Ac500 Cpus: Ac500-Cpus Pm571, Pm581, Pm582, Pm590 and Pm591

Contents
AC500 CPUs
AC500-CPUs PM571, PM581, PM582, PM590 and PM591 ..................................................... 3-2
Short description ...................................................................................................................................... 3-3
Assortment ............................................................................................................................... 3-5
Connections ............................................................................................................................................... 3-6

- I/O-Bus...................................................................................................................................................... 3-6
- Power supply ............................................................................................................................................ 3-7
- Bad wiring on power supply terminals ...................................................................................................... 3-8
- Serial interface COM1 .............................................................................................................................. 3-8
- Network interface Ethernet ....................................................................................................................... 3-9
- Network interface ARCNET...................................................................................................................... 3-9
- FBP interface ............................................................................................................................................ 3-9
Insertion / replacement of the Lithium battery ...................................................................... 3-10
Insertion of the SD Memory Card ........................................................................................... 3-12
Project planning / start-up.................................................................................................................... 3-13
Behaviour of the system in case of power supply interruptions and power recovering .... 3-13
Displays and operating elements on the front panel of the CPU............................................... 3-13
Examples for the use of the displays and pushbuttons .............................................................. 3-15
- Example 1: Setting of the slave address of the FBP plug onto the AC500 CPU
(if needed, but not recommended) ......................................................................................................... 3-15
- Example 2: AC500 CPU, status display and error indication ................................................................. 3-17
Technical data ......................................................................................................................................... 3-21
Ordering data ........................................................................................................................................... 3-24
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V2 AC500 Hardware 3-1 CPUs AC500 / Issued: 08.2007
AC500 CPUs PM571, PM581, PM582, PM590 and PM591
- PM5xx-ETH: CPU with network interface Ethernet RJ45
- PM5xx-ARCNET: CPU with network interface ARCNET BNC
12 PM581
2 3 ETH
SYS FBP
11
13 CPU 13
Lithium
BATT 1 COM1
I/O-Bus COM2
Battery
TA521 PWR RUN ERR
4
9 RUN DIAG 10
8 6
WARNING! VAL CFG
Use of
incorrect
5
ESC
battery may
cause fire or MC INSERT SD Memory Card
502 PUSH
explosion. OK MC502
19 CPU
7 24 V DC 10 W 20
ETHERNET
DC-IN 10W 18
15
FBP
Ethernet TB5xx-ETH
or ARCNET
TB5xx-ARCNET
COM1
COM2
16
14
17
Elements of the CPU Elements of the CPU Terminal Base

1 Six 7-segment status displays 11 I/O-Bus (10-pole, female) to electrically
with background lighting connect the first I/O Terminal Unit
2 Triangle displays for ”Item” 12 Slot for the CPU (CPU is mounted)
3 Square displays for ”Status” 13 Slots for couplers (max. 4)
4 Status LEDs 14 Interface for FieldBusPlug
5 Pushbuttons 15 Supply for 24 V DC
6 Slot for the SD Memory Card 16 Serial interface COM1
7 Label 17 Serial interface COM2
8 Compartment for the Lithium battery 18 Network interface (Ethernet or ARCNET)
9 Lithium battery TA521 19 Holes for wall mounting
10 SD Memory Card MC502 20 DIN rail
Figure: CPU PM581-ETH plugged on a Terminal Base TB521
The CPUs PM571, PM581, PM582, PM590 and PM591 are the central units (basic units) of the control
system Advant Controller 500 (AC500). The types differ in their performance (memory size, speed etc.).
Each CPU must be mounted on a suitable Terminal Base. The Terminal Base type depends on the
number of communication modules (couplers) which are used together with the CPU and on the CPU-
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own network interface type (Ethernet or ARCNET). At the right side of the CPU, up to 7 I/O expansion
modules can be attached.
If both of the following conditions are fulfilled, max. 10 I/O expansion modules can be connected to
the I/O-Bus of the CPU:
- PS501 as of version V1.2
- CPUs as of firmware V1.2.0
The CPUs have several interfaces.
Note: Mounting, disassembling, electrical connection and dimensioned drawings for the Terminal
Bases, CPUs, communication modules, I/O Terminal Units and the I/O expansion modules are
described in detail in the AC500 system data chapters.
Contents
Short description ......................................................................................................................................... 3-3
Assortment.................................................................................................................................................. 3-5
Connections ................................................................................................................................................ 3-6
- I/O-Bus...................................................................................................................................................... 3-6
- Power supply ............................................................................................................................................ 3-7
- Bad wiring on power supply terminals...................................................................................................... 3-8
- Network interface Ethernet ....................................................................................................................... 3-9
- Network interface ARCNET...................................................................................................................... 3-9
- FBP interface ............................................................................................................................................ 3-9
Insertion / replacement of the Lithium battery .......................................................................................... 3-10
Insertion of the SD Memory Card ............................................................................................................. 3-12
Project planning / start-up......................................................................................................................... 3-13
Behaviour of the system in case of power supply interruptions and power recovering............................ 3-13
Displays and operating elements on the front panel of the CPU.............................................................. 3-13
Examples for the use of the displays and pushbuttons ............................................................................ 3-15
- Example 1: Setting of the slave address of the FBP plug onto the AC500 CPU
(if needed, but not recommended) ......................................................................................................... 3-15
- Example 2: AC500 CPU, status display and error indication ................................................................. 3-17
Technical data........................................................................................................................................... 3-21
Ordering data ............................................................................................................................................ 3-24
Short description
Important: Currently, the AC500 CPU can only be used as slave together with the PROFIBUS DP
"Modular" FBP V0/V1 (order No. 1SAJ 240 100 R10xx) and the corresponding GSD file
ABB_091F.GSD.
Hardware configuration
Each CPU can operate up to 4 couplers through its coupler interface. The couplers are mounted on the
left side of the CPU on the same Terminal Base. On the right side of the CPU, up to 7 digital or analog
I/O expansion modules can be attached which are automatically interconnected by the I/O-Bus. Each of
these modules requires its own I/O Terminal Unit, whose type depends on the module type.
Terminal Bases, Terminal Units, I/O modules, couplers and accessories have their own technical
descriptions which can be found under "Hardware AC500" and "Hardware S500".
____________________________________________________________________________________________________________
Each CPU can be used as
• bus master within the control system AC500 together with several field buses and networkings
• slave (remote processor together with the FieldBusPlug) within the control system AC500
• stand-alone CPU
The CPUs are powered with 24 V DC.
CAUTION: Removal of energized modules is not permitted. All power sources (supply and
process voltages) must be switched off while working on any AC500 system.
The following figure shows a CPU with Terminal Base, couplers and I/O modules.
CM572 CM577 PM581 DC532
max. 4 couplers 1 ... 7 (10) *)

