ABB AC500 PLC Hardware Manual
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ABB AC500 PLC Hardware Manual

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Table of Contents

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HARDWARE MANUAL
AC500 PLC
System Assembly and Device Specifications for
AC500 V2 Products

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Summary of Contents for ABB AC500 PLC

  • Page 1 HARDWARE MANUAL AC500 PLC System Assembly and Device Specifications for AC500 V2 Products...

  • Page 2: Table Of Contents

    Table of contents — Table of contents Device Specifications............................. 4 1.1 Terminal Bases (AC500 Standard)......................4 1.1.1 TB51x-TB54x..........................4 1.1.2 TF501-CMS and TF521-CMS - Function Module Terminal Bases .......... 13 1.2 Processor Modules..........................20 1.2.1 AC500-eCo..........................21 1.2.2 AC500 (Standard)........................65 1.3 Communication Modules (AC500 Standard)...................
  • Page 3 Table of contents 2.4.1 Serial I/O Bus........................1178 2.4.2 Mechanical Encoding......................1181 2.4.3 Earthing Concept (Block Diagrams)..................1184 2.4.4 EMC-Conforming Assembly and Construction..............1186 2.4.5 Power Consumption of an Entire Station................1189 2.4.6 Recycling and Disposal......................1192 2.5 AC500-eCo............................1192 2.5.1 System Data AC500-eCo.....................

  • Page 4: Device Specifications

    Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x — 1 Device Specifications 1.1 Terminal Bases (AC500 Standard) For AC500-eCo processor modules and special AC500 (Standard) processor modules the terminal base cannot be removed. 1.1.1 TB51x-TB54x ● TB511-ARCNET: 1 processor module, 1 communication module, with network interface ARCNET BNC ●...
  • Page 5 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x I/O bus (10-pin, female) to electrically connect the I/O terminal units Slot for processor module Slots for communication modules (TB511-xxx: 1 slot, TB521-xxx: 2 slots, TB541-xx: 4 slots) Interface for FieldBusPlug, not for terminal base TB523-2ETH Power supply (5-pin terminal block, removable) Serial interface COM1 (9-pin terminal block, removable) TB5x1: Serial interface COM2 (D-sub 9, female), TB523-2ETH: second Ethernet network...
  • Page 6 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x NOTICE! Risk of malfunctions! Unused slots for communication modules are not protected against accidental physical contact. – Unused slots for communication modules must be covered with dummy Ä Chapter 1.8.2.3 “TA524 - Dummy Com- communication modules (TA524 munication Module”...
  • Page 7 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x 1.1.1.2 Connections 1.1.1.2.1 I/O Bus The I/O bus is the I/O data bus for the I/O modules. Through this bus, I/O and diagnosis data are transferred between the processor module and the I/O modules. Up to 10 I/O modules can Ä...
  • Page 8 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x NOTICE! Risk of damaging the terminal base! Terminal base can be damaged by connecting the power supply terminal block (L+/M) to COM1. Make sure that the COM1 terminal block is always connected to the terminal base even if you do not use COM1 to prevent this.
  • Page 9 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x Serial Interface The serial interface COM2 is connected to a 9-pin D-sub connector. It is configurable for COM2 RS-232 and RS-485 and can be used (depending on the processor module) for: ● Online access (RS-232 programming interface for Automation Builder) ●...
  • Page 10 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x Terminal bases TB5x3-2ETH for processor modules PM5xx-2ETH provide 2 independent Ethernet interfaces. For structured Ethernet cabling only use cables in accordance with TIA/ EIA-568-A, ISO/IEC 11801 or EN 50173. Pin assignment Interface Signal Description TxD+...
  • Page 11 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x NOTICE! Risk of corrosion! Unused connectors and slots may corrode if XC devices are used in salt-mist environments. Protect unused connectors and slots with TA535 protective caps for XC devices Ä Chapter 1.8.4.6 “TA535 - Protective Caps for XC Devices” TA535 on page 1172.
  • Page 12 Device Specifications Terminal Bases (AC500 Standard) > TB51x-TB54x 1.1.1.4 Ordering Data Part No. Description Product Life Cycle Phase *) 1SAP 111 100 R0260 TB511-ARCNET, Active terminal base AC500, slots: 1 processor module, 1 communication module, ARCNET COAX connector 1SAP 111 100 R0270 TB511-ETH, terminal base AC500, Active slots: 1 processor module,...

  • Page 13: Tf501-Cms And Tf521-Cms - Function Module Terminal Bases

    Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases Table 1: Accessories Part No. Description 1SAP 180 200 TK501, programming cable D-sub / D-sub, length: 5 m R0001 1SAP 180 200 TK502, programming cable terminal block / D-sub, length: 5 m R0101 1TNE 968 901 TK503, programming cable USB / D-sub (RS-485), length 3 m...
  • Page 14 Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases Slots for PM592-ETH Slots for FM502-CMS I/O bus to electrically connect the terminal units Terminal blocks for analog/digital inputs/outputs Serial interface COM1 Network interface The TF5x1-CMS are used as terminal bases for FM502-CMS, PM592-ETH and communication Ä...
  • Page 15 Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases NOTICE! Risk of malfunctions! Unused slots for communication modules are not protected against accidental physical contact. – Unused slots for communication modules must be covered with dummy Ä...
  • Page 16 Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases Terminal Signal Description Process voltage M (0 VDC) 2.0...2.7 AI0-...AI7- Negative input signal AI0...AI7 for analog channel 0...7 2.8/2.9 DI0/DI1 Input signal I0/I1 (standard digital input) 3.0...3.7 AI0+...AI7+ Positive input signal AI0...AI7 for analog channel 0...7...
  • Page 17 Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases NOTICE! Risk of damaging the terminal base and power supply! Short circuits might damage the terminal base and power supply. Make sure that the four clamps L+ and M (two of each) are not wrongly con- nected (e.
  • Page 18 Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases Pin assignment Serial Signal Interface Description Interface Functional earth RS-232 Transmit data Output RxD/TxD-P RS-485 Receive/Transmit Positive RS-232 Request to send Output SGND Signal ground 0 V supply out +5 V 5 V supply out...
  • Page 19 Device Specifications Terminal Bases (AC500 Standard) > TF501-CMS and TF521-CMS - Function Module Terminal Bases See supported protocols and used Ethernet ports for AC500 V3 prod- ucts:Ethernet Protocols and Ports. See communication via Modbus for AC500 V3 products: Modbus TCP/IP. See communication via Modbus for AC500 V3 products: Modbus RTU.

