System Description AC500

Scalable PLC
for Individual Automation

Introduction

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 Contents
Introduction
Survey - gain an overview........................................................................................................ 1-3
System structure of AC500/S500-FBP ..................................................................................................... 1-3
AC500 system overview ........................................................................................................................... 1-4
Bus systems overview .............................................................................................................................. 1-8
Documentation overview ........................................................................................................................ 1-15
Short description of the hardware........................................................................................................... 1-19
Short description of the software ............................................................................................................ 1-20
Operating and displaying ........................................................................................................................ 1-22
Services .................................................................................................................................................. 1-26
Service - Control Engineering............................................................................................................... 1-26
Repair services and replacement devices............................................................................................ 1-26
Seminars/Workshops............................................................................................................................ 1-27
Addresses ............................................................................................................................................... 1-28
Regulations concerning the appropriate and safe setup of systems and installations........................... 1-29

Getting started with AC500.................................................................................................... 1-32

Important user information...................................................................................................................... 1-32
Before starting ....................................................................................................................................... 1-33
Assembling the system........................................................................................................................... 1-36
Insertion / replacement of the Lithium battery ........................................................................................ 1-39
Insertion of the SD Memory Card ........................................................................................................... 1-41
Mounting the system............................................................................................................................... 1-42
AC500 system dimensions ..................................................................................................................... 1-48
Setting the FBP slave address ............................................................................................................... 1-50
Status display and error indication on the AC500 CPU.......................................................................... 1-52
LEDs on S500-FBP modules.................................................................................................................. 1-56
Specifications and certifications ............................................................................................................. 1-58

Getting started with S500-FBP .............................................................................................. 1-59

Important user information...................................................................................................................... 1-59
Before starting ....................................................................................................................................... 1-60
Assembling the system........................................................................................................................... 1-62
Mounting the system............................................................................................................................... 1-65
S500 system dimensions........................................................................................................................ 1-70
Setting the FBP slave address ............................................................................................................... 1-72
LEDs on S500-FBP modules.................................................................................................................. 1-73
Specifications and certifications ............................................................................................................. 1-75

Examples ................................................................................................................................ 1-76

Examples for introduction ................................................................................................................... 1-76
Getting started ........................................................................................................................................ 1-76
Examples for decentralized systems connected by network .......................................................... 1-96
Example: AC500 CPU PM581 as PROFIBUS-DP master and coupler DC505-FBP
as PROFIBUS DP slave with FieldBusPlug PDP22-FBP ........................................................ 1-96

For AC1131 experts – connection of S500-FBP I/O module to series 90.......................... 1-122
Example: AC31 Series 90 CPU as PROFIBUS-DP master and
decentralized I/O expansion using a DC505-FBP.................................................................. 1-122

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G1 Introduction to AC500 1-1 AC500 / Issued: 07.2006

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G1 Introduction to AC500 1-2 AC500 / Issued: 07.2006

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 Survey - gain an overview
System structure of AC500/S500-FBP
The principle system structure is shown in the following figure:

AC500

External CPU S500–FBP I/Os

couplers + (max. 7 modules)
(max. 4) internal
couplers

S500–FBP

DC505–FBP S500–FBP I/Os

(7 modules max.
with a maximum of
4 analog modules)

Explanation
The following electronic modules are the basic components of the AC500 system:

• CPUs of three different performance classes

• Couplers for various bus systems: Fieldbus systems PROFIBUS DP, CANopen, DeviceNet; Ethernet
couplers.

Central expansion: One CPU supports direct connection of up to seven S500 FBP system I/O devices.

Decentralized expansion: Using the DC505 FBP interface module (for fieldbus systems PROFIBUS DP,
CANopen, DeviceNet, Modbus RTU), up to seven S500 FBP system I/O devices can be connected (with
a maximum of four analog modules).

Mechanical mounting of the electronic modules is done using CPU terminal bases (for the CPU and the
couplers) and I/O terminal units (for the I/O modules), designed for snap-on mounting on a DIN rail or for
screw-mounting on a mounting panel.

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G1 Introduction to AC500 1-3 AC500 / Issued: 07.2006

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 AC500 system overview
AC500 is a complex state-of-the-art system providing extensive automation potential for your plant.

Figure: AC500 system

The following pages provide a summary of all devices available for the AC500 system. For detailed
information about the individual devices please refer to the respective hardware description.

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G1 Introduction to AC500 1-4 AC500 / Issued: 07.2006

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 Overview of available CPUs

Type Order number Description

PM571 1SAP 130 100 R0100 PM571, CPU 64kB, 24 V DC, Memory Card Slot, 2x RS-
232/485 (Programming, MODBUS/CS31), 1x FBP, Display
PM571-ETH 1SAP 130 100 R0170 PM571-ETH, CPU 64kB, 24 V DC, Memory Card Slot, 2x
RS-232/485 (Programming, MODBUS/CS31), 1x FBP,
Display, integrated Ethernet TCP/IP
PM581 1SAP 140 100 R0100 PM581, CPU 256kB, 24 V DC, Memory Card Slot, 2x RS-
232/485 (Programming, MODBUS/CS31), 1x FBP, Display
PM581- 1SAP 140 100 R0160 PM581-ARCNET, CPU, memory 256 kB, 24 V DC,
ARCNET Memory Card Slot, interfaces 2 x RS-232/485
(programming, Modbus/CS31), 1 x FBP, Display,
integrated coupler ARCNET
PM581-ETH 1SAP 140 100 R0170 PM581-ETH, CPU 256kB, 24 V DC, Memory Card Slot, 2x
RS-232/485 (Programming, MODBUS/CS31), 1x FBP,
Display, with integrated Ethernet TCP/IP coupler
PM582 1SAP 140 200 R0100 PM582, CPU, memory 512 kB, 24 V DC, Memory Card
Slot, interfaces 2 x RS-232/485 (programming,
Modbus/CS31), 1 x FBP, Display
PM582-ETH 1SAP 140 200 R0170 PM582-ETH, CPU, memory 512 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
PM591 1SAP 150 100 R0100 PM591, CPU 4MB, 24 V DC, Memory Card slot, 2x RS-
232/485 (Programming, MODBUS/CS31), 1x FBP, Display
PM591- 1SAP 150 100 R0160 PM591-ARCNET, CPU, memory 4 MB, 24 V DC, Memory
ARCNET Card Slot, interfaces 2 x RS-232/485 (programming,
Modbus/CS31), 1 x FBP, Display, integrated coupler
ARCNET
PM591-ETH 1SAP 150 100 R0170 PM591-ETH, CPU 4MB, 24 V DC, Memory Card Slot, 2x
RS-232/485 (Programming, MODBUS/CS31), 1x FBP,
Display, with integrated Ethernet TCP/IP Coupler

Overview of available couplers

Type Order number Description

CM572-DP 1SAP 170 200 R0001 CM572-DP, Communication Module PROFIBUS DP
Master 12 Mb/s
CM575-DN 1SAP 170 500 R0001 CM575-DN, Communication Module DeviceNet Master
CM577-ETH 1SAP 170 700 R0001 CM577-ETH, Communication Module, Ethernet TCP/IP,
with integrated 2-port switch
CM578-CN 1SAP 170 800 R0001 CM578-CN, Communication Module, CANopen Master

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G1 Introduction to AC500 1-5 AC500 / Issued: 07.2006

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 Overview of available CPU terminal bases

Type Order number Description

TB511- 1SAP111 100 R0160 TB511-ARCNET, CPU Terminal Base AC500, 1x CPU
ARCNET Slot, 1x Coupler Slot, ARCNET COAX Connector
TB511-ETH 1SAP 111 100 R0170 TB511-ETH, CPU Terminal Base AC500, 1x CPU Slot, 1x
Coupler Slot, Ethernet RJ45 Connector
TB521- 1SAP 112 100 R0160 TB521-ARCNET, Terminal Base AC500, 1x CPU Slot, 2x
ARCNET Coupler Slots, ARCNET COAX Connector
TB521-ETH 1SAP 112 100 R0170 TB521-ETH, CPU Terminal Base AC500, 1x CPU Slot, 2x
Coupler Slots, Ethernet RJ45 Connector
TB541-ETH 1SAP 114 100 R0170 TB541-ETH, CPU Terminal Base AC500, 1x CPU Slot, 4x
Coupler Slots, Ethernet RJ45 Connector

Overview of available I/O modules

Type Order Number Description

DI524 1SAP 240 000 R0001 DI524, Digital Input Module, 32 DI, 24 V DC, 1-wire
DC522 1SAP 240 600 R0001 DC522, Digital input/output module, 16 DC, 24 V DC / 0.5
A, 2-wire
DC523 1SAP 240 500 R0001 DC523, Digital input/output module, 24 DC, 24 V DC / 0.5
A, 1-wire
DC532 1SAP 240 100 R0001 DC532, Digital Input/Output Module, 16 DI / 16 DC, 24 V
DC / 0.5 A, 1-wire
DX522 1SAP 245 200 R0001 DX522, Digital Input/Output Module, 8 DI 24 V DC, 8 DO
Relay, 2-wire
DX531 1SAP 245 000 R0001 DX531, Digital Input/Output Module, 8 DI, 230 V AC, 4 DO
Relay, 2-wire
AI523 1SAP 250 300 R0001 AI523, Analog input module, 16 AI, U/I/Pt100, 12 Bit + sign,
2-wires
AO523 1SAP 250 200 R0001 AO523, Analog output module, 16 AO, U/I, 12 Bit + sign, 2-
wires
AX521 1SAP 250 100 R0001 AX521, Analog input/output module, 4 AI / 4 AO, U/I/Pt100,
12 Bit + sign, 2-wires
AX522 1SAP 250 000 R0001 AX522, Analog Input/Output Module, 8 AI / 8 AO,
U/I/Pt100, 12 Bit + sign, 2-wire

