCo 6.3.2.1 Power supply The processor modules PM50x2 can be connected to the 24 V DC supply voltage via a remov- able 3-pin spring terminal block or a 3-pin screw terminal block. Table 8: Removable terminal block for the supply voltage 24 V DC 3-pin spring terminal block 3-pin screw terminal block The terminal block is available as a set for AC500-eCo V3 processor modules. -
Page 72: Control Panels Cp600
Wiring Connection and wiring > Control panels CP600 6.3.2.2 Ethernet Ethernet is also used for Modbus TCP connection. 6.3.2.2.1 Ethernet interface The Ethernet interface is carried out via a RJ45 jack. The pin assignment of the Ethernet interface: Interface Description Transmit Data + Transmit Data - Receive data +... -
Page 73: Configuration And Programming
Configuration and programming — 7 Configuration and programming New to AC500? We recommend to use the step-by-step instructions in the Getting started document to install the engineering suite and to configure and program your first project. Advanced Detailed information is available in the installation and licensing document. installation of engineering suite... -
Page 74: Cyber Security
PLC. This way, the AC500 V3 PLC will only update with valid, authentic firmware, signed by ABB. Open ports and As part of the ABB security concept the AC500 V3 PLC comes with minimal services opened by services default. Only the services needed for initial setup and programming are open before any user application is downloaded. -
Page 75: Defense In Depth
Cyber security > Defense in depth Secure shell The AC500 V3 PLC contains a secure shell service to access core logging data in case of access for ABB problems which need a deeper analysis. This service is inactive by default, which means that no service one can access this privileged shell in the normal operating state. -
Page 76: Secure Operation
Configuration and programming Cyber security > Secure operation Fig. 22: Security zones Fig. 22 shows three safety zones, but the number of zones is not necessarily decisive, there can also be more or less - depending on the safety requirement. The use of multiple zones allows access between zones of different trust levels to be controlled to protect a trusted resource from attack by a less trusted one. - Page 77 Configuration and programming Cyber security > Secure operation ● Physically protect all equipment, i.e., ensure that physical access to computers, network equipment and cables, controllers, I/O systems, power supplies, etc., is limited to authorized persons ● When connecting a trusted network zone to outer networks, make sure that all connections are through properly configured secure interconnections only, such as a firewall or a system of firewalls, which is configured for “deny by default”, i.e., blocks everything except traffic that is explicitly needed to fulfill operational requirements.
- Page 78 Configuration and programming Cyber security > Secure operation Fig. 24: Plant information network connected to an automation system For the purposes of process control security, a general-purpose information system (IS) network should not be considered a trusted network, not the least since such networks are normally further connected to the Internet or other external networks.
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Page 79: Hardening
Configuration and programming Cyber security > Hardening Fig. 25: Automation system and IS network 7.1.3 Hardening System hardening means to eliminate as many security risks as possible. Hardening your system is an important step to protect your personal data and information. This process intends to eliminate attacks by patching vulnerabilities and turning off inessential services. -
Page 80: Certificates Factory Default - No Encryption
Configuration and programming Cyber security > Certificates factory default - no encryption ● Install virus and spyware protection ● Use containers or virtual machines ● Create strong passwords by applying a strong password policy ● Create and keep backups ● Use encryption when possible ●... - Page 81 Configuration and programming Cyber security > Certificates factory default - no encryption Double-click to the PLC main node and select the “PLC Shell” tab. Command line input is on the bottom. Find the index number for the FTP server and type [cert-getapplist] in the below command line.
- Page 82 An application can be encrypted and signed in order to protect a running application in an signed applica- AC500 V3 PLC and to protect a configured project. How to set-up the user management, the tions communication and the boot application in order to prevent unauthorized access is explained in the application note AC500 V3 - Encrypt and sign your application.
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Page 83: Open Ports And Services
Configuration and programming Cyber security > Open Ports and Services White Paper - More information about certificates and cyber security can be found in the white paper AC500 AC500 cyber cyber security. security 7.1.5 Open Ports and Services Overview of minimum cyber security requirements for open ports and services settings. Port Protocol Description... -
Page 84: Commissioning
Commissioning — 8 Commissioning Commissioning Preconditions: the PLC ● All PLC modules are installed and wired according to the configuration in Automation Builder. ● The PLC is connected to the power supply. ● The application and the necessary licenses are available. WARNING! Risk of injury or damage to equipment To avoid endangering persons or equipment, check before commissioning:... - Page 85 Commissioning Commis- Step-by-step instructions using the example of the AC500-eCo starter kit with a control panel sioning included example The PLC has an integrated diagnosis system to output diagnosis messages, e.g., parameter setting is wrong or battery low. A diagnosis message is indicated by ERR LED = on. Ä...