  • Page 20: Processor Modules

    Device Specifications Processor Modules Table 3: Connection of the TF5x1-CMS Parameter Value I/O bus I/O interface for directly adding up to 10 terminal units Terminal block 70 clamps for I/O, shield and power supply connection COM1 Serial interface, 9-pin D-sub connector, female Network interface Ethernet RJ45 (type must be equal to the type of...

  • Page 21: Ac500-Eco

    Device Specifications Processor Modules > AC500-eCo ● AC500-S: AC500-S PLCs are designed for safety applications involved in factory or machinery auto- mation area. ● AC500-XC: AC500 (standard) and AC500-S provide devices with -XC extension as a product variant. These variants operate according to their product group and can, in addition, be operated under extreme conditions.
  • Page 22 Device Specifications Processor Modules > AC500-eCo PM564 CPU PM564-RP-ETH 6DI 24VDC 6DO-R 240VAC 2A 2AI 1AO C0..5 INSERT PUSH STOP SD CARD COM2 COM2 WARNING! Use of incorrect battery may cause fire or explosion 17 NO3 COM1 R3..5 R0..2 24VDC IN 24VDC OUT L+ M FE L+ M 3 LEDs to display the states of the processor module...
  • Page 23 Device Specifications Processor Modules > AC500-eCo 1.2.1.1.1 Short Description The processor modules PM55x-xP and PM56x-xP are the central units of AC500-eCo. Their main characteristics are: ● 128 kB (PM554-xP and PM564-xP types) program memory, 512 kB (PM556-xP and PM566- xP types) program memory ●...
  • Page 24 Device Specifications Processor Modules > AC500-eCo 1.2.1.1.3 Connections I/O Bus The I/O bus is the I/O data bus for the I/O modules. Through this bus, I/O and diagnosis data are transferred between the processor module and the I/O modules. Up to 10 I/O modules can Ä...
  • Page 25 Device Specifications Processor Modules > AC500-eCo According to IEC 60204-1:2016, where control circuits are supplied from an AC source, transformers having separate windings shall be used to separate the power supply from the control supply. Serial interface The serial non-isolated COM1 interface provides communication via RS-485 and is carried out COM1 as a 9-pin D-sub jack.
  • Page 26 Device Specifications Processor Modules > AC500-eCo NOTICE! The internal power supply voltage, which is connected to pin 6 of the D-sub connector, must not be short-circuited or connected to any other voltages. Serial interface The optional serial COM2 interface provides communication via RS-485 and is carried out as a COM2 (optional) removable 5-pin terminal with screw connection.
  • Page 27 Device Specifications Processor Modules > AC500-eCo Interface Description Not connected Receive Data - Not connected Not connected Shield Cable shield Functional earth The supported protocols and used Ethernet ports can be found in a separate chapter. Communication via Modbus TCP/IP is described in detail in a separate chapter. Electrical Con- nection WARNING!
  • Page 28 Device Specifications Processor Modules > AC500-eCo CAUTION! Risk of damaging the processor module and the connected modules! Voltages > 35 VDC (DC variants only) or > 288 VAC (AC variants only) might damage the processor module and the connected modules. Make sure that the supply voltage never exceeds 35 VDC / 288 VAC.
  • Page 29 Device Specifications Processor Modules > AC500-eCo Processor Power No. and type No. and type No. and type No. and type module supply of digital of digital out- of analog of analog inputs puts inputs outputs PM55x-T(P), 24 VDC 8 x 24 VDC 6 x 24 VDC, none none...
  • Page 30 Device Specifications Processor Modules > AC500-eCo 1.2.1.1.6 Diagnosis The AC500 processor module can display various errors according to the error classes. The fol- lowing error classes are possible. The reaction of the processor module is different for each type of error. Error class Type Description...
  • Page 31 Device Specifications Processor Modules > AC500-eCo State Color LED = ON LED = OFF LED flashing Power supply Green Power supply Power supply present missing RUN/STOP Green Processor Processor Fast flashing state module is in module is in (4 Hz): The state RUN state STOP processor...
  • Page 32 Device Specifications Processor Modules > AC500-eCo State LEDs Table 6: State LEDs at Ethernet Connector (-ETH models only) Color Flashing Activity Yellow No activity Activity Link Green No link Link 1.2.1.1.8 Technical Data Ä Chapter 2.5.1 “System Data AC500-eCo” The System Data of AC500-eCo apply on page 1192 Only additional details are therefore documented below.
  • Page 33 Device Specifications Processor Modules > AC500-eCo Power supply 24 VDC 100 - 240 VAC Max. power dissipation within PM554-TP: 3.0 W PM554-RP-AC: 4.8 W the processor module PM554-TP-ETH: 3.3 W PM564-RP-AC: 4.8 W PM554-RP: 3.5 W PM564-RP-ETH-AC: 5.3 W PM556-TP-ETH: 3.3 W PM564-TP: 3.9 W PM564-TP-ETH: 4.4 W PM564-RP: 4.5 W...
  • Page 34 Device Specifications Processor Modules > AC500-eCo Programming languages - Instruction List (IL) - Function Block Diagram (FBD) - Ladder Diagram (LD) - Sequential Function Chart (SFC) - Structured Text (ST) - Continuous Function Chart (CFC) Cycle time for 1000 instructions Binary 0.08 ms Word...