Overview of available terminal units

Type Order Number Description

TU515 1SAP 212 200 R0001 TU515, I/O Terminal Unit, 24 V DC, Screw Terminals
TU516 1SAP 212 000 R0001 TU516, I/O Terminal Unit, 24 V DC, Spring Terminals
TU531 1SAP 217 200 R0001 TU531, I/O Terminal Unit, 230 V AC, Relay, Screw
Terminals
TU532 1SAP 217 000 R0001 TU532, I/O Terminal Unit, 230 V AC, Relay, Spring
Terminals
TU551-CS31 1SAP 210 600 R0001 TU551-CS31, Bus-I/O Terminal Unit, 24 V DC, Screw
Terminals
TU552-CS31 1SAP 210 400 R0001 TU552-CS31, Bus-I/O Terminal Unit, 24 V DC, Spring
Terminals

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G1 Introduction to AC500 1-6 AC500 / Issued: 07.2006

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 Overview of available FBP interface modules

Type Order Number Description

DC505-FBP 1SAP 220 000 R0001 DC505-FBP, FBP-Interface Module, 8 DI / 8 DC, 24 V DC /
0,5 A, 1-wire
DC551-CS31 1SAP 220 500 R0001 DC551-CS31, Digital Input/Output-Bus Module, 8DI / 16DC
24 V DC / 0,5 A, 1-wire

Overview of available FBP terminal units

Type Order Number Description

TU505 1SAP 210 200 R0001 TU505, FBP Terminal Unit, Screw Terminals
TU506 1SAP 210 000 R0001 TU506, FBP Terminal Unit, Spring Terminals

Overview of available FieldBusPlugs and accessories

Type Order number Description

PDP22-FBP.025 1SAJ 2401 00 R1003 PDP22-FBP.025 PROFIBUS DP-V0/V1-FBP 0.25 m,
modular (FieldBusPlug)
PDP22-FBP.050 1SAJ 2401 00 R1005 PDP22-FBP.050 PROFIBUS DP-V0/V1-FBP 0.5 m,
modular (FieldBusPlug)
PDP22-FBP.100 1SAJ 2401 00 R1010 PDP22-FBP.100 PROFIBUS DP-V0/V1-FBP 1 m,
modular (FieldBusPlug)
PDP22-FBP.200 1SAJ 2401 00 R1020 PDP22-FBP.200 PROFIBUS DP-V0/V1-FBP 2 m,
modular (FieldBusPlug)
PDP22-FBP.500 1SAJ 2401 00 R1050 PDP22-FBP.500 PROFIBUS DP-V0/V1-FBP 5 m,
modular (FieldBusPlug)
PDV11-FBP.0 1SAJ 924 008 R0001 Feeding connector 24 V DC, Code B-A
PDV12-FBP.0 1SAJ 924 011 R0001 Feeding connector 24 V DC, Code A-A
PDA11-FBP.050 1SAJ 924 009 R0005 Adapter M12-Dsub9-M12, cable length 0.50 m
PDA12-FBP.050 1SAJ 924 010 R0005 Adapter M12-Dsub9-M12, cable length 2 x 0.50 m
PDR11-FBP.150 1SAJ 924 007 R0001 Terminating resistor 150 Ohm

Overview of available accessories

Type Order Number Description

TA521 1SAP 180 300 R0001 TA521, Lithium Battery
MC502 1SAP 180 100 R0001 MC502, SD Memory Card 128 MB
TK501 1SAP 180 200 R0001 TK501, Programming Cable, D-Sub / D-Sub
TK502 1SAP 180 200 R0101 TK502, Programming Cable, Terminal Block / D-Sub
TA523 1SAP 180 500 R0001 TA523, Pluggable Marker Holder (10 pcs)
TA524 1SAP 180 600 R0001 TA524, Dummy Coupler Module
TA525 1SAP 180 700 R0001 TA525, Set of 10 white Plastic Markers
TA526 1SAP 180 700 R2001 TA526, Wall mounting accessory, 10 pcs
PS501-PROG 1SAP 190 100 R0001 PS501-PROG, Control Builder AC500, Programming
Software German / English / French (CD-ROM incl.
Online Help and PDF Docs)

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G1 Introduction to AC500 1-7 AC500 / Issued: 07.2006

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 Bus systems overview
Bus System Short information / Web Links / Block Libraries
ARCNET www.arcnet.com ARCNET Trade Association, USA; -> Literature -> Other Puplications
-> ARCNET Tutorial and Product Guide
CANopen www.can-cia.org
DeviceNet www.odva.org -> DEVICENET
Ethernet www.ethermanage.com
The Ethernet Library -> see ‘Function Block Libraries AC500’
Modbus www.modbus.org
PROFIBUS www.profibus.com -> Web Based Training
The PROFIBUS DP Library -> see ‘Function Block Libraries AC500’

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G1 Introduction to AC500 1-8 AC500 / Issued: 07.2006

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 Brief information about ARCNET
ARCNET (Attached Resource Computer NETwork)
ARCNET is an open, multi-purpose field bus solution with real-time capability. It can be used for multi-
master networking and for programming the AC500 and AC31 controller series, but also for connecting
additional ARCNET subscribers, e.g. PCs via an appropriate interface card (see catalog).

Topology
ARCNET is one of the few networks that can be operated in every conceivable topology. Options include
bus, star, or tree topologies, or mixtures of these. This means that ARCNET can be used for a broad
field of different applications.

Bus assignments
ARCNET operates on the token-passing procedure, where each subscriber has equal rights.

Configuration mechanisms
ARCNET subscribers can freely join and leave during an active runtime session. The system will
automatically configure the available user database.

Security mechanisms
A 16-bit CRC is appended to every data packet, and checked by the recipient. If the token is lost, a
reconfiguration routine will be initiated, and the network will automatically be restructured. Additionally,
diagnostic registers are available.

Physical characteristics
ABB recommends coaxial cables as transmission medium, for direct connection to the CPU. But also
twisted-pair cables or (glass, plastic) fiber-optic cables can be connected via bus converters. The line
lengths that can be achieved without any intermediate amplifiers depend not only on the used medium,
but also on the selected baud rate and the number of subscribers. The ranges per segment vary from
approximately 120 m for a simple two-wire bus, up to 3 km for fiber-optics, in each case at 2.5 MBit/s. By
providing appropriate hubs, different topologies and transmission media can be combined with each
other and the transmission distance can be increased. The coaxial cables used are a type with 93 Ohm,
e.g. RG 62. The permissible twisted-pair cables are specified in IEEE 802.3i-1990. At 2.5 MBit/s and with
coaxial cables, for example, the maximum length of a bus segment is 300 m with eight subscribers and
without a hub. With twisted-pair cables, under the same conditions, a maximum length of approximately
120 m can be achieved. The maximum transmis-sion length depends on the number of connected
subscribers. With coaxial cables, a maximum of 16 km can be achieved; with twisted-pair cables
approximately 6 km, in each case at 2.5 MBit/s. The fiber-optic link provides the highest degree of
interference immunity. With glass fiber-optics, distances of up to 3 km are possible at 2.5 MBit/s; with
plastic fiber-optic cables only small distances of up to approximately 100 m. The baud rate plays no
significant role in fiber-optic cable transmission. Here, the range can as well be extended using hubs.

Diagnostics
Detailed diagnostic messages for rapid trouble-shooting are shown on the CPU display or can be called
using the programming tool.

ARCNET – the functionality at a glance

• Guaranteed collision-free data transmission, guaranteed response times and real-time capability thanks
to token-passing
• Large network dimensions: network length 300 m, with amplifier max. 16 km
• Secure, thanks to checksums in the data packet and handshake protocol between transmitter and
receiver
• Variable network structure: bus, tree and star topologies are possible, plus any desired mixtures of them
• Variable networking media, coaxial cables, twisted-pair cables and fiber-optic cables can be mixed
• Automatic subscriber log-on and log-off; the network automatically incorporates new stations in the ring
and cancels them as well
• Master-master access: the subscriber that holds the token is the master. With up to 255 masters at the
same network
• Data transmission rate of max. 2.5 MBit/s
• ARCNET is configured and programmed using the AC500 Control Builder engineering tool

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 Brief information about CANopen and DeviceNet

CANopen (Controller Area Network) and DeviceNet

The CANopen protocol was originally developed for the European automotive industry to replace
expensive cabling with an affordable system. Today, it is also used in the field of automation for
transmitting process data between control systems, decentralized I/O modules, drives, valves, etc. CAN
features a high level of transmission security, since large portions of the monitoring mechanisms have
been implemented directly in the CAN chip. DeviceNet and CANopen utilize the physical structure and
the data transport mechanisms of CAN (Controller Area Network). The difference lies in the transmission
protocols. DeviceNet and CANopen can be used correspondingly for the AC500 and AC31 controller
series and for field-bus-neutral FBP devices (decentralized I/Os and intelligent switching devices), via
the CANopen-FBP plug connector.