max. 7 (10) *)
I/O modules
Figure: CPU with Terminal Base, couplers and I/O modules
*) If both of the following conditions are fulfilled, max. 10 I/O expansion modules can be connected to
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Assortment
CPUs
CPU Program Cycle time for Network Other Suitable

memory 1000 instructions interface interfaces Terminal
Ether- ARC- Bases
net NET
PM571 Binary: 0.3 ms TB5xx-xx
PM571-ETH 64 kB Word: 0.3 ms TB5xx-ETH
Floating point: yes
6 ms
PM581 TB5xx-xx
PM581-ETH 256 kB Binary: 0.15 ms yes TB5xx-ETH
PM581- Word: 0.15 ms Serial TB5xx-
Floating point: yes interfaces
ARCNET ARCNET
3 ms COM1 and
PM582 COM2, TB5xx-xx
512 kB
PM582-ETH yes FBP, TB5xx-ETH
PM590 coupler TB5xx-xx
interface,
PM590-ETH 2 MB yes TB5xx-ETH
I/O-Bus
PM590- Binary: 0.02 ms TB5xx-
yes
ARCNET Word: 0.01 ms ARCNET
PM591 Floating point: TB5xx-xx
0.02 ms
PM591-ETH 4 MB yes TB5xx-ETH
PM591- TB5xx-
yes
ARCNET ARCNET
For further information see Technical data and Ordering data
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Terminal Bases
Number of slots
Terminal Base TB511 TB521 TB541

Slots for CPUs 1 1 1
Slots for communication modules 1 2 4
Terminals and interfaces
Terminal Base TB511- TB521- TB541-

available = (x) ETH (x) ARCNET ETH (x) ARCNET ETH (x) ARCNET
(x)
Connection
I/O-Bus I/O interface for directly adding up to 7 I/O Terminal Units *)
Power supply 5-pole removable terminal block
COM1 serial interface, 9-pole removable terminal block
COM2 serial interface, 9-pole SUB-D connector (female)
Network interface Ethernet ARCNET Ethernet ARCNET Ethernet ARCNET
(type must be equal to RJ45 BNC RJ45 BNC RJ45 BNC
the type of the used
CPU)
FBP interface Fieldbus-neutral slave interface (M12, 5-pole, male, fastening with screw)
Connections
I/O-Bus
The I/O-Bus is the I/O data bus for the S500 expansion modules. Through this bus, I/O and diagnosis
data are transferred between the AC500 CPU and the I/O expansion modules. Up to 7 I/O Terminal
Units (for 1 I/O expansion module each) can be added to one Terminal Base.
The I/O Terminal Units have a bus input at the left side and a bus output at the right side. Thus the
length of the I/O-Bus increases with the number of the I/O expansion modules used.
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11
I/O-Bus
(10-pole,
female)
Figure: I/O-Bus
Power supply
The supply voltage of 24 V DC is connected to a 5-pole removable terminal block. ZP and UP exist
twice. So it is possible to supply external sensors from these terminals, for instance.
Important: Exceeding the maximum power supply voltage (>30 V DC) for process or supply
voltages could lead to unrecoverable damage of the system. The system could be destroyed.
Supply voltage 24 V DC, 5-pole, terminals
L+ +24 V DC UP
ZP/UP
L+ +24 V DC UP
15 M 0V ZP
M 0V ZP
FE FE Functional Earth
1 Term. P RS-485 Terminator P
2 RxD/TxD-P RS-485 Receive/Transmit, positive
3 RxD/TxD-N RS-485 Receive/Transmit, negative
COM1
4 Term. N RS-485 Terminator N

5 RTS RS-232 Request To Send (Output)
6 TxD RS-232 Transmit Data (Output)
16 7 SGND Signal Ground
8 RxD RS-232 Receive Data (Input)
9 CTS RS-232 Clear To Send (Input)
Terminal block COM1 9-pole, terminals

removed Terminal block inserted
Figure, upper part: Power supply via a 5-pole terminal block