  • Page 35 Device Specifications Processor Modules > AC500-eCo Serial interface COM2 (optional) Physical link Non-isolated RS-485 (TA562-RS or TA562- RS-RTC) With 500 VDC galvanically isolated RS-485 (TA569-RS-ISO) Baudrate Configurable from 1.2 to 115.2 kB/s Connection Removable 5-pin terminal block Common mode range Typ.
  • Page 36 Device Specifications Processor Modules > AC500-eCo 1.2.1.1.9 Ordering Data Table 7: Processor Modules for AC500-eCo Part No. Description Product Life Cycle Phase *) 1SAP 120 600 R0001 PM554-TP, processor module, 128 kB Active memory, 8 DI, 6 DO-T, 24 VDC, with pluggable I/O terminal blocks 1SAP 120 600 R0071 PM554-TP-ETH, processor module, Active...
  • Page 37 Device Specifications Processor Modules > AC500-eCo Table 8: Accessories Part No. Description 1TNE 968 901 Terminal Block TA563-9, 9-pin, screw front, cable side, 6 pieces per R3101 unit 1TNE 968 901 Terminal Block TA563-11, 11-pin, screw front, cable side, 6 pieces per R3102 unit 1TNE 968 901...
  • Page 38 Device Specifications Processor Modules > AC500-eCo Terminals of Onboard I/Os for PM55x-T Terminals of Onboard I/Os for PM55x-R and PM55x-R-AC AC500-eCo processor modules are equipped with non-removable terminals. AC500-eCo processor modules are equipped with removable terminal blocks which must be ordered separately. The electrical functionality of both processor module types is identical.
  • Page 39 Device Specifications Processor Modules > AC500-eCo 1.2.1.2.2 Functionality Parameter Value Digital inputs 8 (24 VDC), can be used as source inputs or as sink inputs Interrupt inputs 4 (DI0...DI3), configurable Interrupt response time Max. 0.8 ms when input delay is set to 0.1 ms Fast counter 2 (DI0 and DI1), configurable Digital outputs...
  • Page 40 Device Specifications Processor Modules > AC500-eCo PM55x-T(P) PM55x-R(P) The assignment of the terminals for PM55x-T(P): Terminal Signal Description C0...7 Input common for digital input signals DI0 to Digital input signal DI0 Digital input signal DI1 Digital input signal DI2 Digital input signal DI3 Digital input signal DI4 Digital input signal DI5 Digital input signal DI6...
  • Page 41 Device Specifications Processor Modules > AC500-eCo Terminal Signal Description Digital output signal O1 Digital output signal O2 Digital output signal O3 Digital output signal O4 Digital output signal O5 Process supply voltage UP +24 VDC Process supply voltage ZP 0 VDC The assignment of the terminals for PM55x-R(P): Terminal Signal...
  • Page 42 Device Specifications Processor Modules > AC500-eCo NOTICE! Risk of malfunctions in the plant! A ground closure, e. g. caused by a damaged cable insulation, can bridge switches accidentally. Use sink inputs when possible or make sure that, in case of error, there will be no risks to persons or plant.
  • Page 43 Device Specifications Processor Modules > AC500-eCo NOTICE! Risk of malfunctions in the plant! The outputs may switch on for a period of 10 to 50 µs if the process supply voltage UP/ZP is switched on. This must be considered in the planning of the application. CAUTION! Risk of damaging the processor module! The outputs are not protected against short circuit and overload.
  • Page 44 Device Specifications Processor Modules > AC500-eCo CAUTION! Risk of damaging the processor module! – Never short-circuit or overload the outputs. – Never connect inductive loads without an external suppression against voltage peaks due to inductive kickback. – Never connect voltages > 240 V. All outputs must be fed from the same phase.
  • Page 45 Device Specifications Processor Modules > AC500-eCo E1...E Identifier AC500-Display <− Display in 000...063 Class Comp Dev PS501 PLC Browser Class Inter- Device Module Channel Error- Error message Remedy face Identifier Invalid configuration value for Correct frequency PWM channel. Frequency / cycletime for the PWM channel of the 8DI+6DO and 8DI+6DO +2AI+1AO module are common...
  • Page 46 Device Specifications Processor Modules > AC500-eCo Parameter Value Input signal range -24 VDC +24 VDC Signal 0 -5 V...+3 V -3 V...+5 V Undefined signal -15 V...- 5 V +5 V...+15 V Signal 1 -30 V...-15 V +15 V...+30 V Ripple with signal 0 Within -5 V...+3 V Within -3 V...+5 V...
  • Page 47 Device Specifications Processor Modules > AC500-eCo Parameter Value Way of operation Non-latching type Min. output voltage at signal 1 20 VDC at max. current consumption Output delay (max. at rated load) 0 to 1 50 µs 1 to 0 200 µs Rated protection fuse (per group) 3 A fast Output current...
  • Page 48 Device Specifications Processor Modules > AC500-eCo Parameter Value Indication of the output signals 1 yellow LED per channel; the LED is on when the output signal is high (signal 1) and the module is powered through the I/O bus Way of operation Non-latching type Output delay 0 to 1...
  • Page 49 Device Specifications Processor Modules > AC500-eCo 1.2.1.3 Onboard I/Os in Processor Module PM56x ● 6 DI 24 VDC ● PM56x-T(P): 6 DO (24 VDC, 0.5 A max. transistor outputs) ● PM56x-R(P) and PM56x-R(P)-AC: 6 DO (24 VDC or 120/240 VAC, 2 A max. relay outputs) ●...