Data transmission
Two types of message have been defined: I/O data transfer and direct link. I/O data transfer is used for
time-critical process data, while the direct link can be, for example, used for diagnostic messages.

Bus access for subscribers

The connection ID with the lower address has higher priority on the bus. Data is transmitted by the
source, while the sinks (i.e. receivers of the data) have likewise been specified during the configuration
phase.

CANopen
The bus operates on the master/slave principle with one master and up to 127 slaves. A shielded
twisted-pair cable is used, according to ISO 11898. Cable lengths and transmission rates: from max. 40
m at 1 MBit/s to 1000 m at 20 kBit/s.

DeviceNet
The bus operates on the multi-master and/or the master/slave principle, with up to 64 bus subscribers.
Two types of shielded twisted-pair cables are used: trunk cable for the main line and drop cable for the
branch line.

Transmission rate 125 Kbit/s 250 Kbit/s 500 Kbit/s

Max. cable length of 500 m (1610 ft) 250 m (820 ft) 100 m (328 ft)
trunk line
Trunk cable
Max. cable length of 100 m (328 ft) 100 m (328 ft) 100 m (328 ft)
trunk line Drop cable
Max. cable length per 6 m (20 ft) 6 m (20 ft) 6 m (20 ft)
branch line
Trunk cable/Drop
cable
Max. cable length total 156 m (512 ft) 78 m (256 ft) 39 m (128 ft)
branch line
Trunk cable/Drop
cable

Diagnostics
Detailed diagnostic messages for rapid trouble-shooting are shown on the CPU display or can be called
using the programming tool. In addition, the device status is indicated at the communication module by
four LEDs.

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 Brief information about CS31 field bus

CS31 (Communication Serial Field Bus, developed by ABB in 1989) for continuity and
migration
CS31 is a proprietary master/slave field bus. It is characterized by simple handling, easy configuration,
and inexpensive installation. The COM1 interface of the AC500 can be configured as a CS31 field bus
master.

Communication
Is handled using polling, i.e. the master sends a request to the slave and then receives the response.
The CS31 operating mode of COM1 is set using the engineering tool.

Topology
Multi-point line, RS485, approved without branch lines. A system consists of one master and up to 31
slaves. The maximum cable length is 500 m, or 2 km with an amplifier. Slaves are primarily
decentralized input/output modules with integrated CS31 bus connection.

Data transmission
Is performed at 187.5 kB/s. Each telegram has an 8-bit CRC appended. The telegrams enable process
data (input/output data) to be written and read.

Transmission medium
Primarily a twisted-pair, shielded cable with terminators. Other transmission media: fiber-optic cables via
a converter (glass fibers max. 3 km, plastic max. 100 m), contact lines, slip rings (bus length max. 50 m)
and data photocells.

Diagnostics
Detailed diagnostic messages for rapid trouble-shooting are shown on the CPU display or can be called
using the programming tool.

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 Brief information about Ethernet

Ethernet
Ethernet operates with a data rate of 10 MBit/s and as Fast-Ethernet with 100 MBit/s. Ethernet utilizes
the producer/consumer model. This means that every station possesses equal rights. While it is
transmitting, all other stations listen in and accept the data directed to them. Bus access is regulated by
the CSMA/CD procedure (Carrier-Sense Multiple-Access with Collision Detection), where each station
may autonomously transmit when the bus is free. If a collision occurs, if two stations begin to transmit
simultaneously, both of them will stop transmission and wait for a randomly determined time before they
transmit again. Ethernet defines the Layers 1 (Physical Link) and 2 (Data Link) of the OSI model.

The AC500 supports transmission and reception of data using TCP/IP and/or UDP/IP. Further
application layers can be implemented by subsequent loading. Simultaneous operation of TCP/IP,
UDP/IP and application layer is also assured. The IP, TCP, UDP, ARP, RP, BOOTP, and DHCP
protocols are supported as a standard feature, as application layer Modbus/TCP.

Topology
Star- or ring-shaped using Ethernet hub or switch.

Data transmission
Max. 10 MB/s with 10 Base T and max. 100 MB/s with Fast-Ethernet.

Transmission media
Twisted-pair cables with RJ45 connector. The maximum cable length is 100 m for 100 MB/s.

Diagnostics
Detailed diagnostic messages for rapid trouble-shooting are shown on the CPU display or can be called
using the programming tool. In addition, the device status is indicated at the communication module by
four LEDs.

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 Brief information about Modbus

Modbus® RTU (developed by Modicon in 1979)

Modbus® RTU is an open master/slave protocol, and can be easily implemented on serial interfaces.
Numerous automation systems have Modbus® RTU interfaces as standard or optional features, and are
thus easily able to communicate with the AC500 via its integrated COM1 and COM2 interfaces (RS232
or RS485). The Modbus® is used not only in industrial applications, but also in building installations, in
energy optimization systems, for long-distance data transmission and for linking up operator panels.

Communication
By polling, i.e. the master transmits a request to the slave and then receives the response. Both
interfaces COM1 and COM2 can operate simultaneously as Modbus interfaces. The Modbus operating
mode of an interface is set using the engineering tool.

Topology
Point-to-point via RS232 or multi-point via RS485. With RS232, a maximum of one master and one slave
is possible, while with RS485 one master and a maximum of 31 slaves can be operated. The maximum
cable length is 15 m with RS232 and 1.2 km with RS485.

Data transfer
Max. 187.5 kB/s. Each telegram has a 16-bit CRC appended. The telegrams permit process data
(input/output data) to be written and read, either individually or in groups. The data are packed in the
RTU format.

Transmission media
May vary. One widely used option is the RS485 bus physics, a twisted-pair, shielded cable with
terminators.

Diagnostics
Detailed diagnostic messages for rapid trouble-shoot-ing are shown on the CPU display or can be called
using the programming tool.

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 Brief information about PROFIBUS DP

PROFIBUS DP (Process Field Bus - Decentral Periphery)

PROFIBUS DP is an open, high-speed and widely-used field bus. It provides multi-master and master-
slave communication in the field area. This field bus can accordingly be used for AC500 and AC31
control system series and for field-bus-neutral FBP devices (decentralized I/Os and intelligent switching
devices) via the PROFIBUS-FBP connector.

Communication
The masters rule data traffic on the bus. When in possession of the bus access authorization (token), the
masters can transmit data without an external request. The passive devices, known as slaves, do not
receive any bus access rights; they acknowledge messages received, or respond to a query from a
master. Baud rates from 9.6 kBaud to 12 MBaud are supported. A maximum of 126 devices can be
operated on the bus.

Data exchange
This is handled predominantly in cyclical mode be-tween master and slave. The requisite communication
functions have been specified by the PROFIBUS DP basic functions in accordance with EN 50170. Each
master has full write and read access to its assigned slaves, but only read access to the slaves assigned
to other bus masters. There is no direct data exchange between masters. Acyclical services (DP-V1) for
parameterization and diagnostics between master and slave are also available. This is performed in
parallel to the master’s cyclical user data traffic.

PROFIBUS DP – the functionality at a glance

• Max. 126 subscribers via amplifier and max. 32 subscribers (master/slaves) per bus segment
• Data transmission rate from max. 12 MBit/s with a cable length of 100 m, up to 93.75 kBit/s with 1200 m
• Multi-master or master/slave communication. Bus access of the masters using token
• Connection of the master CPU and the associated communication module via a 9-pole SUB-D plug
connector. Connection of slaves (CPU, I/Os and intelligent switching devices) via FieldBusPlug
• The system cable is a shielded twisted-pair line or a fiber-optic cable; transmission standard EIA RS485

Diagnostics
Detailed diagnostic messages for rapid trouble-shooting are shown on the CPU display or can be called
using the programming tool. In addition, the device status is indicated at the communica-tion module by
four LEDs.

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 Documentation overview
The documentation consists of six parts:

• CoDeSys programming system - Describes the functionality of the programming software

• Target system - Documentation of the AC500 system
• CoDeSys libraries
• CoDeSys visualization
• CoDeSys HMI
• CoDeSys license management

CoDeSys programming system

Section Comment
A brief introduction to CoDeSys - Explanation of the acronym 'CoDeSys'
- Software functionality
- Components of a project
- Programming languages
- Debugging
We write a little program - Controlling a traffic signal unit
- Visualizing a traffic signal unit
The individual components - Main window and functions
- Options for project organization
- Object handling (blocks, data types, visualizations,
resources)
- Editing functions
- Online functions
- Explanation of the help system
Editors in CoDeSys - General
- Declaration editor for the variables
- Pragma instructions for controlling the compilation
process
- Text editor for instruction list and structured text
- Graphical editors for sequential function chart, ladder
diagram, function block diagram and free-graphic
function block diagram editor
The resources - PLC configuration
- Global variables
- Alarm configuration
- Library manager
- Logging (chronological recording of actions during
online session)
- Task configuration
- Watch and recipe manager
- Workspace (image of the project options set)
- Target system settings
- Target specific resources
ENI revision control ENI (engineering interface for accessing an external
project database from the programming system)
IEC operators and additional norm- - Arithmetic operators (ADD, MUL, SUB, ...)
extending functions - Bitstring operators (AND, OR, XOR, NOT)
- Bitshift operators (SHL, SHR, ROL, ROR)
- Selection operators (SEL, MAX, MIN, LIMIT, MUX)
- Comparison operators (GT, LT, LE, GE, EQ, NE)
- Address operators (ADR, ADRINST, BITADR, content
operator)
- Calling operator (CAL)
- Type conversions
- Numeric operators (ABS, SQRT, LN, LOG, ...)
- Initialization operator (INI)

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 Section Comment
Operands in CoDeSys - Constants
- Variables
- Addresses
- Functions
Data types in CoDeSys - Standard data types
- Defined data types
Overview of operators and library blocks
Command line / command file commands - Commands provided when CoDeSys is started
- Command set for building a command file (Cmdfile)
Use of keyboard - Operating CoDeSys using the keyboard only
- Key combinations
Siemens import (not available) Commands for importing blocks and variables from
Siemens STEP5 files
DDE communication Using the DDE interface (Dynamic Data Exchange)
Keywords in CoDeSys Reserved keywords in CoDeSys (ABS, ACOS, ADD, ...)
CoDeSys files Files generated by CoDeSys
Compiler errors and warnings Information about possible error and warning messages
displayed in the message window during project
compilation.