Figure, lower part: Terminal assignment of the serial interface COM1
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Bad wiring on power supply terminals
Attention: The product should be installed by trained people who have the knowledge of wiring
electronic devices. In case of bad wiring, although the modules are protected against various errors
(reverse polarity, short circuit, etc.), some problems could always happen:
- On the CPU Terminal Base, the terminals L+ and M are doubled. If the power supply is badly
connected, a short circuit could happen and lead to a destruction of the power supply or its fuse. If no
suitable fuse exists, the Terminal Base itself could be destroyed.
- The CPUs (Terminal Bases) and all electronic modules (and Terminal Units) are protected against
reverse polarity.
- All necessary measures should be carried out to avoid damages to modules and wiring. Notice the
wiring plans and connection examples.
Serial interface COM1 (for terminal assignment see the figure above)
The serial interface COM1 is connected to a removable 9-pole terminal block. It is configurable for RS-
232 and RS-485 and can be used for
• an online access (RS-232 programming interface for PC/Control Builder)

• a free protocol (communication via the function blocks COMSND and COMREC)
• Modbus RTU, master and slave or
• a CS31 system bus (RS-485), as master only
A detailed description for COM1 can be found under "Hardware AC500 / System data / System data and
System construction / Serial interface COM1 or Serial interfaces".
Serial interface COM2

The serial interface COM2 is connected to a 9-pole SUB-D connector. It is configurable for RS-232 and
RS-485 and can be used for
• an online access (RS-232 programming interface for PC/Control Builder)

• a free protocol (communication via the function blocks COMSND and COMREC)
• MODBUS RTU, master and slave
COM2 is not intended to establish a CS31 system bus.
Housing FE Functional Earth

1 FE Functional Earth
2 TxD RS-232 Transmit Data Output
9 5 3 RxD/TxD-P RS-485 Receive/Transmit positive
4 RTS RS-232 Request To Send Output
17 5 SGND Signal Ground 0 V supply out
6 6 +5 V 5 V supply out
1 7 RxD RS-232 Reiceive Data Input
8 RxD/TxD-N RS-485 Receive/Transmit negative
9 CTS RS-232 Clear To Send Input
COM2 9-pole, female
Figure: Pin assignment of the serial interface COM2
A detailed description for COM2 can be found under "Hardware AC500 / System data / System data and
System construction / Serial interface COM2 or Serial interfaces".
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Network interface Ethernet
This interface is the connection to the internal Ethernet coupler of the CPUs PM5xx-ETH. Applications
are:
• TCP/IP for PC/Control Builder (programming)

• UDP (communication via function blocks ETH_UDP_SEND and ETH_UDP_REC)
• Modbus on TCP/IP (Modbus on TCP/IP, master and slave)
8 NC not used
8 7 NC not used
6 RxD– Receive Data
Ethernet 5 NC not used
18 RJ45 4 NC not used
3 RxD+ Receive Data
1 2 TxD– Transmit Data
1 TxD+ Transmit Data
Shield Cable shield / Signal Ground
Figure: Pin assignment of the Ethernet interface
Network interface ARCNET

This interface is the connection to the internal ARCNET coupler of the CPUs PM5xx-ARCNET.
18
ARCNET BNC
Figure: ARCNET interface
FBP interface
Through this 5-pole fieldbus-neutral interface, the AC500 CPU can be connected as a slave to a fieldbus
master. The FieldBusPlug is fastened by a screw.
Pin assignment in serial mode

2 1 1 +24 V Standard power supply
14 5 2 Diagnosis pin
3 4
3 0V Standard power supply
4 Serial data
male 5 Serial data
Figure: Pin assignment of the FBP interface
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Insertion / replacement of the Lithium battery TA521
AC500 CPUs are supplied without a Lithium battery. It therefore must be ordered separately. The TA521
Lithium Battery is used to save RAM contents of AC500 CPUs and back-up the real-time clock. Although
the CPUs can work without a battery, its use is still recommended in order to avoid process data being
lost.
The CPU monitors the battery status. A low battery error is output before the battery condition becomes
critical (about 2 weeks before). After the error message appears, the battery should be replaced as soon
as possible.
Attention: The TA521 Lithium Battery is the only one, which can be used with AC500 CPUs.
The following procedures describe the insertion / replacement of the Lithium battery.
WARNING! WARNING!
Use of Use of
incorrect incorrect
battery may battery may
cause fire or
explosion.
cause fire or
explosion.
2
1a 1b
WARNING!
Use of
incorrect
battery may
4+5 cause fire or
explosion.
3 6
Figure: Insertion / replacement of the Lithium battery
Insertion of the battery:
1. Open the battery compartment by inserting a fingernail in the small locking mechanism, press it
down and slip down the door. The door is attached to the front face of the CPU and cannot be
removed.
2. Remove the TA521 battery from its package and hold it by the small cable.
3. Insert the battery connector into the small connector port of the compartment. The connector is
keyed to find the correct polarity (red = plus-pole = above).
4. Insert first the cable and then the battery into the compartment, push it until it reaches the
bottom of the compartment.
5. Arrange the cable in order not to inhibit the door to close.
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6. Pull-up the door and press until the locking mechanism snaps.
Note: In order to prevent data losses or problems, the battery should be replaced after 3 years of
utilisation or at least as soon as possible after receiving the "Low battery warning" indication.
Do not use a battery older than 3 years for replacement, do not keep batteries too long in stock.
Replacement of the battery:
Attention: In order to avoid any data losses (if needed), the battery replacement should be done
with the system under power. Without battery and power supply there is no data buffering possible.
1. Open the battery compartment by inserting a fingernail in the small locking mechanism, press it
down and slip down the door. The door is attached to the front face of the CPU and cannot be
removed.
2. Remove the old TA521 battery from the battery compartment by pulling it by the small cable.
Remove then the small connector from the socket, do this best by lifting it out with a screwdriver
(see photo).
3. Follow the previous instructions to insert a new battery.
Attention: Lithium batteries must not be re-charged, not be disassembled and not be disposed of
in fire. They must be stored in a dry place. Exhausted batteries must be recycled to respect the
environment.
The technical data sheet for the Lithium battery can be found in the chapter "Accessories / Lithium
Battery TA521".
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Insertion of the SD Memory Card MC502
AC500 CPUs are supplied without an SD Memory Card. It therefore must be ordered separately. The SD
Memory Card is used to back-up user data and store user programs as well as to update the internal
CPU firmware. AC500 CPUs can be operated with and without SD Memory Cards.
The CPU uses a standard file system. This allows standard card readers to read the MC502 SD Memory
Cards.
Attention: The use of memory cards other than the MC502 SD Memory Card is prohibited. ABB
is not responsible nor liable for consequences resulting from the use of unapproved memory cards.
Attention: In operation, the plugged-in SD Memory Card withstands vibrations up to 1 g. Without