  • Page 50 Device Specifications Processor Modules > AC500-eCo Processor Power No. and type No. and type No. and type No. and type module supply of digital of digital out- of analog of analog inputs puts inputs outputs PM56x-T(P), 24 VDC 6 x 24 VDC *) 6 x 24 VDC, 2 x voltage *) 1 x voltage or PM56x-T(P)-...
  • Page 51 Device Specifications Processor Modules > AC500-eCo 1.2.1.3.3 Electrical Connection NOTICE! Risk of damaging the PLC modules! The PLC modules must not be removed while the plant is connected to a power supply. Make sure that all voltage sources (supply and process voltage) are switched off before you –...
  • Page 52 Device Specifications Processor Modules > AC500-eCo PM56x-T(P) PM56x-R(P) Assignment of Terminal Signal Description the Terminals C0...5 Input common for digital input signals DI0 to DI5 for PM56x-T(P) Digital input signal DI0 Digital input signal DI1 Digital input signal DI2 Digital input signal DI3 Digital input signal DI4 Digital input signal DI5 Analog voltage input signal AI0...
  • Page 53 Device Specifications Processor Modules > AC500-eCo Terminal Signal Description Digital output signal O3 Digital output signal O4 Digital output signal O5 Process supply voltage UP +24 VDC Process supply voltage ZP 0 VDC Assignment of Terminal Signal Description the Terminals C0...5 Input common for digital input signals DI0 to DI5 for PM56x-R(P)
  • Page 54 Device Specifications Processor Modules > AC500-eCo *) The M-terminal of the onboard I/Os is inter- *) The M-terminal of the Onboard I/Os is inter- nally connected to the M-terminal of the pro- nally connected to the M-terminal of the pro- cessor-module supply voltage cessor-module supply voltage Electrical connection of digital inputs (sink...
  • Page 55 Device Specifications Processor Modules > AC500-eCo NOTICE! Risk of malfunctions in the plant! The outputs may switch on for a period of 10 to 50 µs if the process supply voltage UP/ZP is switched on. This must be considered in the planning of the application. CAUTION! Risk of damaging the processor module! The outputs are not protected against short circuit and overload.
  • Page 56 Device Specifications Processor Modules > AC500-eCo CAUTION! Risk of damaging the processor module! – Never short-circuit or overload the outputs. – Never connect inductive loads without an external suppression against voltage peaks due to inductive kickback. – Never connect voltages > 240 V. All outputs must be fed from the same phase.
  • Page 57 Device Specifications Processor Modules > AC500-eCo Connection of analog actuator (voltage) Connection of analog actuator (current) 1.2.1.3.4 Internal Data Exchange Parameter Value Digital inputs (bytes) Digital outputs (bytes) Analog inputs (bytes) Analog outputs (bytes) 1.2.1.3.5 I/O Configuration The configuration data of the onboard I/Os is stored in the processor module PM56x. 1.2.1.3.6 Parameterization For information about parameterization, refer to the description for onboard I/Os for processor...
  • Page 58 Device Specifications Processor Modules > AC500-eCo E1...E4 Identifier AC500- <− Display in Display 000...063 Class Comp PS501 Browser Class Inter- Device Module Channel Error- Error message Remedy face Identifier Invalid configuration of Correct onboard I/O module, e. PLC con- g. 2 input channels are figuration configured as fast counter and interrupt...
  • Page 59 Device Specifications Processor Modules > AC500-eCo 1.2.1.3.8 Displays Status Color LED = ON LED = OFF DI0...DI5 Digital input yellow Input is ON Input is OFF DO0...DO5 Digital output yellow Output is ON Output is OFF AI0, AI1*) Analog input yellow Input is ON Input is OFF...
  • Page 60 Device Specifications Processor Modules > AC500-eCo Range 0 V...+10 V 0 mA...20 mA Digital value Decimal Hex. 0.00 0.00 0000 Output value too FFE0 low or underflow -6912 E500 0.00 -32768 8000 Range 4 mA...20 mA Digital value Decimal Hex. Overflow 22.80 32767...
  • Page 61 Device Specifications Processor Modules > AC500-eCo Parameter Value Signal 0 -5 V...+3 V -3 V...+5 V Undefined signal -15 V...- 5 V +5 V...+15 V Signal 1 -30 V...-15 V +15 V...+30 V Ripple with signal 0 Within -5 V...+3 V Within -3 V...+5 V Ripple with signal 1 Within -30 V...-15 V Within +15 V...+30...
  • Page 62 Device Specifications Processor Modules > AC500-eCo Parameter Value Min. output voltage at signal 1 20 VDC at max. current consumption Output delay (max. at rated load) 0 to 1 50 µs 1 to 0 200 µs Rated protection fuse (per group) 3 A fast Output current Rated current per channel (max.)
  • Page 63 Device Specifications Processor Modules > AC500-eCo Parameter Value Indication of the output signals 1 yellow LED per channel; the LED is on when the output signal is high (signal 1) and the module is powered through the I/O bus Way of operation Non-latching type Output delay 0 to 1...
  • Page 64 Device Specifications Processor Modules > AC500-eCo Technical Data of the Analog Inputs Parameter Value Number of channels per module 2 voltage inputs Distribution of channels into groups 1 group for 2 channels Galvanic isolation None Power Supply Voltage Via the L+ and the M terminal of the pro- cessor-module power supply Resolution Voltage 0 VDC...10 VDC: 10 bits...