Documentation for the AC500 system

Section Comment
Introduction - Overview: Here you can gain an overview of the
AC500 system. This section provides further useful
information.
- First steps when working with AC500 and S500-FBP;
examples
- For AC1131 experts
Your tasks - Documentation from the user's - Engineering company
point of view - Sales and export
- Control cabinet building and construction
- Commissioning
- Program creation
- Operation, service and maintenance
- Training and education
- Callcenter, helpline
AC500 hardware - System data
- CPU terminal bases and terminal units
- CPUs
- Communication modules
- CS31 modules
- FBP interface modules
- Digital input and output modules
- Analog input and output modules
- Accessories
S500-FBP hardware (system description) - System data and system structure
- Terminal units
- FBP interface modules
- Digital input and output modules
- Analog input and output modules
- Accessories

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 Section Comment
Block libraries - System libraries
- Modbus library
- Series 90 AC500 library
- ASCII communication library
- CS31 library
- Ethernet library
- PROFIBUS DP library
- CANopen library
- DeviceNet library
- DC541 library
System technology - Basic units
- Couplers
- I/O modules
OPC OPC (Object Linking and Embedding) for Project
Control - a standardized interface for accessing
process data

CoDeSys libraries
Section Comment
'Standard.lib' library Standard library
'util.lib' library Various blocks, e.g. for BCD conversion, bit/byte
functions, etc.
'AnalyzationNew.lib' library Analysis of expressions
CoDeSys system libraries Depends on the target system

CoDeSys visualization
Section Comment
Creating a visualization object A CoDeSys project block. The project block
contains a set of visualization elements and can
have specific properties as one complete object
Inserting visualization elements E.g. rectangle, curve, button, etc.
Positioning visualization elements Selecting, copying, modifying, etc. of visualization
elements
Configuring the visualization, visualization - Configuring the visualization - Overview
elements or visualization objects - Configuring selected elements using
configuration dialogs
- Summarizing graphical elements to one
visualization object which can have specific
parameters assigned
Visualization in online mode With operation by keyboard (configurable)
Visualizations in libraries Storage of visualizations in libraries

System variables within the visualization Implicitly created system variables for
programming visualizations
Possible key combinations For operation by keyboard

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 CoDeSys HMI
Section Comment
Overview Runtime system for execution of visualizations
Installation, starting and operation - Program which has to be purchased and
installed separately
- Notes regarding start from command line
- Operation by keyboard/mouse via visualization
elements

CoDeSys license management (not available)

Section Comment
Overview License management using the tool
Creating a module which is subject to licensing Using the command 'File -> Save as -> Edit
License Information dialog'

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 Short description of the hardware
Example of an AC500 system.

1. Back-lighted LCD display and keypad

2. SD card slot

3. Plug-in communication modules (1 to max. 4)

4. Optionally with integrated Ethernet or ARCNET

5. FBP interface (for slave)

6. Two serial interfaces for programming, ASCII,

Modbus or CS31 field bus (master)

7. Expandable by up to seven local I/O modules

Figure: AC500 system, module arrangement beginning from the left: communication module, CPU, I/O
module

CPUs
Available in three performance classes:

• PM571 (64kB memory, 2 RS-232/485 interfaces - programming, MODBUS/CS31 (COM1), 1 x FBP)

• PM581 or PM582 (256kB or 512kB memory, 2 RS-232/485 interfaces - programming, MODBUS/CS31
(COM1), 1 x FBP)
• PM591 (4MB memory, 2 RS-232/485 interfaces - programming, MODBUS/CS31 (COM1), 1 x FBP)

All three types are also available with an integrated Ethernet coupler (TCP/IP).

Communication modules
For connection to standard field bus systems and integration into existing networks.

Ethernet coupler supporting the protocols TCP/IP, UDP/IP and Modbus TCP.

Coupler for fieldbus systems – PROFIBUS DP, DeviceNet and CANopen.

Up to four communication modules in any desired combination are allowed at one CPU.

The CPU terminal base

For easy plug-in mounting of a CPU and one, two or four communication modules (three types available
accordingly).

The I/O modules

Digital and analog in different versions. Can be simply plugged onto the terminal units – for local
expansion of the CPU (max. seven modules) and decentralized expansion via the FBP interface (max.
seven modules, thereof max. four analog modules). Flexible use thanks to configurable channels.

The I/O terminal units

Multi-purpose usage for both digital and analog I/Os, for 1, 2 and 3-wire designs. Enable simple
prewiring without electronics. For 24 V DC and 230 V AC, optionally for spring or screw-type terminals.

The FBP interface module

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 With embedded digital I/Os and a field-bus-neutral interface for connecting the chosen FBP connector.
For decentralized expansion by up to seven I/O modules.

The SD card
The SD memory card is used for the following purposes: Backup of user data, storage of the user
program, storage of the project’s source code, update of the internal CPU firmware.

Short description of the software

Programming in conformity with IEC 61131-3

AC500 Control Builder provides the following functionalities:

■ Five standardized programming languages: Function Block Diagram (FBD), Instruction List (IL),
Ladder Diagram (LD), Structured Text (ST), Sequential Function Chart (SFC)

■ Free graphical function chart (CFC)

■ Debugging functions for the program test: Single step, Single cycle, Breakpoint

Offline simulation
IEC 61131-3 commands can be simulated without a PLC being connected, including the relevant
malfunctions. After the program test, the application can be downloaded to the control system.

Sampling trace
Timing diagrams for process variables and storage of data in a ring buffer with event trigger.

Recipe management and watch lists

Values of selected variables are displayed. Pre-defined values can be assigned to variables which can
then be downloaded to the control system all at once (“Write recipe”). Ongoing values from the control

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 system can also be pre-assigned for reading into the Watch and Recipe Manager, and stored in memory
there (“Read recipe). These functions are also helpful, for example, for setting and entering control
parameters.

Visualization
Includes color change, moving elements, bitmaps, text display, allows input of setpoint values and
display of process variables read from the PLC, dynamic bar diagrams, alarm and event management,
function keys and ActiveX elements.

Configurators of the communication interfaces

Integrated field bus configurator SYCON.net for PROFIBUS DP, CANopen, DeviceNet, Ethernet,
Modbus and CS31.

Open interfaces
DDE and OPC.

Programming
Serial or via Ethernet or ARCNET networks.

Engineering interface
Provides access from the programming system to an external project database in which the program
source code of one or several automation projects is managed. Optionally, a version control system,
such as Visual Source Safe, can be used in order to ensure data consistency of the program code for
several different users and projects.

• Comprehensive libraries.
• Windows 32-bit standard.
• Operating systems Windows 2000 and XP.

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 Operating and displaying
The AC500 offers as well an extensive range of products for communication between operator and
machine. There are many different displays to choose from, which satisfy application-specific demands
regarding required operator actions and information density.

Users can communicate with the AC500s CPUs via the various operator panels, read and write access
on device data is possible. Configuration is quick and easy to perform, using the same software for all
devices (programming software CPsoft, 1SBS 260 283 R1001). Commands and programming
languages are identical for all devices. With regard to frequently harsh conditions at the place of
installation, all operator panels fulfill IP65 protection at the front. Operator panels and automation
devices are linked either simply via serial interfaces, or in case of complex applications via Ethernet,
Modbus or PROFIBUS DP.