using an SD Memory Card, the CPU itself withstands vibrations up to 4 g.
PM581
ETH
SYS FBP
BATT COM1 SD Memory Card
I/O-Bus COM2 MC502
PWR RUN ERR
RUN DIAG
WARNING! VAL CFG

Use of
incorrect
battery may
ESC
cause fire or MC INSERT
502 PUSH
explosion. OK
CPU
24 V DC 10 W
Figure: Insertion of the SD Memory Card
To insert the SD Memory Card, follow the procedure shown below.
1. Remove the SD Memory Card from its package.
2. Insert the memory card into the opening of the front face of the CPU with the memory aligned as
shown above (contacts are visible on the left side, bevelled edge below).
3. Push on the card until it moves forward, then release your pressure, the SD card comes slightly
backward and it locks into the card slot.
Removing the SD Memory Card

To remove the card, first push on the card until it moves forward (that unlocks the card), then release
your pressure, the card will go forward out of the slot and can be easily removed.
The technical data sheet for the SD Memory Card can be found in the chapter "Accessories / SD
Memory Card MC502".
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Project planning / start-up
Programming is carried out with the AC500 Control Builder software, which is based on the CodeSys
standard. The software can be run on the operating systems Windows 2000 and XP.
A fast Online Program Modification of the user program is possible without interrupting the running
operation.
If data areas should be saved during power OFF/ON, they can be stored in the Flash EPROM. The
installed Lithium battery saves data in the RAM.
Behaviour of the system in case of power supply interruptions and power

recovering
AC500 system supply (terminals L+, M)

As soon as the CPU power supply is higher than 19.2 V DC, the power supply detection is activated and
the CPU is started. When during operation the power supply is going down to lower than 19.2 V DC for
more than 10 ms, the CPU is switched to safety mode (see System Technology of the CPUs).
A warm restart of the CPU only occurs by switching the power supply off and on again (see also
the description of the function modes of the CPU in the "AC500 System Technology" chapters.
Displays and operating elements on the front panel of the CPU
PM581
2 3 ETH
SYS FBP
BATT 1 COM1
I/O-Bus COM2
PWR RUN ERR
4
RUN DIAG
WARNING! VAL CFG

Use of
incorrect
5
ESC
battery may
502 PUSH
explosion. OK
CPU
24 V DC 10 W
Figure: Displays and operating elements on the front panel of the CPU
LCD display with background lighting

1 Six 7-segment status displays for displaying
• the CPU status (e.g. RUN or STOP)
• error codes and error classes
• address modifications and parameters of the integrated couplers (Ethernet or ARCNET)
• values at the channels of I/O modules
2 Triangle displays
• show what is just selected (active)
3 Square displays
• show that the communication is running between the CPU and the bus
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Status LEDs
4 Meaning of the status LEDs
LED Color Function