  • Page 65: Ac500 (Standard)

    Device Specifications Processor Modules > AC500 (Standard) Parameter Value Output load ability as voltage output +2 mA max. Accuracy for current and voltage output Typical (25 °C) ±1 % of full-scale Worst case (at 0 °C...60 °C or EMC distur- ±2.5 % of full-scale bances) Relationship between input signal and hex...
  • Page 66 Device Specifications Processor Modules > AC500 (Standard) 6x 7-segment state displays with background 14 Interface for FieldBusPlug lighting 15 Power supply (5-pin terminal block, removable) "Triangle" displays for "item" 16 Serial interface COM1 (9-pin terminal block, remov- "Square" displays for "state" able) 3 state LEDs 17 PM5xy-ETH and PM5xy-ARCNET: D-sub 9 for serial...
  • Page 67 Device Specifications Processor Modules > AC500 (Standard) The terminal base type depends on the number of communication modules which are used together with the processor module and on the processor module's network interface type (1x Ethernet, 2x Ethernet or ARCNET). Each processor module can operate multiple communication modules through its communica- tion module interface (defined by the terminal base).
  • Page 68 Device Specifications Processor Modules > AC500 (Standard) 1.2.2.1.2 Assortment Module Program Cycle Time Network Interface Other Inter- Suitable and Data for 1 Instruc- faces Terminal Base Ethernet ARCNET Memory tion PM572 128 kB Binary: min. TB5x1-ETH 0.06 µs PM573-ETH 512 kB Onboard TB5x1-ETH Word: min.
  • Page 69 Device Specifications Processor Modules > AC500 (Standard) 1.2.2.1.3 Connections All terminals for electrical connection are available on the terminal base. For information on con- nection and available interfaces see the descriptions for Ä Chapter 1.1.1 “TB51x-TB54x” on page 4 ● TB511 Ä...
  • Page 70 Device Specifications Processor Modules > AC500 (Standard) 1.2.2.1.5 LEDs, Display and Function Keys on the Front Panel Detailed information on using the LEDs, display and the function keys such as startup procedure and error coding is described in the System Technology sec- tion Display.
  • Page 71 Device Specifications Processor Modules > AC500 (Standard) Parameter Value PM59x: 90 mA PM59x-ETH: 150 mA PM59x-2ETH: 150 mA PM59x-ARCNET: 150 mA Fuse melting integral at 24 VDC Min. 1 A²s Ä Chapter 2.4.5.2 “Dimensioning of the Fuses” on page 1191 Max.
  • Page 72 Device Specifications Processor Modules > AC500 (Standard) Detailed Data Table 10: PM57x Processor Module PM572 PM573-ETH Program memory flash EPROM 128 kB 512 kB and RAM Data memory, integrated 128 kB, incl. 12 kB 512 kB, incl. 288 kB buffered buffered Expandable memory None...
  • Page 73 Device Specifications Processor Modules > AC500 (Standard) Processor Module PM572 PM573-ETH Physical link Configurable for RS-232 or RS-485 (from 0.3 to 187.5 kB/s) pluggable terminal block, spring connection for pro- Connection gramming, as Modbus (master/slave), as serial ASCI communication, as CS31 Master Usage Serial interface COM2 (not for PM5xy-2ETH models): Physical link...
  • Page 74 Device Specifications Processor Modules > AC500 (Standard) Processor Module PM582 PM583-ETH PM585-ETH Program storage Firmware update Cycle time for 1 instruction: Binary Min. 0.05 µs Min. 0.004 µs Word Min. 0.06 µs Min. 0.008 µs Floating point Min. 0.50 µs Min.
  • Page 75 Device Specifications Processor Modules > AC500 (Standard) Processor Module PM582 PM583-ETH PM585-ETH ETH = Ethernet ETH onboard with web server, SNTP and IEC60870-5-104 RJ45 protocol ARCNET = ARCNET BNC Number of external communication modules Up to 4 communication modules like PRO- FIBUS DP, Ethernet, CANopen.
  • Page 76 Device Specifications Processor Modules > AC500 (Standard) Processor Module PM59x-ETH PM59x- PM59x-ETH ARCNET PM59x-2ETH Binary Min. 0.002 µs Min. 0.002 µs Min. 0.002 µs Word Min. 0.004 µs Min. 0.004 µs Min. 0.004 µs Floating point Min. 0.004 µs Min. 0.004 µs Min.
  • Page 77 Device Specifications Processor Modules > AC500 (Standard) Processor Module PM59x-ETH PM59x- PM59x-ETH ARCNET PM59x-2ETH ETH = Ethernet ARCNET ETH onboard with Web- RJ45 ARCNET server, SNTP ARCNET = ARCNET ARCNET IEC60870-5-10 4 protocol Number of external communication mod- Up to 4 communication modules like PROFIBUS ules DP, Ethernet, CANopen.
  • Page 78 Device Specifications Processor Modules > AC500 (Standard) 1.2.2.1.7 Ordering Data Processor Mod- Part No. Description Product Life Cycle Phase *) ules for AC500 1SAP 130 200 R0200 PM572, processor module, memory Active (Standard) V2 128 kB, 24 VDC, memory card slot, Products interfaces 2x RS-232/485 (programming, Modbus/CS31),...
  • Page 79 Device Specifications Processor Modules > AC500 (Standard) Part No. Description Product Life Cycle Phase *) 1SAP 150 000 R0271 PM590-ETH, processor module, Active memory 2 MB, 24 VDC, memory card slot, interfaces 2x RS-232/485 (programming, Modbus/CS31), 1x FBP, display, onboard Ethernet TCP/IP with web server, SNTP, IEC60870-5-104 protocols 1SAP 150 100 R0271 PM591-ETH, processor module,...
  • Page 80 Device Specifications Processor Modules > AC500 (Standard) Processor module PM591-2ETH can only be used with TB523-2ETH. Processor modules PM57x-ETH(-XC), PM58x-ETH(-XC) and PM59x-ETH(-XC) with ordering No. 1SAPxxxxxxR0271 can only be used with terminal bases TB5x1-ETH(-XC) with ordering No. 1SAPxxxxxxR0270. 1.2.2.2 PM595 ●...
  • Page 81 Device Specifications Processor Modules > AC500 (Standard) 1.2.2.2.1 Short Description The processor module is a central unit for AC500 with high performance. Each processor module can operate up to 2 communication modules via its communication module interface. The communication modules are mounted on the left side of the processor module.
  • Page 82 Device Specifications Processor Modules > AC500 (Standard) For PM595 only: For EtherCAT and PROFINET support make sure the following firmware is installed: – PROFINET: V 2.8.1.2 or newer – EtherCAT: V 4.2.23 (2) or newer To update the Firmware of PM595, please follow the instructions in the chapter Firmware update.
  • Page 83 Device Specifications Processor Modules > AC500 (Standard) Power Supply Pin assignment The supply voltage of 24 VDC is connected to a removable 5-pin terminal block. L+/M exist twice. It is therefore possible to feed e.g. external sensors (up to 8 A max. with 1.5 mm con- ductor) via these terminals.
  • Page 84 Device Specifications Processor Modules > AC500 (Standard) NOTICE! Risk of damaging the terminal base! Excessive current might damage the clamp and terminal base. Make sure that the current flowing through the removable clamps never exceeds 8 A (with 1.5 mm conductor).
  • Page 85 Device Specifications Processor Modules > AC500 (Standard) Pin assignment Serial Signal Interface Description Interface Functional earth RS-232 Transmit data Output RxD/TxD-P RS-485 Receive/Transmit Positive RS-232 Request to send Output SGND Signal ground 0 V supply out +5 V 5 V supply out RS-232 Receive data Input...
  • Page 86 Device Specifications Processor Modules > AC500 (Standard) MAC Addresses The MAC addresses of the network interfaces of the PM595-4ETH are printed on the label in the following way: MAC ETH1 MAC ETH2 MAC ETH3 MAC ETH4 The figure below shows the assignment of the MAC addresses to the corresponding interface. Fig.
  • Page 87 Device Specifications Processor Modules > AC500 (Standard) The memory card can be used ● to read and write user files ● for firmware updates Detailed information can be found in the System Technology chapter. AC500 processor modules can be operated with and without memory cards. The processor module uses a standard file system (FAT;...
  • Page 88 Device Specifications Processor Modules > AC500 (Standard) Color Status Description Green Power supply available Blinking Power supply not available or defec- tive hardware Green Processor module is in RUN mode Blinking Processor module is in STOP mode Red/green An error has occurred Blinking Flashing fast (4 Hz): Indicates together with RUN a firmware update...
  • Page 89 Device Specifications Processor Modules > AC500 (Standard) Button Description RESET If pressed during power-on: Enter serial download of firmware. This is signalized by blinking of the RUN LED with a frequency of 1 Hz. If pressed during normal operation: reserved for future implementation. If pressed during power-on: Bootproject will not be loaded.
  • Page 90 Device Specifications Processor Modules > AC500 (Standard) Detailed data Parameter Value Flash memory for boot projects, symbols and web 32768 kB pages SDRAM for user program 16384 kB SDRAM for user data 16384 kB Expandable memory None Integrated mass storage memory 4 GB non rotating flashdisk Pluggable memory card for: User data storage...
  • Page 91 Device Specifications Processor Modules > AC500 (Standard) Parameter Value LCD display Optional Buttons and switches 1 button for Reset (Reserved) 1 Button (Reserved) 1 Switch for RUN/STOP 1.2.2.2.7 Ordering Data Part No. Description Product Life Cycle Phase *) 1SAP 155 500 R0279 PM595-4ETH-F, processor module, Active user progr./data memory 16 MB / 16 MB,...