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 Overview of CP500 operator panels - part 1

Type CP501 CP502 CP503 CP511 CP512

Order Number 1SBP 260 170 1SBP 260 171 1SBP 260 172 1SBP 260 173 1SBP 260 174
R0101 R0101 R0101 R0101 R0101
Display type STN LCD STN LCD STN LCD STN LCD B/W STN LCD
with backlight with backlight with backlight with backlight with backlight

Representation Text Text Text Grafic and text Grafic and text

Display size 2 lines x 16 2 lines x 20 4 lines x 20 240 x 64 pixels 240 x 128

characters characters characters (5.2") pixels (5.3")
Display area 55,7 x 11,0 73,5 x 11,5 70,4 x 20,8 127,2 x 33,9 120,0 x 64,0
W x H (mm)

Text height 5 5 5 variable variable

(mm)
LEDs 5 (2 colors) 16 (2 colors) 16 (2 colors)

Function keys 4 3 5 8 16 (8 with

labeling strip)

Web functions x x
Buzzer x x
Alarm 1 group 4 groups 4 groups
management
Time channel x x x x

Real-time x x x x
clock
Trend curves real-time developing of
values
Data logger

Recipe x x x x
management
Report printing x x x x
Password 8 levels 8 levels 8 levels 8 levels
protection
Multilanguage x x x x
support

Application 16 kB Flash 64 kB Flash 64 kB Flash 400 kB Flash 400 kB Flash

memory

Power supply 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC

Current 200 mA 150 mA 150 mA 450 mA 450 mA

consumption
Ambient 0 - 50 °C 0 - 50 °C 0 - 50 °C 0 - 50 °C 0 - 50 °C
temperature

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 Type CP501 CP502 CP503 CP511 CP512

Communication RS232 or RS232, RS422 RS232, RS422 RS232, RS422 RS232, RS422
interfaces RS422 RS485 (of which 2
at the same time)

Expansion - - - 1 1
slots

Degree of IP65 IP65 IP65 IP65 IP65

protection
front cover
Dimensions 104 x 69 x 38 142 x 100 x 29 147 x 163,5 x 211 x 198 x 69 214 x 232 x 87
WxHxD 38
(mm)
Weight (kg) 0.2 0.5 0.7 1.5 1.4

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 Overview of CP500 operator panels - part 2

Type CP513 CP551 CP552 CP554 CP555

Order Number 1SBP 260 175 1SBP 260 176 1SBP 260 177 1SBP 260 178 1SBP 260 179
R0101 R0101 R0101 R0101 R0101
Display type TFT 256 Color Touch B/W 16 grey levels TFT 256 Color TFT 256 Color
LCD with STN Touch LCD touch LCD touch LCD
backlight with backlight with backlight
Representation Grafic and text Grafic and text Grafic and text Grafic and text Grafic and text
Display size 320 x 240 Pixel 320 x 240 Pixel 320 x 240 Pixel 320 x 240 Pixel 640 x 480 Pixel
Display area 115,2 x 86,4 78,0 x 58,5 115,2 x 86,4 115,2 x 86,4 211,2 x 158,4
W x H (mm)
Text height variable variable variable variable variable
(mm)
LEDs 16 (2 colors)
Function keys 16 (8 with
labeling strip)
Web functions x x x x x
Buzzer x x x x x
Alarm 16 groups 4 groups 5 groups 5 groups 11 groups
management
Time channel x x x x x
Real-time clock x x x x x
Trend curves developing of developing of developing of developing of developing of
values values values values values
Datalogger x x x x x
Recipe x x x x x
management
Report printing x x x x x
Password 8 levels 8 levels 8 levels 8 levels 8 levels
protection
Multilanguage x x x x x
support
Application 400 kB Flash 400 kB Flash 400 kB Flash 400 kB Flash 1600 kB Flash
memory
Power supply 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC
Current 550 mA 450 mA 400 mA 450 mA 1A
consumption
Ambient 0 - 50 °C 0 - 50 °C 0 - 50 °C 0 - 50 °C 0 - 50 °C
temperature
Communication RS232, RS422 RS232, RS422 RS232, RS422 RS232, RS422 RS232, RS422
interfaces RS485, RS485 RS485
Ethernet (of which 2 at (of which 2 at
(of which 2 at the same time) the same time)
the same time)
Expansion slots 2 - 1 1 2
Degree of IP65 IP65 IP65 IP65 IP65
protection
front cover
Dimensions 276 x 198 x 89 138 x 100 x 30 200 x 150 x 69 200 x 150 x 69 290 x 250 x
W x H x D (mm) 105
Weight (kg) 1.7 1.4 1.5 1.5 3.3

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 Services

Service - Control Engineering

ABB operates a Technical Support Center to assist with even the most difficult of problems.

• Consultation by phone (Helpline)

• Failure analysis and removal at the machine/installation

In order to provide the customer with qualified assistance, customers are requested to provide the
following:

• Provide all required application documentation and information.

• Provide access (if required) to the system being examined.
• Assign key individuals to assist as required.

For inquiries and orders, please contact:

ABB STOTZ-KONTAKT GmbH

Dept. STO/CPT, Control Engineering Helpline
Eppelheimer Straße 82
D-69123 Heidelberg

Postfach 10 16 80
D-69006 Heidelberg

Phone +49 6221 701-1444

Telefax +49 6221 701-1382

E-mail: [email protected]

For further information about control engineering please also refer to our Internet Website
http://www.abb.de/stotzkontakt.

Repair services and replacement devices

The following services are also covered by our activities:

• Delivery of replacement devices

• Repair of defective devices and systems

Please contact your responsible sales office for your inquiry.

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 Seminars/Workshops

We also offer seminars and workshops to support you in planning, commissioning and operation of
Advant Controller AC500 controls. Please contact:

ABB STOTZ-KONTAKT GmbH

Dept. STO/VPS
Eppelheimer Straße 82 Postfach 10 16 80
D-69123 Heidelberg D-69006 Heidelberg
Phone +49 6221 701-1202 or -1205
Telefax +49 6221 701-1361
E-mail: [email protected] or [email protected]

If desired, we also offer seminars at the customer's facility. Please find detailed information in our
seminar brochure. You can order this brochure from the address given above or from every ABB
STOTZ-KONTAKT GmbH office or you can download it from our Internet website (PDF file, see the
following link).

Please send your enrolment directly to ABB STOTZ-KONTAKT GmbH using the address given above or
via Internet (http://www.abb.de/stotzkontakt -> Schulungen und Seminare -> Seminare).

If necessary, it is also possible to arrange the seminar contents according to the customer's wishes.
Depending on the special requirements, the training can be held in Heidelberg or at any other location
favored by the customer. We are pleased to prepare an individual offer for you according to your special
requirements.

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 Addresses
ABB STOTZ-KONTAKT GmbH
P.O. Box 10 16 80
D-69006 Heidelberg
Telephone: ++49 62 21 / 701-0
Telefax: ++49 62 21 / 701-729

http://www.abb.de/stotz-kontakt

ABB Entrelec - Control Division

184, rue Léon Blum
F-69100 Villeurbanne / France
Telephone: ++33 (0) 4 72 35 35
Telefax: ++33 (0) 4 72 35 12

http://www.abb.com/lowvoltage

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 Regulations concerning the appropriate and safe setup of systems and
installations
Apart from the basic „Regulations for the Setting up of Power Installations“ DIN VDE* 0100 and for „The
Rating of Creepage Distances and Clearances“ DIN VDE 0110 Part 1 and Part 2 the regulations „The
Equipment of Power Installations with Electrical Components“ DIN VDE 0160 in conjunction with DIN
VDE 0660 Part 500 have to be taken into due consideration.

To insure project success and to insure that all systems are properly and safely installed, the customer
must be familiar and proficient with the following standards and must comply with their directives:

• Working & Process Machinery: DIN VDE 0113 Part 1 & Part 200
• Close proximity to dangerous voltages: DIN VDE 0106 Part 100
• Protection against direct contact: DIN VDE 0160, DIN VDE 0110 Part 1

The user has to guarantee that the devices and the components belonging to them are mounted
following these regulations. For operating the machines and installations, other national and international
relevant regulations, concerning prevention of accidents and using technical working means, also have
to be met.

Advant Controller Devices are designed according to: IEC 1131 Part 2 under overvoltage category II per
DIN VDE 0110 Part 2.

For direct connection of AC Category III overvoltages provide protection measures for overvoltage
category II according to IEC-Report 664/1980 and DIN VDE 0110 Part 1.

Equivalent standards:

DIN VDE 0110 Part 1 ↔ IEC 664

DIN VDE 0113 Part 1 ↔ EN 60204 Part 1

DIN VDE 0660 Part 500 ↔ EN 60439-1 ↔ IEC 439-1

All rights reserved to change design, size, weight, etc.

* VDE stands for „Association of German Electrical Engineers“.

Safety technical instructions

Please read!

General
Completely safe installation and starting up and problemfree functioning of the devices at their work
location can be ensured by observing the following instructions.

Qualified personnel
Both the control system AC500 and other components in the vicinity are operated with dangerous
contact voltages. Touching parts, which are under such voltages, can cause grave damage to health.

In order to avoid such risks and the occurrence of material damage, everyone involved with the
assembly, starting up and servicing must possess pertinent knowledge of the following:

• the automation technology sector,

• dealing with dangerous voltages,
• using standards and regulations, in particular VDE, accident prevention regulations and regulations
concerning special ambient conditions (e.g. areas potentially endangered by explosive materials,
heavy pollution or corrosive influences).

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 Use as directed
Properly installed systems that are "used as directed" and properly conform with the applicable codes,
regulations and sound engineering principles pose no risks or dangers to health.

"Used as directed" implies that the devices are installed, maintained and operated in accordance with
appropriate ABB manuals & documents.

No liability is assumed for the direct or indirect consequences of the improper use, improper application
or inadequate maintenance of these devices.

Risk reduction instructions

Protect the devices from dampness, dirt and damage during transport, storage
and operation!

Do not operate devices outside of the specified, technical data!

Trouble-free functioning cannot be guaranteed outside of the specified data.

Operate the control system only in an enclosed housing (switch cabinet)!