PWR green indicates that the power supply of the CPU is ON
RUN green indicates that the CPU is running (is OFF with STOP)
ERR red indicates an error occurred (goes off after error acknowledgement)
Pushbuttons
5 The CPU can be operated manually using the eight pushbuttons on the front panel. Meaning
of the pushbuttons:
Button Meaning
RUN toggles the CPU between RUN and STOP mode
VAL reserved for future use
ESC ESC, quit menu without saving
OK OK, leave menu after saving
DIAG diagnosis, evaluate error message in detail
CFG set address for ARCNET, CS31 and FBP
↑ Move up selection or increase value (e.g. address) by 1
↓ Move down selection or decrease value (e.g. address) by 1
The entire functionality of the CPUs is described in detail under "System technology of the CPUs".
In the following examples, the use of the displays and pushbuttons is represented in detail.
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Examples for the use of the displays and pushbuttons
Example 1: Setting of the slave address of the FBP plug onto the AC500 CPU (if
needed, but not recommended)
The FieldBusPlug must have a properly assigned slave module address. The AC500 CPU gives them an
address at system power-up. The address could be set with the use of the display and the pushbutton on
the top of the module, but it is mainly assigned by the AC500 Control Builder configuration.
Attention: The local setting of an FBP address by means of pushbuttons and display has a
higher priority than an FBP address configured by the AC500 Control Builder!
The locally set address replaces the address configured by the software.
It is highly recommended to be extremely careful when modifying the address locally, because it has
high influence on the behaviour of the application.
Up to 99 addresses can be then set with the display.
PM581
ETH
SYS FBP
BATT COM1
I/O-Bus COM2
PWR RUN ERR
By using the CFG, the ar- RUN DIAG

row keys and the OK
WARNING! VAL CFG
pusbutton, some parame- Use of
ters of the CPU can be incorrect
ESC
battery may
configured. INSERT
cause fire or MC
CFG explosion. OK 502 PUSH
CPU
24 V DC 10 W
OK
Figure: Configuration on the CPU
Attention: If the FBP address set on the AC500 CPU module (or by the AC500 Control Builder
software) is different from that address assigned by the Master device for the same station, the station
cannot be accessed and the complete Fieldbus cannot work properly or is completely down!
____________________________________________________________________________________________________________
To configure the FBP address, please follow the procedure described below:
1. First select the item to be configured by ETH

pressing the CFG key, the CPU changes to SYS FBP
CFG
configuration mode and a small triangle is BATT COM1
I/O-Bus COM2
displayed on the LCD on the first right up
position of the display beside the ETH in-
scription and the already configured ad-
ETH
dress is displayed. SYS FBP
Press one time more the CFG key to move CFG
BATT COM1
the triangle to the position below ”FBP” . I/O-Bus COM2
The FBP is then selected, and the current
address is shown.
2. Press then the arrow keys UP or DOWN to ETH

increase or decrease the address, the mo- SYS FBP
dified value blinks to indicate that it di ffers BATT COM1
I/O-Bus COM2
from the previously stored one.
3. Once the desired address is reached,
OK ETH
press OK to accept and quit or only ESC to SYS FBP
exit the menu without saving the changes. or
BATT COM1
The CPU status is then displayed ESC I/O-Bus COM2
run/StoP.
Figure: Configuration of an FBP address
A AC500 CPU equipped with a FieldBusPlug is always a slave device on the bus. To act as a master, a
AC500 CPU should be equipped with master couplers (e.g CM572-DP for PROFIBUS DP).
Attention: The locally modified address will only be valid after a power OFF/ON of the CPU!
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Example 2: AC500-CPU, status display and error indication
All AC500 CPUs have LEDs and a LC Display for indicating operating statuses and errors. The following
drawing shows the front face of a AC500 CPU.
The CPU statuses are displayed on the CPU front

PM581 face with 3 LEDs:
ETH – PWR
SYS FBP
BATT COM1 – RUN
I/O-Bus COM2 – ERR
– and by means of a background-lighted display
PWR RUN ERR
The display contains the following indications:
RUN DIAG – small black squares indications acting as a
LED status for the device written beneath
WARNING! VAL CFG
Use of – small black arrows used for indication by
incorrect
ESC pointing the selected device to be con-
battery may
cause fire or MC INSERT figured or read
502 PUSH
explosion. OK
– 6 x 7-segment displays for ”plain text” or
CPU error codes display
24 V DC 10 W
Figure: Front face of a AC500 CPU
The display is normally OFF and the status of the CPU is shown as plain text "run" or "Stop", which
reflects the operating status of the CPU program.
By pressing one of the dialog keys "RUN, DIAG, CFG or VAL", the background lighting is turned ON
and the desired function is performed.
In case of a function error, the display background lighting is also switched on and an error code is
displayed.
The meaning of the LEDs and of LCD is given in the following table.
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AC500 CPU module LEDs
LED Status Color LED = ON LED = OFF LED flashes

PWR 24 V DC green voltage is present voltage is --
power supply missing
is provided
RUN activity status green CPU is in RUN CPU is in If flashes fast (4 Hz):
mode STOP mode The CPU is
reading/writing the SD
card, indicates together
with the blinking error
LED that the CPU is
writing the internal Flash
EEPROM.
If flashes slow (1 Hz):
The firmware update
from the SD card is
finished without errors.
ERR error indication red An error has No errors are Flashing fast (4 Hz):
occurred. After encountered or Indicates together with
pressing the only warnings RUN a firmware update
DIAG key, the (E4 errors). process and a Flash
error type and This is EEPROM write.
code is displayed configurable
in the LC Display. (by error 2 - 4,
The error codes the LED
can be shown by behaviour is
means of the configurable.
DIAG and OK
keys.
Working black Device is present No activity or Flashing according to
activity of the and OK (e.g. the device not the device activity, e.g.
beneath battery is present present when data exchange on
described and OK). ETH, COM1, etc...
device (e.g. communication lines.
top right of the
display ETH
communication
line).
or Indicates the black Points out the No device --
selected selected device selected
device to be of which the
read or name is written
configured. beneath (e.g. top
Acts as a right of the
cursor moving display ETH
with the arrow communication
keys line).
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Displaying error messages (error codes) on the AC500 CPU
When an error occurs, the red error LED goes on.
By pressing the DIAG key, the complete error code can be shown and an acknowledgement of the error
can be performed.
PM581
ETH
SYS FBP
BATT COM1
I/O-Bus COM2
PWR RUN ERR
By using the DIAG and RUN DIAG