  • Page 92: Communication Modules (Ac500 Standard)

    Device Specifications Communication Modules (AC500 Standard) > Overview 1.3 Communication Modules (AC500 Standard) 1.3.1 Overview AC500 communication modules are required for ● a connection to standard field bus systems and ● for integration into existing networks. AC500 communication modules ● enable communication on different field buses.
  • Page 93 Device Specifications Communication Modules (AC500 Standard) > Overview WARNING! Removal/Insertion under power The devices are not designed for removal or insertion under power. Because of unforeseeable consequences, it is not allowed to plug or unplug devices with the power being ON. Make sure that all voltage sources (supply and process voltage) are switched off before you –...
  • Page 94 Device Specifications Communication Modules (AC500 Standard) > Overview 1.3.1.1 Technical Data (Overview) CM574- CM574- CM579 CM582-DP CM598-CN CM589- CM597-ETH RCOM PNIO(-4) CM592-DP CM588-CN ETHC CM579-PNIO Field bus RCOM/ Serial EtherC PROFIBUS CANopen PROFINET 2 x Ethernet RCOM+ (ASCII/ Modbus) Transmission 2.4 kBit/s 9.6 kBit/s 9.6 kBit/s to...

  • Page 95: Cm574-Rcom For Rcom/Rcom

    Device Specifications Communication Modules (AC500 Standard) > CM574-RCOM for RCOM/RCOM+ 1.3.2 CM574-RCOM for RCOM/RCOM+ 5 LEDs for state display Label 2 interfaces: 1x RCOM protocol interface, 1x CONSOLE 1.3.2.1 Purpose Communication module CM574-RCOM is equipped with 2 serial interfaces (RCOM protocol communication and Console) which provide the remote protocol RCOM/RCOM+.
  • Page 96 Switch between two protocols (Online access, Modbus, ASCII, SysLibCom) using the block COM_SET_PROT CS31 bus CS31 bus master RCOM/RCOM+ ABB remote protocol RCOM or RCOM+ (only available as sepa- rate communication module CM574-RCOM) COM2 Online access Online access for IEC 61131-3 programming with serial driver...
  • Page 97 Device Specifications Communication Modules (AC500 Standard) > CM574-RCOM for RCOM/RCOM+ Bus line Remarks Commonly used telephone cables with PE insulation and a core diameter of > 0.8 mm are usually sufficient. Cables with PVC core insulation and core diameter of 0.8 mm can be used up to a length of approx.
  • Page 98 Device Specifications Communication Modules (AC500 Standard) > CM574-RCOM for RCOM/RCOM+ Color State Description Flashes Protocol error occurred cyclically No communication Yellow Flashes Traffic detected Error No error 1.3.2.4 Technical Data Ä Chapter 2.6.1 “System Data AC500” on page 1248 are The System Data of AC500 and S500 valid for standard version.
  • Page 99 Device Specifications Communication Modules (AC500 Standard) > CM574-RCOM for RCOM/RCOM+ Table 19: Technical Data of the Interfaces Parameter Value Serial interface standard EIA RS-232 or EIA RS-485 Interface connector Pluggable 9-pin terminal block Potential separation Yes, from the CPU, 500 VDC Serial interface parameters Protocol interface configurable via PLC config- uration.

  • Page 100: Cm574-Rs With 2 Serial Interfaces

    Device Specifications Communication Modules (AC500 Standard) > CM574-RS with 2 Serial Interfaces 1.3.3 CM574-RS with 2 Serial Interfaces 5 LEDs for state display 2 rotary switches for address setting Label 2 serial communication interfaces 1.3.3.1 Purpose Communication module CM574-RS is equipped with 2 serial interfaces (COM1 and COM2) which can be used as programming interface or for communication e.g.
  • Page 101 Switch between two protocols (Online access, Modbus, ASCII, SysLibCom) using the block COM_SET_PROT CS31 bus CS31 bus master RCOM/RCOM+ ABB remote protocol RCOM or RCOM+ (only available as sepa- rate communication module CM574-RCOM) COM2 Online access Online access for IEC 61131-3 programming with serial driver...
  • Page 102 Device Specifications Communication Modules (AC500 Standard) > CM574-RS with 2 Serial Interfaces Bus line Remarks Commonly used telephone cables with PE insulation and a core diameter of > 0.8 mm are usually sufficient. Cables with PVC core insulation and core diameter of 0.8 mm can be used up to a length of approx.
  • Page 103 Device Specifications Communication Modules (AC500 Standard) > CM574-RS with 2 Serial Interfaces 1.3.3.4 Technical Data Ä Chapter 2.6.1 “System Data AC500” on page 1248 are The System Data of AC500 and S500 valid for standard version. Ä Chapter 2.7.1 “System Data AC500-XC” on page 1309 are The System Data of AC500-XC valid for the XC version.