Due to their construction (degree of protection IP 20 according to EN 60529) and their connection
technology, the devices are suitable only for operation in enclosed housings (switch cabinets).

Earth the devices!

The earthing (switch cabinet earthing, PE) is supplied both by the mains connection (or 24 V supply
voltage) and via DIN rail.

The DIN rail must be connected to the earth before the device is subjected to any power. The earthing
may be removed only if it is certain that no more power is being supplied to the control system.

In the description for the devices (operating manual or AC500 system description), reference is made at
several points to earthing, electrical isolation and EMC measures. One of the EMC measures consists of
discharging interference voltages into the earthing via Y-type capacitors. Capacitor discharge currents
must basically be able to flow off to the earthing (in this respect, see also VBG 4 and the relevant VDE
regulations).

In the description, special attention must be paid to designs using electrical isolation, earthing and EMC
measures for the reasons stated. For more information see Target System -> AC500/S500-FBP ->
Hardware AC500 -> System data -> General considerations for EMC-conforming assembly and
construction.

The earthing concept of these busses apply to the connection to external bus systems.

Connection of the supply voltage

The supply voltage (or mains connection) terminal block must only be plugged in or withdrawn with the
power off!

The same applies to the terminal blocks of input or output channels (e.g. relay outputs) if they are
operated with dangerous contact voltages.

Do not open live devices!

The devices work with voltages with which contact must be avoided under all circumstances. Therefore
they must not be opened when live. The same applies to the networking interfaces.

Lifting up the cover of the battery compartment to exchange the battery module is not construed as
opening in this context.
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 Do not obstruct the ventilation for cooling!

The ventilation slots on the upper and lower side of the devices must not be covered by wiring, cable
ducts and things like that.

Run signal and power wiring separately!

Signal and supply lines (power cables) must be laid out so that no malfunctions due to capacitive and
inductive interference can occur (EMC).

Precautions against wiring short-circuits and breakages

Connection plans and user software must be created so that all technical safety aspects, legal
regulations and standards are observed. In practice, possible shortcircuits and breakages must not be
able to lead to dangerous situations. The extent of resulting errors must be kept to a minimum.

Use only ABB approved lithium battery modules!

At the end of the battery’s lifetime, always replace it only with a genuine battery module.

Never short-circuit or operate lithium batteries with the polarities reversed!

They are likely to overheat and explode. Avoid chance short circuiting and therefore do not store
batteries in metal containers and do not place them on metallic surfaces. Escaping lithium is a health
hazard.

Never charge lithium batteries!

Lithium batteries are primary cells and cannot be recharged. Attempts to charge lithium batteries lead to
overheating and possible explosions.

Dispose of lithium batteries environmentally consciously!

Do not open lithium batteries and never throw them into fires (risk of explosion). Do not dispose of along
with the household rubbish but in an environmentally conscious manner, in accordance to local-authority
regulations.

Additional notes

Avoidance of electrostatic charging

ATTENTION
Electrostatic charging can cause internal defects of the devices and impair the
proper function. Observe the following rules when handling the system:
• Touch an earthed object in order to discharge the electrostatic
charging.
• Wear a suitable earthed strap around your wrist.
• Do not touch any connections or pins on the printed circuit boards.
• Do not touch any circuits inside the devices.
• If available, use a work place which is equipped with suitable
electrostatic discharge.
• In order to avoid electrostatic charging, the devices must only be
stored when packed in suitable packaging material.

Minimum clearances: Refer to target system - AC500/S500-FBP -> Introduction -> Getting Started ->
Getting Started with AC500 -> Assembling the system

ABB STOTZ-KONTAKT GmbH Heidelberg

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 Getting started with AC500
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical
equipment. Because of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy themselves that each
intended application of this equipment is acceptable.

In no event will ABB be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the
many variants and requirements associated with any particular installation, ABB cannot assume
responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by ABB with respect to use of information, circuits, equipment, or software
described in this manual.

Throughout this manual we use notes to make you aware of safety considerations.

Identifies information about practices or circumstances that can cause an

WARNING explosion in a hazardous environment, which may lead to personal injury or
death, property damage, or economic loss.
Identifies information that is critical for successful application and
IMPORTANT understanding of the product.
Identifies information about practices or circumstances that can lead to
ATTENTION personal injury or death, property damage, or economic loss. Attentions help
you:
• identify a hazard
• avoid a hazard
• recognize the consequence
SHOCK HAZARD Labels may be located on or inside the device to alert people that dangerous
voltage may be present.
SHOCK HAZARD Labels may be located on or inside the device to alert people that surfaces may
have dangerous temperatures.

Environment and Enclosure Information

Environment and Enclosure

ATTENTION
This equipment is intended for use in a Pollution Degree 2 industrial
environment, in overvoltage Category II applications (as defined in IEC
publication 60664-1), at altitudes up to 2000 meters without derating.

This equipment is considered Group 1, Class A industrial equipment according

to IEC/CISPR Publication 11. Without appropriate precautions, there may be
potential difficulties ensuring electromagnetic compatibility in other
environments due to conducted as well as radiated disturbance.

This equipment is supplied as "open type" equipment. It must be mounted

within an enclosure that is suitably designed for those specific environmental
conditions that will be present and appropriately designed to prevent personal
injury resulting from accessibility to live parts. The interior of the enclosure must
be accessible only by the use of a tool. Subsequent sections of this publication
may contain additional information regarding specific enclosure type ratings
that are required to comply with certain product safety certifications.

See NEMA Standards publication 250 and IEC publication 60529, as

applicable, for explanations of the degrees of protection provided by different
types of enclosure. Also, see the appropriate sections in this publication, as

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 well as the S500 User's manual for additional installation requirements
pertaining to this equipment.

Before starting
Use this document as a guide for installing and powering-up your AC500 PLC. You should already be
familiar with the system components.

How to handle AC500 components

Preventing Electrostatic Discharge

ATTENTION
This equipment is sensitive to electrostatic discharge, which can cause internal
damage and affect normal operation. Follow these guidelines when you handle
this equipment:
• Touch a grounded object to discharge potential static.
• Wear an approved grounding wrist strap.
• Do not touch connectors or pins on component boards.
• Do not touch circuit components inside the equipment.
• If available, use a static-safe workstation.
• When not in use, store the equipment in appropriate static-safe
packaging.

Make sure that you have all the components you need
To use the AC500 PLC (in our example CPU PM581-ETH) you should use at least the following parts:

Part Number Designation

1SAP 1121 00 R0170 TB521-ETH Terminal Base for CPU with 2 coupler slots
1SAP 1401 00 R0170 PM581-ETH CPU
1SAP 1806 00 R0001 TA524 Dummy coupler module to cover the unused coupler slots
1SAP 1802 00 R0001 TK501 Programming Cable D-Sub / D-Sub

Optional:

Part Number Designation

1SAP 1803 00 R0001 TA521 Lithium Battery
1SAP 1801 00 R0001 MC502 Memory SD-Card

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 You can use the following components to add additional I/O modules:

If you want … … use the following component(s):

• to connect a digital 24 VDC sensor or DI524 (32 DI ), DC522 (16DC), DC523 (24DC),
actuator to the CPU … DC532 (16DI/16DC) or DX522 (8DI/8 DO-R) with
the corresponding terminal unit with screw or
spring connection TU515/516 or TU531/532
• to connect a 115-230 VAC sensor or DX531 (8DI 115-230 V AC / 4 DO-R) +
actuator to the CPU ... corresponding Terminal Unit TU531/532 with
screw or spring technology
• to connect an analog 24 VDC sensor or AI523 (16AI U/I/PT100), AO523 (16AO), AX521
actuator to the CPU … (4AI/4AO U/I/PT100) or AX522 (8AI/8AO
U/I/PT100) + corresponding Terminal Unit
TU515/516
• to label the I/O channels … TA523 (Pluggable Marking Holder) + TA525 Set
of Plastic Markers

The following components are recommended for fieldbus communication:

If you want … … use the following component(s):

• the system to act as a master on
CM572-DP for PROFIBUS DP, CM575-DN for
PROFIBUS DP, DeviceNet or CANopen
DeviceNet or CM578-CN for CANopen
fieldbuses …
• the system to act as a slave on FieldBusPlug standard plugs like PDP22-FBP
PROFIBUS DP, DeviceNet or CANopen (PROFIBUS DP slave) or DNP21-FBP
fieldbuses … (DeviceNet) or other one’s
• to exchange data via the network … CM577-ETH to achieve Ethernet TCP/IP
communication with integrated 2-ports switch

System planning
Consider the following when planning your AC500 system:

• The AC500 PLC consists of a CPU Terminal Base TB5xx (from 1 to 4 coupler slots) and a pluggable
CPU. Three different CPU classes are offered: from PM571 with 64kB memory up to PM591 with
4MB memory; available also with integrated Ethernet coupler.
• Proper CPU Terminal Base selection requires that sufficient slots are available for all current or
future network and fieldbus communication modules (e.g. Ethernet, ARCNET, PROFIBUS, etc.) if
required.
• Up to 4 communication couplers can be connected to the CPU through the dedicated CPU terminal
base.
• All types of external communication couplers can be used together in the same time but only up to 4
external couplers in total (e.g. a mix of coupler types like Ethernet + Ethernet + Profibus DP +
CANopen, etc …).
• The total number of communication couplers (internal + external) is limited to 5.
• The CPU terminal base is always the left-most device in the system.
• An external 24 Vdc power supply has to be provided to the CPU Cluster; the additional I/O modules
have to be installed to the right of the PLC module.
• The AC500 PLC module supports as many as 7 local I/O expansion modules.
• An additional process power supply has to be provided for the I/Os of each module. Each I/O
expansion module can be powered with its own power supply (for isolation purposes) or the same
power supply can also be used.
• One FieldBusPlug can be plugged directly into an AC500 PLC cluster