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Page 86: Operation
Operation PLC firmware/application update — 9 Operation The common operating mode is called run mode. Table 9: Run mode Display Description PWR LED = on Power supply is present. PLC is in run mode. RUN LED = on ERR LED = off If the PLC is connected to the power supply, but does not operate, it is in stop mode. -
Page 87: Control Panel Firmware/Application Update
Operation Reset to factory settings Updating the firmware and the application on a processor module is the same process than installing a firmware and an application on a very new processor module. The installation can be performed either via the engineering suite Automation Builder (recom- Ä... -
Page 88: Troubleshooting
Replace the control panel. panel is not functional any more. ERR LED of the processor A fatal system error occured. Contact ABB technical support module flashes fast. The dis- play shows “AC500”. ERR LED of the processor Installation or update of firm- Restart the device. - Page 89 CPU load (e.g., end- Wait for response from other device who will less loop in user program and block the execution from other code. not activated task watchdog). If a problem persists, contact ABB technical support. 2023/03/03 3ADR011074, 1, en_US...
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Page 90: Maintenance
Maintenance Replace an AC500 module — 11 Maintenance Interval Maintenance work After 3 years of utilisation or as soon as pos- Replace battery of the CPU. sible after the PLC diagnosis message "low Refer to the hardware manual. battery warning" Regularly or when the faceplate of the control Keep the faceplate of the control panel clean. -
Page 91: Replace An I/O Module With Hot Swap
86. If a processor module is replaced, you must install the firmware, the application, the licenses and the certificates on the new processor module. If a problem persists, contact ABB technical support. 11.2 Replace an I/O module with hot swap... - Page 92 Maintenance Replace an I/O module with hot swap > Preconditions for using hot swap WARNING! Electric shock due to negligent behavior during hot swapping! To avoid electric shock – make sure the following conditions apply: – Digital outputs are not under load. –...
- Page 93 Maintenance Replace an I/O module with hot swap > Preconditions for using hot swap The index of the module is in the right corner of the label. NOTICE! Risk of damage to I/O modules! Modules with index below F0 can be damaged when inserted or removed from the terminal unit in a powered system.
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Page 94: Compatibility Of Hot Swap
Compatibility of hot swap Hot swap is not supported by AC500-eCo V3 CPU! Central I/O on V3 CPU I/O module on TU5xx-H connected to I/O bus AC500 V3 CPU types: master PM56xx-2ETH Required version of I/O bus master Firmware as of V3.2.0... -
Page 95: Hot Swap Behavior
Maintenance Replace an I/O module with hot swap > Hot swap behavior 11.2.3 Hot swap behavior Hot swap behavior Central I/O on V3 CPU Start-up behavior with unplugged or damaged System and I/O modules attached to the CPU I/O module on hot swap terminal unit TU5xx-H are starting (except unplugged or damaged module when plugged on hot swap terminal unit). -
Page 96: Decommissioning
Decommissioning — 12 Decommissioning Delete the runtime licenses. Delete certificates available on the CPU. Delete applications. Delete applications from memory card, if available. If available, remove memory card and battery from CPU. Delete all user accounts and user data. Demount and dispose the hardware modules. Ä... -
Page 97: Recycling
Recycling — 13 Recycling Disposal and recycling information This symbol on the product (and on its packaging) is in accordance with the European Union's Waste Electrical and Electronic Equipment (WEEE) Directive. The symbol indicates that this product must be recycled/disposed of separately from other household waste. -
Page 98: Appendix
Appendix Diagnosis messages via display of the processor module — 14 Appendix 14.1 Diagnosis messages via display of the processor module We recommend to read out the diagnosis messages within the engineering suite Automation Builder or with the IEC application. If the processor module has a display, you can access the diagnosis system via the display and the buttons. -
Page 99: Error Severity E2: Severe Errors
Appendix Diagnosis messages via display of the processor module > Error severity E2: Severe errors The display of the processor module does not show any communication modules or fieldbus diagnosis. To view these diagnosis messages use Automation Builder or IEC application. This is valid for: –... -
Page 100: Error Severity E3: Minor Errors
Test pulse cross-talk Check (I/O bus) number number error wiring and sensor. If this error persists, replace I/O module. Contact ABB tech- nical sup- port. Module Channel Test error (I/O bus) number number Error at initialization (display) of display Module... - Page 101 Appendix Diagnosis messages via display of the processor module > Error severity E3: Minor errors Error Location Error Description Remedy severity code Loading boot project failed due to mis- match of retain data Loading boot project failed due to insuf- ficient license for application Loading boot project...