the OK or the ESC push-
WARNING! VAL CFG
buttons, the error mes- Use of
sage/code can be dis- incorrect
ESC
played and the error can battery may
be acknowledged. 502 PUSH
explosion. OK
CPU
DIAG OK ESC
24 V DC 10 W
Figure: Error display on the CPU
The AC500 CPU can display various errors according to the error classes. The following error classes
are possible. The reaction of the CPU is different for each type of error.
Error class Type Meaning Example

E1 Fatal error A safe function of the operating system Checksum error in the
is no longer guaranteed. system Flash or RAM error
E2 Severe error The operating system is functioning Checksum error in the
without problems, but the error-free user Flash, independent of
processing of the user program is no the task duration
longer guaranteed.
E3 Light error It depends on the application, if the user Flash could not be
program should be stopped by the programmed, I/O module
operating system or not. The user has failed.
should decide, which reaction is
necessary.
E4 Warning Error in the periphery (e.g. I/O) which Short-circuit at an I/O
only can have influence in the future. module, the battery is
The user should decide the reaction to exhausted or not inserted.
provide.
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How an error message is built-up in the display
An error always consists of an Error Class (E1 to E4, see the previous table) and a number (0 to 63)
which indicates the identifier of the error for direct error recognition. Moreover, there are further four
detailed error codes from d1 to d4 which define the error in detail:
E1...E4 = 00...63 (error identifier) e.g. wrong value, checksum error, short-circuit, exhausted or
missing battery, etc. which is directly displayed in the LCD
-> d1 = 000...015 indicates the component which has sent the error (coupler, CPU,
COM1, FBP, IO-Bus, etc.)
d2 = 000...255 defines the faulty device within the component
d3 = 000...030 defines the part of the module with an error (slot)
d4 = 000...031 defines the channel within the module
Example of an error display for an exhausted battery

To display the complete error codes, please follow the procedure described below:
The CPU is running. The display only shows ETH

the RUN status and the background lighting is SYS FBP
OFF. BATT COM1
I/O-Bus COM2
When an error occurs, the red ERR LED goes
on. An error message is output after pressing ETH
the DIAG key and, for example, the screen SYS FBP
shown to the right displays ”E4=008”. Accor- BATT COM1
I/O-Bus COM2
ding to the error level, E1 to E4 can be dis-
played.
In this example, ”E4=008” is a warning (E4)
and ”008” means ”Empty/Missing”.
By pressing on the DIAG button, the LCD

background lighting is turned ON, the error ETH
codes can be displayed to achieve more (dea- SYS FBP
DIAG
per) diagnostic. The display shows ”d1=009” BATT COM1
(detail level 1) and ”009” indicates that the I/O-Bus COM2
CPU has sent the error.
By pressing DIAG one more time, the display ETH
SYS FBP
shows ”d2=022” (detail level 2) and ”022” indi- DIAG BATT COM1
cates that the device type = battery. I/O-Bus COM2

SYS FBP
shows ”d3=031” (detail level 3) and ”031” DIAG BATT COM1
means ”no module type” (= device itself). I/O-Bus COM2

SYS FBP
shows ”d4=031” (detail level 4) and ”031” DIAG BATT COM1
means ”no channel” (= device itself). I/O-Bus COM2
By pressing OK, the error is acknowledged OK ETH

and the display returns to the normal state. SYS FBP
or BATT COM1
ESC returns to the normal state without ack-
I/O-Bus COM2
nowledging the error! ESC
Figure: Example of an error display for an exhausted battery
____________________________________________________________________________________________________________
Technical data
The system data of AC500 and S500 are valid here. Only additional details are therefore documented
below.
General data of the CPUs and the Terminal Bases

For more information, please refer to the "AC500 System Data" chapters.
Connection of the supply voltage 24 V at a 5-pole removable terminal block with spring connection
DC at the Terminal Base of the CPU
Current consumption from 24 V DC PM571: 50 mA
PM571-ETH: 110 mA
PM581: 50 mA
PM581-ETH: 110 mA
PM581-ARCNET: 110 mA
PM582: 50 mA
PM582-ETH: 110 mA
PM59x: 90 mA
PM59x-ETH: 150 mA
PM59x-ARCNET: 150 mA
Inrush current at 24 V DC PM571: 1 A²s
PM571-ETH: 1 A²s
PM581: 1 A²s
PM581-ETH: 1 A²s
PM581-ARCNET: 1 A²s
PM582: 1 A²s
PM582-ETH: 1 A²s
PM59x: 1 A²s
PM59x-ETH: 1 A²s
PM59x-ARCNET: 1 A²s
Max. power dissipation within the 10 W
module
Slots on the Terminal Bases TB511: 1 CPU, 1 communication module
TB521: 1 CPU, 2 communication modules
TB524: 1 CPU, 4 communication modules
CPU interfaces at the Terminal Bases I/O-Bus, COM1, COM2, FBP
CPU network interfaces at the Terminal TB5xx-ETH / PM5xx-ETH: Ethernet
Bases TB5xx-ARCNET / PM5xx-ARCNET: ARCNET
Connection system see AC500 system data
Dimensions further details see AC500 system data