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G1 Introduction to AC500 1-34 AC500 / Issued: 07.2006

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 Steps for installation

√ Installation step: Further

information:
1 Snap the AC500 PLC Terminal Base onto DIN Rail or wall-mount with
screws.
2 Snap the additional Terminal Units for I/O modules onto DIN Rail
(optional) or screw them (wall mounting).
3 Make the sensor/actuator wire connections according to the dedicated (*)
Electronic module you want to use. Provide external process power
supply as required.
4 If required, make the fieldbus connections according to the dedicated (*)
master coupler module you want to use.
5 Plug the appropriate electronic and I/O modules in the correct locations
(CPU module, communication couplers on TB, and eventually also I/O
modules onto dedicated TUs).
6 Install the battery and the memory SD card; this is optional and the
CPU is able to run without them.
7 If required, make the FBP fieldbus slave connection according to the (**)
chosen FBP and use the dedicated FBP accessories (cables, master
cable to M12, line termination, power supply connector, etc…).
8 If required, plug the FBP-Plug on the M12 connector located on the
CPU Terminal Base of the AC500 PLC.
9 Connect a programming cable (e.g. TK501 in COM2/PLC and
COM1/PC; TK502 is necessary for COM1/PLC) on the PC and on the
AC500 PLC.
10 Set the power on (process power supply first and PLC power supply).
11 If required, set the an address for the integrated Ethernet
communication interface by using the front face LCD Display +
keyboard of the CPU module (see the dedicated chapter of the user’s
manual).
12 Install the AC500 Control Builder programming software on your PC. If (*)
required, also copy the appropriate EDS/GSD files into the Fieldbus
configurator (AC500 Control Builder) to manage the possible fieldbus
slave modules connected to the AC500 master couplers.
13 Program the hardware configuration.

(*) Refer to the AC500 hardware description for proper wiring and addressing information.

(**) Refer to the Installation Instructions for the particular FBP devices. Follow appropriate fieldbus
practices outline by the conventions and standards of each protocol used in the system.

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 Assembling the system

The AC500 modules are not designed for removal or insertion under power.
WARNING Because of unforeseeable consequences, it is not allowed to plug or unplug
modules with the power being ON.

Disconnecting the FBP or any powered modules while energized in a

hazardous location could result in an arc, which could create a flammable
ignition resulting in a fire or explosion.

Be sure that power is removed and that an area has been thoroughly checked
to insure that flammable materials are not present prior to proceeding.

Using S500 I/O Modules

The S500 I/O modules could be used either directly connected to an AC500 CPU (central expansion) or
together with an FBP Interface Module DC505-FBP + an FBP (PROFIBUS DP, DeviceNet, etc.) as
decentralized expansion.

CM572 CM577 PM581 DC532 DC532

Figure: S500 I/O modules directly connected to an AC500 CPU (central I/O expansion)

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 DC505 DC532 DC532

Figure: S500 I/O modules connected to an FBP Interface Module DC505-FBP with an FBP
(decentralized expansion)

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G1 Introduction to AC500 1-37 AC500 / Issued: 07.2006

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 Minimum spacing

CM572 CM577 PM581 DC532 DC532

DIN rail,
earthed

Mounting
plate,
earthed

Cable duct

20 mm minimum distance between

the modules and the cable duct

DC505 DC532 DC532

DIN rail,
earted

Mounting
plate,
earthed

Figure: AC500/S500 module mounting into cabinets

Maintain spacing from enclosure walls, wireways, adjacent equipment, etc. Allow minimum 20 mm (1 in.)
of space on all sides, as shown. This provides ventilation and electrical isolation.

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 Important: Horizontal mounting is highly recommended. Vertical mounting is possible,
however, derating consideration should be made to avoid problems with poor air circulation and the
potential for excessive temperatures (see also the AC500 system data, operating and ambient
conditions, for reduction of ambient temperature).

Note: By vertical mounting, always place an end-stop terminal block (e.g. type BADL, P/N:
1SNA399903R0200) at the bottom and on the top of the modules to properly secure the modules.

By high vibration applications and horizontal mounting, we also recommend to place end-stop
terminals at the right and left side of the device to properly secure the modules, e.g. type BADL,
P/N: 1SNA399903R0200.

Insertion / replacement of the Lithium battery

The CPU is shipped without a battery. Please order the TA521 lithium battery separately. The battery is
used to retain data stored in the user’s RAM and in the Real Time Clock. Although the CPU can be used
without any battery, it is recommended to install it to avoid process data loss.
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.

The TA521 Lithium Battery is the only one, which can be used with AC500 CPUs.
ATTENTION

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

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G1 Introduction to AC500 1-39 AC500 / Issued: 07.2006

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 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. The connector is keyed to find the correct
polarity (red = plus pole = above).

4. Bend the cable and 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.

6. Pull-up the door and press until the locking mechanism snaps.

In order to prevent data losses or problems, the battery should be replaced after 3
NOTICE years of utilisation or at least as soon as possible after receiving the “Low battery
Warning” indication.
Don’t use a battery older than 3 years for replacement. Do not keep batteries too
long in stock.

Replacement of the battery:

In order to avoid any data losses (if needed), the battery replacement should be
ATTENTION 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.

Lithium batteries must not be re-charged, not be disassembled and not be

ATTENTION disposed of in fire. They must be stored in a dry place. Exhausted batteries
must be recycled to respect the environment.

Please refer to chapter "Hardware/Accessories/TA521" for the technical data sheet of the Lithium battery
TA521.

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G1 Introduction to AC500 1-40 AC500 / Issued: 07.2006

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 Insertion of the SD memory card
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 or project source codes 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, which allows the MC502 SD Memory card to be read with a
standard memory card reader.

The use of memory cards other than the MC502 SD Memory Card is prohibited.
ATTENTION ABB is not responsible nor liable for consequences resulting from use of
unapproved memory cards.

In operation, the plugged-in SD Memory Card withstands vibrations up to 1 g.

ATTENTION 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 card 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 SD 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 "Hardware / Accessories /
SD Memory Card MC502".

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G1 Introduction to AC500 1-41 AC500 / Issued: 07.2006

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 Mounting the System
During panel or DIN rail mounting of all devices, be sure that all debris (metal
ATTENTION chips, wire strands, etc.) is kept from falling into the controller. Debris that falls
into the controller could cause damage while the controller is energized.

Mounting and Demounting of the Terminal Base, the Terminal Unit and the Electronic
Modules

Mounting on DIN rail

Step 1: Install the 7.5 mm or 15 mm DIN Rail
Step 2: Snap the AC500 Terminal Base (TB5xx)

Figure: Mounting of the AC500 Terminal Base (TB5xx)

The AC500 Terminal Base will be placed on top of the DIN Rail and then snapped on the bottom. Follow
the reverse order to disassembly.

Figure: Disassembly of the CPU Terminal Base (TB5xx) or Terminal Unit (TU5xx)

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 Step 3: Mounting of the I/O Terminal Unit (TU515, TU516, TU531 or TU532) to the CPU Terminal Base

Figure: I/O Terminal Unit assembly (TU515, TU516, TU531 or TU532)

The I/O Terminal Unit is snapped into the DIN rail in the same way as the Terminal Base. Once secured
to the DIN rail, slide the I/O unit to the left until it fully locks into place creating a solid mechanical and
electrical connection.

Up to 7 I/O Terminal Units could be combined with a CPU Terminal Base.

When attaching the CPU Terminal Base and I/O modules, make sure the bus
ATTENTION connectors are securely locked together to ensure proper electrical connection.

1 ... 7

Figure: Maximum configuration (1 CPU Terminal Base plus 7 I/O Terminal Units)

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G1 Introduction to AC500 1-43 AC500 / Issued: 07.2006

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 Disassembly of a Terminal Unit

Figure: CPU Terminal Base (TB5xx) or I/O Terminal Unit disassembly (TUxx)

A screwdriver is inserted in the indicated place to separate the Terminal Units.

Step 4: CPU or Electronic Module assembly

PM581

Figure: Mounting of the CPU (PM5xx) on a Terminal Base (TB5xx), in the same way as I/O modules on
Terminal Units

The CPU or I/O module will be plugged on the dedicated Terminal Base / Terminal Unit. And will be
locked in place. The disassembly is done in reverse order.

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 1

Figure: CPU / I/O Module disassembly

For disassembly, press top and bottom, then pull out the CPU / I/O module.

Step 5: Communication Couplers on Terminal Base assembly

Figure: Mounting of a communication coupler (CM5xx) on a CPU Terminal Base (TB5xx)

First insert the bottom nose of the communication Coupler module into the dedicated holes of the
Terminal Base and then rotate the coupler until it will be plugged on the dedicated Terminal Base slot,
push to be sure that the connection is well done. It will be locked in place.

The disassembly is done in reverse order.

