2CDC125028M0203
2CDC125028M0203
2CDC125028M0203
AC500 CPUs
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
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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
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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V2 AC500 Hardware 3-2 CPUs AC500 / Issued: 08.2007
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
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
- Serial interface COM1 .............................................................................................................................. 3-8
- Serial interface COM2 .............................................................................................................................. 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.
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
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".
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V2 AC500 Hardware 3-3 CPUs AC500 / Issued: 08.2007
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
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.
*) 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
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V2 AC500 Hardware 3-4 CPUs AC500 / Issued: 08.2007
Assortment
CPUs
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V2 AC500 Hardware 3-5 CPUs AC500 / Issued: 08.2007
Terminal Bases
Number of slots
*) 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
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.
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 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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V2 AC500 Hardware 3-6 CPUs AC500 / Issued: 08.2007
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.
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
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V2 AC500 Hardware 3-7 CPUs AC500 / Issued: 08.2007
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
A detailed description for COM1 can be found under "Hardware AC500 / System data / System data and
System construction / Serial interface COM1 or Serial interfaces".
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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V2 AC500 Hardware 3-8 CPUs AC500 / Issued: 08.2007
Network interface Ethernet
This interface is the connection to the internal Ethernet coupler of the CPUs PM5xx-ETH. Applications
are:
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
18
ARCNET BNC
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.
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V2 AC500 Hardware 3-9 CPUs AC500 / Issued: 08.2007
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
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.
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V2 AC500 Hardware 3-10 CPUs AC500 / Issued: 08.2007
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.
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).
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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V2 AC500 Hardware 3-11 CPUs AC500 / Issued: 08.2007
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.
PM581
ETH
SYS FBP
BATT COM1 SD Memory Card
I/O-Bus COM2 MC502
PWR RUN ERR
RUN DIAG
CPU
24 V DC 10 W
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.
The technical data sheet for the SD Memory Card can be found in the chapter "Accessories / SD
Memory Card MC502".
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V2 AC500 Hardware 3-12 CPUs AC500 / Issued: 08.2007
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.
PM581
2 3 ETH
SYS FBP
BATT 1 COM1
I/O-Bus COM2
PWR RUN ERR
4
RUN DIAG
CPU
24 V DC 10 W
Figure: Displays and operating elements on the front panel of the CPU
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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V2 AC500 Hardware 3-13 CPUs AC500 / Issued: 08.2007
Status LEDs
4 Meaning of the status LEDs
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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V2 AC500 Hardware 3-14 CPUs AC500 / Issued: 08.2007
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.
PM581
ETH
SYS FBP
BATT COM1
I/O-Bus COM2
PWR RUN ERR
CPU
24 V DC 10 W
OK
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!
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V2 AC500 Hardware 3-15 CPUs AC500 / Issued: 08.2007
To configure the FBP address, please follow the procedure described below:
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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V2 AC500 Hardware 3-16 CPUs AC500 / Issued: 08.2007
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 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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V2 AC500 Hardware 3-17 CPUs AC500 / Issued: 08.2007
AC500 CPU module LEDs
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V2 AC500 Hardware 3-18 CPUs AC500 / Issued: 08.2007
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
CPU
DIAG OK ESC
24 V DC 10 W
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.
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V2 AC500 Hardware 3-19 CPUs AC500 / Issued: 08.2007
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
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V2 AC500 Hardware 3-20 CPUs AC500 / Issued: 08.2007
Technical data
The system data of AC500 and S500 are valid here. Only additional details are therefore documented
below.
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
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V2 AC500 Hardware 3-21 CPUs AC500 / Issued: 08.2007
Detailed data of the CPUs
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V2 AC500 Hardware 3-22 CPUs AC500 / Issued: 08.2007
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
*) 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
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V2 AC500 Hardware 3-23 CPUs AC500 / Issued: 08.2007
Ordering data
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,
Ethernet RJ45 connector
1SAP 114 100 R0170 TB541-ETH, CPU Terminal Base AC500, slots: 1 CPU, 4 communication modules,
Ethernet RJ45 connector
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
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V2 AC500 Hardware 3-24 CPUs AC500 / Issued: 08.2007