  • Page 104: Canopen

    Device Specifications Communication Modules (AC500 Standard) > CANopen 1.3.3.5 Ordering Data Part No. Description Product Life Cycle Phase *) 1SAP 170 400 R0201 CM574-RS, communication module, Active 2x serial RS232/485, free configurable serial interface module *) For planning and commissioning of new installations use modules in Active status only.
  • Page 105 Device Specifications Communication Modules (AC500 Standard) > CANopen 1.3.4.1.1 Purpose Communication module CM588-CN enables communication via the CANopen field bus. Ä Chapter 1.3.4.1 “CM588-CN - CANopen Slave” on page 104 is a slave in a CAN- CM588-CN open network. It is connected to the processor module via an internal communication bus. CM588-CN allows communicating of multiple CPUs in a CANopen network.
  • Page 106 Device Specifications Communication Modules (AC500 Standard) > CANopen Types of Bus For CANopen, only bus cables with characteristics as recommended in ISO 11898 are to be Cables used. The requirements for the bus cables depend on the length of the bus segment. Regarding this, the following recommendations are given by ISO 11898: Length of seg- Bus cable (shielded, twisted pair)
  • Page 107 Device Specifications Communication Modules (AC500 Standard) > CANopen +24 V Fig. 8: DeviceNet interface, bus terminating resistors connected to the line ends DeviceNet power supply COMBICON connection, DeviceNet interface Data lines, twisted pair cables black white blue bare The earthing of the shield should take place at the switch-gear. Please refer to Ä...
  • Page 108 Device Specifications Communication Modules (AC500 Standard) > CANopen 1.3.4.1.3 State LEDs The state of the CANopen communication module is displayed by means of 5 state LEDs. Table 21: Meaning of the diagnosis LEDs Color State Description Green ON (light) Power supply available OFF (dark) Power supply not available or defective hardware...
  • Page 109 Device Specifications Communication Modules (AC500 Standard) > CANopen Parameter Value Ä Chapter 1.2.2.1 Usable CPUs PM57x, PM58x, PM59x “PM57x (-y), PM58x (-y) and PM59x (-y)” on page 65 Usable terminal bases All TB5xx Ä Chapter 1.1.1 “TB51x-TB54x” on page 4 Bus connection Pluggable connector COMBICON, 2x5-pin Internal power supply...
  • Page 110 Device Specifications Communication Modules (AC500 Standard) > CANopen 1.3.4.2 CM598-CN - CANopen Master ● CANopen master 1 Mbit/s ● XC version for use in extreme ambient conditions available 5 LEDs for state display Label Communication interface, 5-pin, Combicon, male, removable plug with spring terminals Sign for XC version 1.3.4.2.1 Purpose...
  • Page 111 Device Specifications Communication Modules (AC500 Standard) > CANopen Transmission protocol CANopen (CAN), 1 Mbaud max. Transfer rate (baud rate) 10 kbit/s, 20 kbit/s, 50 kbit/s, 100 kbit/s, 125 kbit/s, 250 kbit/s, 500 kbit/s, 800 kbit/s and 1 Mbit/s, The CANopen connector has the following pin assignment: Pin Assignment Interface Signal...
  • Page 112 Device Specifications Communication Modules (AC500 Standard) > CANopen Length of seg- Bus cable (shielded, twisted pair) Max. baud rate ment [m] [kbit/s] Conductor Line resistance Wave impe- cross section [W/km] dance [W] [mm²] 0...40 0.25...0.34 / 1000 at 40 m AWG23, AWG22 40...300 0.34...0.60 /...
  • Page 113 Device Specifications Communication Modules (AC500 Standard) > CANopen +24 V Fig. 10: DeviceNet interface, bus terminating resistors connected to the line ends DeviceNet power supply COMBICON connection, DeviceNet interface Data lines, twisted pair cables black white blue bare The earthing of the shield should take place at the switch-gear. Please refer to Ä...
  • Page 114 Device Specifications Communication Modules (AC500 Standard) > CANopen 1.3.4.2.3 State LEDs Table 22: Meaning of the diagnosis LEDs Color State Description Green ON (light) Power supply available OFF (dark) Power supply not available or defective hardware Yellow ON Boot procedure Blinking Boot failure Green...
  • Page 115 Device Specifications Communication Modules (AC500 Standard) > CANopen Parameter Value Protocol CANopen Master, CAN2A, CAN2B Transmission rate 10 kbit/s to 1 Mbit/s Ambient temperature see: Ä Chapter 2.6.1 “System System data AC500 Data AC500” on page 1248 Ä Chapter 2.7.1 System Data AC500 XC “System Data AC500-XC”...

  • Page 116: Ethercat

    Device Specifications Communication Modules (AC500 Standard) > EtherCAT 1.3.5 EtherCAT 1.3.5.1 CM579-ETHCAT - EtherCAT Master 5 LEDs for state display 2 rotary switches for address setting (not used) Label 2 communication interfaces RJ45 (ETHCAT1 and ETHCAT2) 1.3.5.1.1 Intended Purpose Communication module CM579-ETHCAT is for EtherCAT communication. The comunication module is configured via the dual-port memory by means of a system config- urator.
  • Page 117 Device Specifications Communication Modules (AC500 Standard) > EtherCAT Table 23: Pin assignment RJ45 jack: Interface Signal Description TxD+ Transmit data + TxD- Transmit data - RxD+ Receive data + not used not used RxD- Receive data - not used not used Shield Cable shield Functional earth...
  • Page 118 Device Specifications Communication Modules (AC500 Standard) > EtherCAT 1.3.5.1.3 State LEDs The EtherCAT state is shown by the EtherCAT communication module's LEDs. Some LEDs are two-colored. Table 24: Meaning of the diagnosis LEDs Color State Description Green Power supply available Blinking Power supply not available or defective hardware...
  • Page 119 Device Specifications Communication Modules (AC500 Standard) > EtherCAT 1.3.5.1.4 Technical Data Ä Chapter 2.6.1 “System Data AC500” on page 1248 are The System Data of AC500 and S500 valid for standard version. Ä Chapter 2.7.1 “System Data AC500-XC” on page 1309 are The System Data of AC500-XC valid for the XC version.