Width x height x depth TB511 with CPU: 95.5 x 135 x 75 mm
TB521 with CPU: 123.5 x 135 x 75 mm
TB541 with CPU: 179.5 x 135 x 75 mm
Weight (CPU without Terminal Base) PM571: 135 g
PM571-ETH: 150 g
PM581: 135 g
PM581-ETH: 150 g
PM581-ARCNET: 160 g
PM582: 135 g
PM582-ETH: 150 g
PM59x: 135 g
PM59x-ETH: 150 g
PM59x-ARCNET: 160 g
Mounting position horizontal or
vertical with derating (50 % output load, reduction of temperature to
40°C)
____________________________________________________________________________________________________________
Detailed data of the CPUs
CPU PM571 PM571 PM58x PM58x PM581- PM59x PM59x PM59x-

-ETH -ETH ARCNET -ETH ARCNET
Program memory 64 kB PM581: 256 kB PM590: 2048 kB
Flash EPROM and RAM PM582: 512 kB PM591: 4096 kB
Data memory, integrated 24 kB, incl. 4 kB 288 kB, incl. 32 kB RETAIN PM590: 2048 kB,
RETAIN PM591:3072 kB, incl. 512 kB
RETAIN
Expandable memory none none none
Pluggable SD Memory Card 128 MB 128 MB 128 MB
for:
- User data storage
- Program storage
- Firmware update
Cycle time for
1000 instructions
- Binary 0.3 ms 0.15 ms 0.05 ms
- Word 0.3 ms 0.15 ms 0.05 ms
- Floating point 6.0 ms 3.0 ms 0.5 ms
Max. number of central inputs
and outputs (up to 7 exp.
modules):
- Digital inputs 224 224 224
- Digital outputs 168 168 168
- Analog inputs 112 112 112
- Analog outputs 112 112 112
Max. number of central inputs
and outputs (up to 10 exp.
modules): *)
- Digital inputs 320 320 320
- Digital outputs 240 240 240
- Analog inputs 160 160 160
- Analog outputs 160 160 160
Number of decentralized depends on the used field bus
inputs and outputs (as an info on the CS31 bus: up to 31 stations with up to 120 DI / 120 DO each)
Data backup battery battery battery
Data buffering time at 25°C about 3 years
Battery low indication warning indication issued about 2 weeks before the battery charge becomes
critical
Real-time clock
- with battery back-up X X X
Program execution
- cyclic X X X
- time-controlled X X X
- multitasking X X X
Protection of the user
program by a password X X X
- Physical link: configurable for RS-232 or RS-485 (from 0.3 to 187.5 kB/s)
- Connection: pluggable terminal block, spring connection
- Usage: for programming,
as Modbus (master/slave),
as serial ASCI communication,
as CS31 master
- Physical link: configurable for RS-232 or RS-485 (from 0.3 to 187.5 kB/s)
- Connection: SUB-D connector
- Usage: for programming,
as Modbus (master/slave),
as serial ASCI communication
Integrated coupler, ETH ETH ARCNET ETH ARCNET
ETH = Ethernet RJ45
ARCNET = ARCNET BNC
____________________________________________________________________________________________________________
Number of external couplers up to 4 communication couplers like PROFIBUS DP, Ethernet, CANopen,
DeviceNet. There is no restriction concerning the coupler types and coupler
combinations (e.g. up to 4 PROFIBUS DP couplers are possible)
LEDs, LCD display, for RUN/STOP switch-over, status displays and diagnosis
8 function keys
Number of timers unlimited unlimited unlimited
Number of counters unlimited unlimited unlimited
Programming languages
- Instruction List IL X X X
- Function Block Diagram X X X
FBD
- Ladder Diagram LD X X X
- Sequential Function X X X
Chart SFC
- Continuous Function X X X
Chart (CFC)
Certifications CE, GL, DNV, BV, RINA, LRS, cUL
____________________________________________________________________________________________________________
Ordering data
Order No. Scope of delivery

1SAP 130 100 R0100 PM571, CPU, memory 64 kB, 24 V DC, Memory Card Slot, interfaces 2 x RS-
232/485 (programming, Modbus/CS31), 1 x FBP, Display
1SAP 130 100 R0170 PM571-ETH, CPU, memory 64 kB, 24 V DC, Memory Card Slot, interfaces 2 x RS-
232/485 (programming, Modbus/CS31), 1 x FBP, Display, integrated coupler
Ethernet TCP/IP
1SAP 140 100 R0160 PM581-ARCNET, CPU, memory 256 kB, 24 V DC, Memory Card Slot, interfaces 2
x RS-232/485 (programming, Modbus/CS31), 1 x FBP, Display, integrated coupler
ARCNET
1SAP 140 100 R0170 PM581-ETH, CPU, memory 256 kB, 24 V DC, Memory Card Slot, interfaces 2 x
RS-232/485 (programming, Modbus/CS31), 1 x FBP, Display, integrated coupler
Ethernet TCP/IP
1SAP 140 200 R0170 PM582-ETH, CPU, memory 512 kB, 24 V DC, Memory Card Slot, interfaces 2 x
Ethernet TCP/IP
1SAP 150 000 R0100 PM590, CPU, memory 2 MB, 24 V DC, Memory Card Slot, interfaces 2 x RS-
1SAP 150 000 R0160 PM590-ARCNET, CPU, memory 2 MB, 24 V DC, Memory Card Slot, interfaces 2 x
ARCNET
1SAP 150 000 R0170 PM590-ETH, CPU, memory 2 MB, 24 V DC, Memory Card Slot, interfaces 2 x RS-
Ethernet TCP/IP
1SAP 150 100 R0100 PM591, CPU, memory 4 MB, 24 V DC, Memory Card Slot, interfaces 2 x RS-
1SAP 150 100 R0160 PM591-ARCNET, CPU, memory 4 MB, 24 V DC, Memory Card Slot, interfaces 2 x
ARCNET
1SAP 150 100 R0170 PM591-ETH, CPU, memory 4 MB, 24 V DC, Memory Card Slot, interfaces 2 x RS-
Ethernet TCP/IP
1SAP 180 300 R0001 TA521, Lithium Battery