- Page 102 Appendix Diagnosis messages via display of the processor module > Error severity E3: Minor errors Error Location Error Description Remedy severity code 8480 Module Not supported pro- (I/O bus) number tocol variant 8707 Module PROFIsafe (I/O bus) number watchdog timed out 8708 Module Overvoltage...
- Page 103 I- and F- Parameters. 16148 Module PROFIsafe commu- Restart I/O (I/O bus) number nication error module. If this error persists, contact ABB technical support. 16153 Module PROFIsafe Restart I/O (I/O bus) number watchdog timed out module. If this error...
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Page 104: Error Severity E4: Warnings
Appendix Diagnosis messages via display of the processor module > Error severity E4: Warnings 14.1.3 Error severity E4: Warnings Table 13: Error severity E4: Warnings Error Location Error Description Remedy severity code Empty or missing (battery) 0...n Medium has used (flash- 80 % of its spare disk) - Page 105 Appendix Diagnosis messages via display of the processor module > Error severity E4: Warnings Error Location Error Description Remedy severity code Module Channel Measurement over- Check (I/O bus) number number flow at an analog channel output wiring Module Channel Measurement under- Check (I/O bus) number...
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Page 106: Error Severity E11: Parameter Errors
Appendix Diagnosis messages via display of the processor module > Error severity E11: Parameter errors Error Location Error Description Remedy severity code 16172 Module Has not passed fac- (I/O bus) number tory test 16173 Module No process voltage Check (I/O bus) number UP or UP3 process... - Page 107 Appendix Diagnosis messages via display of the processor module > Error severity E11: Parameter errors Error Location Error Description Remedy severity code 1 (too Value of parameter big) or "Reboot on E2" is not in range 2 (too small) 1 (too Invalid value of big) or parameter "Enable...
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Page 108: Diagnosis Messages Of Communication Modules Or Fieldbuses
14.2.1 Preparation of memory card Firmware packages can be downloaded from ABB website or exported from Automation Builder. In Automation Builder, you can choose if you want to export the firmware only or, in addition, the boot project as well. If the boot project does not exist yet, it will be created automatically. - Page 109 Appendix PLC firmware/application update via memory card > Preparation of memory card Fig. 28: Example Right-click “Application” in the device tree. Select “Export è Boot project and firmware” or “Export è Firmware”. Choose a location for the export folder. Select [Make New Folder] and type in "MEMORY CARD". Select [OK] to add the folder.
- Page 110 Appendix PLC firmware/application update via memory card > Preparation of memory card Select folder “MEMORY CARD”. ð The "MEMORY CARD" structure has been created and the firmware and application have been exported. The created "MEMORY CARD" folder does not contain user data, remanent data, config data, safety PLC power dip data and safety PLC password.
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Page 111: Execution Of Update Via Memory Card
Appendix PLC firmware/application update via memory card > Execution of update via memory card On the right side, select and open the folder “sdcard”. On the left side, select all the subfolders and files of the MEMORY CARD folder, but not the folder itself. - Page 112 Appendix PLC firmware/application update via memory card > Execution of update via memory card Switch on the device. ð The alternate flashing of the RUN and the ERR LED indicates the running update process. At the end of the update process a reboot is executed and the boot project and system firmware is started for the finishing of the update process.
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Page 113: Glossary
Tool AC500-S- Safety PLCs suitable for extreme environmental conditions AC500 V2 Range of AC500 and AC500-eCo CPUs AC500 V3 Range of AC500 and AC500-eCo CPUs AC500-XC Standard PLCs suitable for extreme environmental conditions Alarm Diagnosis message which must be acknowledged by the user. The alarm will continue to be displayed even if the issue has been resolved in the meantime until it is acknowl- edged. - Page 114 Glossary Event Diagnosis message which does not require acknowledgement. The event describes the current status of the device. The event disappears once the issue has been resolved. Human machine interface Online ● After a project has changed, only these changes are compiled when pressing the change key <F11>...
- Page 115 Glossary STOP -> ● STOP -> RUN means short pressing the RUN function key on the PLC while the PLC is in STOP mode (AC500 PLC display "StoP", AC500-eCo "RUN LED" is ON). "RUN LED" is OFF of the toggle switch of an AC500-eCo CPU. ●...
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Page 116: Index
....39 AC500 V2/AC500 V3 ......4 AC500-eCo configuration . - Page 117 ..... 98 I/O module Differentiation AC500 V2/AC500 V3 ... . . 4 mounting and demounting ....41, 46 disassembly .
- Page 118 Index SM560-S-FD-1 ......21 SM560-S-FD-4 ......21 older versions of this document .
- Page 119 Telephone: +49 (0)6221 701 1444 E-mail: plc.support@de.abb.com new.abb.com/plc new.abb.com/plc/automationbuilder new.abb.com/contact-centers — © Copyright 2023 ABB. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.