  • Page 120: Ethernet

    Device Specifications Communication Modules (AC500 Standard) > Ethernet 1.3.5.1.5 Ordering Data Part No. Description Product Life Cycle Phase *) 1SAP 170 902 R0101 CM579-ETHCAT, EtherCAT Active communication module *) For planning and commissioning of new installations use modules in Active status only.
  • Page 121 Device Specifications Communication Modules (AC500 Standard) > Ethernet 1.3.6.1.1 Purpose The communication module provides communication via the Ethernet bus. Ethernet connection can be established directly to the communication module, an additional switch is not necessary. The Ethernet communication module is an intelligent 100-base-T-Ethernet communication inter- face based on the highly integrated netX100 micro-controller.
  • Page 122 Device Specifications Communication Modules (AC500 Standard) > Ethernet 1.3.6.1.3 State LEDs The Ethernet state is shown by the Ethernet communication module's LEDs. Table 27: Meaning of the diagnosis LEDs Color State Description Green Power supply available Power supply not available or defective hardware Yellow On Boot procedure...
  • Page 123 Device Specifications Communication Modules (AC500 Standard) > Ethernet 1.3.6.1.4 Technical Data Ä Chapter 2.6.1 “System Data AC500” on page 1248 are The System Data of AC500 and S500 valid for standard version. Ä Chapter 2.7.1 “System Data AC500-XC” on page 1309 are The System Data of AC500-XC valid for the XC version.

  • Page 124: Profibus

    Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 1.3.6.1.5 Ordering Data Part No. Description Product Life Cycle Phase *) 1SAP 173 700 R0001 CM597-ETH, communication module Active Ethernet TCP/IP with integrated 2-port switch 1SAP 373 700 R0001 CM597-ETH-XC, Active communication module Ethernet TCP/IP with integrated 2-port switch, XC version *) For planning and commissioning of new installations use modules in Active...
  • Page 125 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 5 LEDs for state display Label Communication interface PROFIBUS DP D-sub, 9-pin, female Sign for XC version 1.3.7.1.1 Purpose Communication module CM582-DP enables communication over the PROFIBUS DP field bus. For use in extreme ambient conditions (e.g. wider temperature and humidity range), a special XC version of the device is available.
  • Page 126 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 1.3.7.1.2 Electrical Connection Field Bus Interface The PROFIBUS DP connector (9-pin, female) has the following pin assignment: Signal Description Not connected Not connected RxD/TxD-P Receive/Transmit positive CNTR-P Control signal for repeater, positive DGND Reference potential for data exchange and +5 Vl +5 V (power supply for the bus terminating resistors)
  • Page 127 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 1.3.7.1.3 State LEDs The PROFIBUS state is shown by state LEDs. Table 30: Meaning of the diagnosis LEDs Color State Description Green ON (light) Power supply available. OFF (dark) Power supply not available or defective hardware Yellow ON Boot procedure...
  • Page 128 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS Parameter Value Ä Chapter 1.1.1 “TB51x-TB54x” Usable terminal bases All TB5xx on page 4 Current consumption from 24 VDC power Typ. 65 mA supply at the terminal base of the CPU Internal power supply Through the communication module interface of the terminal base Maximum number of cyclic input data...
  • Page 129 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 5 LEDs for state display Label Communication interface PROFIBUS DP D-sub, 9-pin, female Sign for XC version 1.3.7.2.1 Purpose Communication module CM592-DP enables communication over the PROFIBUS DP field bus. For use in extreme ambient conditions (e.g. wider temperature and humidity range), a special XC version of the device is available.
  • Page 130 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 1.3.7.2.2 Electrical Connection Field Bus Interface The PROFIBUS DP connector (9-pin, female) has the following pin assignment: Signal Description Not connected Not connected RxD/TxD-P Receive/Transmit positive CNTR-P Control signal for repeater, positive DGND Reference potential for data exchange and +5 Vl +5 V (power supply for the bus terminating resistors)
  • Page 131 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS 1.3.7.2.3 State LEDs The PROFIBUS state is shown by state LEDs. Table 32: Meaning of the diagnosis LEDs Color State Description Green ON (light) Power supply available OFF (dark) Power supply not available or defective hardware Yellow ON Boot procedure...
  • Page 132 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS Parameter Value State indication By 5 LEDs PWR, RDY, RUN, STA, ERR Ä Chapter 1.2.2.1 Usable CPUs PM57x, PM58x, PM59x “PM57x (-y), PM58x (-y) and PM59x (-y)” on page 65 Usable terminal bases All TB5xx Ä...
  • Page 133 Device Specifications Communication Modules (AC500 Standard) > PROFIBUS *) For planning and commissioning of new installations use modules in Active status only. 1.3.7.3 PROFIBUS Connection Details Attachment 9-pin D-sub connector, male Plug for the Bus Cable Parameter Value Fastening torque 0.4 Nm Assignment Signal...

  • Page 134: Profinet

    Device Specifications Communication Modules (AC500 Standard) > PROFINET Baud Rate Maximum Cable Length 9.6 / 19.2 / 93.75 kBaud 1200 m 187.5 kBaud 1000 m 500 kBaud 400 m 1.5 MBaud 200 m 3 MBaud to 12 MBaud 100 m Branch lines are generally permissible for baud rates of up to 1500 kbit/s.
  • Page 135 Device Specifications Communication Modules (AC500 Standard) > PROFINET 5 LEDs for state display 2 rotary switches for address setting (not used) Label 2 communication interfaces RJ45 (PNIO1 and PNIO2) Sign for XC version 1.3.8.1.1 Intended Purpose The communication module is for PROFINET RT communication. The PROFINET communication module includes an internal Ethernet switch.