1SAP 180 100 R0001 MC502, SD Memory Card 128 MB
1SAP 180 200 R0001 TK501, Programming cable SUB-D / SUB-D, length: 5 m
1SAP 180 200 R0101 TK502, Programming cable terminal block / SUB-D, length: 5 m
1SAP 180 800 R0001 TA526, Wall Mounting Accessory
1SAP 111 100 R0170 TB511-ETH, CPU Terminal Base AC500, slots: 1 CPU, 1 communication module,
Ethernet RJ45 connector
1SAP 112 100 R0160 TB521-ARCNET, CPU Terminal Base AC500, slots: 1 CPU, 2 communication
modules, ARCNET COAX connector
1SAP 112 100 R0170 TB521-ETH, CPU Terminal Base AC500, slots: 1 CPU, 2 communication modules,
1SAP 114 100 R0170 TB541-ETH, CPU Terminal Base AC500, slots: 1 CPU, 4 communication modules,
1SAP 212 200 R0001 TU515, I/O Terminal Unit, 24 V DC, screw-type terminals
1SAP 212 000 R0001 TU516, I/O Terminal Unit, 24 V DC, spring terminals
1SAP 217 200 R0001 TU531, I/O Terminal Unit, 230 V AC, relays, screw-type terminals
1SAP 217 000 R0001 TU532, I/O Terminal Unit, 230 V AC, relays, spring terminals
____________________________________________________________________________________________________________

Ac500 Cpus: Ac500-Cpus Pm571, Pm581, Pm582, Pm590 and Pm591

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Contents

AC500-CPUs PM571, PM581, PM582, PM590 and PM591 ..................................................... 3-2

Short description ...................................................................................................................................... 3-3

Assortment ............................................................................................................................... 3-5

Connections ............................................................................................................................................... 3-6

Insertion / replacement of the Lithium battery ...................................................................... 3-10

Insertion of the SD Memory Card ........................................................................................... 3-12

Project planning / start-up.................................................................................................................... 3-13

Technical data ......................................................................................................................................... 3-21

Ordering data ........................................................................................................................................... 3-24

Elements of the CPU Elements of the CPU Terminal Base

Figure: CPU PM581-ETH plugged on a Terminal Base TB521

The CPUs have several interfaces.

The CPUs are powered with 24 V DC.

CM572 CM577 PM581 DC532

max. 4 couplers 1 ... 7 (10) *)

Figure: CPU with Terminal Base, couplers and I/O modules

CPU Program Cycle time for Network Other Suitable

For further information see Technical data and Ordering data

Terminal Base TB511 TB521 TB541

Terminals and interfaces

Terminal Base TB511- TB521- TB541-

Supply voltage 24 V DC, 5-pole, terminals

4 Term. N RS-485 Terminator N

Terminal block COM1 9-pole, terminals

Figure, upper part: Power supply via a 5-pole terminal block

• an online access (RS-232 programming interface for PC/Control Builder)

Serial interface COM2

• an online access (RS-232 programming interface for PC/Control Builder)

COM2 is not intended to establish a CS31 system bus.

Housing FE Functional Earth

Figure: Pin assignment of the serial interface COM2

• TCP/IP for PC/Control Builder (programming)

Figure: Pin assignment of the Ethernet interface

Network interface ARCNET

Figure: ARCNET interface

Pin assignment in serial mode

Figure: Pin assignment of the FBP interface

Figure: Insertion / replacement of the Lithium battery

Insertion of the battery:

5. Arrange the cable in order not to inhibit the door to close.

Replacement of the battery:

3. Follow the previous instructions to insert a new battery.

Attention: In operation, the plugged-in SD Memory Card withstands vibrations up to 1 g. Without

WARNING! VAL CFG

Figure: Insertion of the SD Memory Card

To insert the SD Memory Card, follow the procedure shown below.

1. Remove the SD Memory Card from its package.

Removing the SD Memory Card

Behaviour of the system in case of power supply interruptions and power

AC500 system supply (terminals L+, M)

Displays and operating elements on the front panel of the CPU

WARNING! VAL CFG

LCD display with background lighting

LED Color Function

Up to 99 addresses can be then set with the display.

By using the CFG, the ar- RUN DIAG

Figure: Configuration on the CPU

1. First select the item to be configured by ETH