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 1

Figure: Communication coupler module disassembly

Disassembly: Press Top and Bottom, then rotate the coupler module and pull it out.

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G1 Introduction to AC500 1-46 AC500 / Issued: 07.2006

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 Panel mounting
If the CPU Terminal Base should be mounted with screws, Wall Mounting Accessories TA526 must be
inserted at the rear side first. These plastic parts prevent bending of the Terminal Base while screwing
on. TB511 needs one TA526, TB521 and TB541 need two TA526.

Rear view

1 1

Holes for wall mounting

Rear view

2 Front view 3
Figure: Fastening with screws of the Terminal Base TB521-ETH (as an example)

1 The two Wall Mounting Accessories TA526 are snapped on the rear side of the CPU Terminal Base
like DIN rails. The arrows point to the middle of the CPU Terminal Base. One TA526 is turned by 180°.

2 Two accessories for wall mounting inserted

3 CPU Terminal Base, fastened with screws. Use two screws per module (three for the TB). Use M4 or
#8 pan head screws. Mounting screws are required on every module.

By wall mounting, the CPU Terminal Base is earthed through the screws. It is necessary that

• the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-plated)
• the mounting plate is earthed
• the screws have a good electrical contact to the mounting plate

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G1 Introduction to AC500 1-47 AC500 / Issued: 07.2006

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 The following procedure allows you to use the assembled modules as a template for drilling holes in the
panel. Due to module mounting hole tolerance, it is important to follow these procedures:

1. On a clean work surface, assemble no more than three modules (e.g. one TB + two TUs).
2. Using the assembled modules as a template, carefully mark the center of all module-mounting
holes on the panel.
3. Return the assembled modules to the clean work surface, including any previously mounted
modules.
4. Drill and tap the mounting holes for the recommended M4 or #8 screw.
5. Place the modules back on the panel and check for proper hole alignment.
6. Attach the modules to the panel using the mounting screws.

TIP: If mounting more modules, mount only the last one of this group and put the others aside. This
reduces remounting time during drilling and tapping of the next group.
7. Repeat steps 1 to 6 for any remaining modules.

Grounding considerations
This product is designed to be mounted to a well-grounded mounting surface such as a metal panel.
Additional grounding connections from the AC500 mounting tabs or DIN rail (if used), are not required
unless the mounting surface cannot be grounded. Refer to appropriate Chapter of the S500-FBP User's
Manual, for additional information.

This product is grounded through the DIN rail to chassis ground. Use zinc
ATTENTION plated yellow-chromate steel DIN rail to assure proper grounding. The use of
other DIN rail materials (e.g. aluminium, plastic, etc.) that can corrode, oxidize,
or are poor conductors, can result in improper or intermittent grounding.

AC500 System dimensions

40.3 57.7 4.9 (0.19)

(1.59) (2.27)
59 (2.32)
70.5 (2.78)
135 (5.31)

28 28 28 28
67.5 (2.66) Dimensions:
(1.10) (1.10) (1.10) (1.10)
135 mm
TB511 95.5 (3.76) (5.31) inches
TB521 123.5 (4.86)
TB541 179.5 (7.07)

Figure: Dimensions of the CPU Terminal Bases (front view)

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G1 Introduction to AC500 1-48 AC500 / Issued: 07.2006

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 57.7
(2.27)

DC505

59 (2.32)
70.5 (2.78)
135 (5.31)
67.5 (2.66) 67.5 (2.66) Maße:
135 mm
TU505/506 TU515/516/531/532 (5.31) Zoll

Figure: Dimensions of the Terminal Unit (front view)

84.5 (3.33)
77 (3.03)
75 (2.95)
21 (0.83)
54 (2.13)
70.5 (2.78)
59 (2.32)

76 (2.99)
135 (5.31)

DIN rail 15 mm
DIN rail 7.5 mm

Dimensions:
135 mm
28 (1.10) (5.31) inches

View on the left side View on the right side

Note: All dimensions are in mm (in.). Hole spacing tolerance: ±0.4 mm (0.016 in.)

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G1 Introduction to AC500 1-49 AC500 / Issued: 07.2006

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 Setting of the Slave Address of the FBP plug onto the AC500 CPU (if needed, but
not recommended)
Normally the FBP slave address is set using the AC500 Control Builder. Neverthless it is possible to set
this address using the CPU.

The FieldBusPlug must have a properly assigned slave module address. The AC500 CPU gives them an
address at system power-up. The address can be set with the use of the display and the pushbutton on
the top of the module.

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

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G1 Introduction to AC500 1-50 AC500 / Issued: 07.2006

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 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.

If the FBP address set on the AC500 CPU module is different from those
ATTENTION assigned into the Fieldbus configurator software of the Master device for that
station, the station could not be accessed and the complete Fieldbus could not
work properly or be completely down!
The modified address will only be valid after a Power OFF / Power ON!
ATTENTION

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).

Make the Connection of the FieldBusPlug to the Fieldbus Master Device

The FieldBusPlug module has to be connected to the master device and the power supply has to be
provided. Please use the dedicated accessories to the FBP used for the desired Fieldbus.

Refer to the FBP documentation for the installation instructions.

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 Status display and error indication on the AC500 CPU
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 – 6 x 7-segment displays for “plain text” or
explosion. OK
error codes display
CPU
24 V DC 10 W

Figure: Front face of a AC500 CPU

The display’s background lighting is normally switched off. 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.

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 The meanings of the LEDs and the LCD display are listed in the following table:

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. The encountered or Indicates together with
error type and only warnings RUN a firmware update
code is displayed (E4 errors). process and a Flash
in the LC Display. This is EEPROM write.
The error codes configurable
can be shown by (by error 2 - 4,
means of the the LED
DIAG and OK behaviour is
keys. configurable.
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 and an error message is displayed in the LC Display.

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
cause fire or MC INSERT
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.

Note: The error messages are displayed as error codes using the Control Builder software (via
PLC browser). Errors are displayed as text in the status line of the Control Builder software or with
function blocks for diagnosis.

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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

By pressing DIAG one more time, the display ETH

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

By pressing DIAG one more time, the display ETH

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

Please refer to the Error Code list for further information. See the AC500 user manual.

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 LEDs on S500-FBP modules
All S500 modules have LEDs for the display of operating statuses and error messages. They indicate:

LED Meaning Color LED = ON LED = OFF LED flashes

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

For the meaning of the different LEDs and their behaviour when the system is running, please refer to
the S500 System Data of the S500 User’s manual for further information.

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 FBP LEDs – PROFIBUS DP

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 AC500 Modules Specifications
Please refer to the AC500 User’s Manual chapter System Data.

AC500 Modules Certifications

Please refer to the AC500 User’s Manual chapter System Data.

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 Getting Started with S500-FBP
Important user information
Solid state equipment has operational characteristics differing from those of electromechanical
equipment. Because of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy themselves that each
intended application of this equipment is acceptable.

In no event will ABB be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the
many variants and requirements associated with any particular installation, ABB cannot assume
responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by ABB with respect to use of information, circuits, equipment, or software
described in this manual.

Throughout this manual we use notes to make you aware of safety considerations.

Identifies information about practices or circumstances that can cause an

WARNING explosion in a hazardous environment, which may lead to personal injury or
death, property damage, or economic loss.
Identifies information that is critical for successful application and
IMPORTANT understanding of the product.
Identifies information about practices or circumstances that can lead to
ATTENTION personal injury or death, property damage, or economic loss. Attentions help
you:
• identify a hazard
• avoid a hazard
• recognize the consequence
SHOCK HAZARD Labels may be located on or inside the device to alert people that dangerous
voltage may be present.
SHOCK HAZARD Labels may be located on or inside the device to alert people that surfaces may
have dangerous temperatures.

Environment and Enclosure Information

Environment and Enclosure

ATTENTION
This equipment is intended for use in a Pollution Degree 2 industrial
environment, in overvoltage Category II applications (as defined in IEC
publication 60664-1), at altitudes up to 2000 meters without derating.

This equipment is considered Group 1, Class A industrial equipment according

to IEC/CISPR Publication 11. Without appropriate precautions, there may be
potential difficulties ensuring electromagnetic compatibility in other
environments due to conducted as well as radiated disturbance.

This equipment is supplied as "open type" equipment. It must be mounted

within an enclosure that is suitably designed for those specific environmental
conditions that will be present and appropriately designed to prevent personal
injury resulting from accessibility to live parts. The interior of the enclosure must
be accessible only by the use of a tool. Subsequent sections of this publication
may contain additional information regarding specific enclosure type ratings
that are required to comply with certain product safety certifications.

See NEMA Standards publication 250 and IEC publication 60529, as

applicable, for explanations of the degrees of protection provided by different
types of enclosure. Also, see the appropriate sections in this publication, as

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 well as the S500 User's manual for additional installation requirements
pertaining to this equipment.

Before starting
Use this document as a guide for installing and powering-up your S500-FBP Interface Module. You
should already be familiar with the system components.

How to handle S500-FBP components

Preventing Electrostatic Discharge

ATTENTION
This equipment is sensitive to electrostatic discharge, which can cause internal
damage and affect normal operation. Follow these guidelines when you handle
this equipment:
• Touch a grounded object to discharge potential static.
• Wear an approved grounding wrist strap.
• Do not touch connectors or pins on component boards.
• Do not touch circuit components inside the equipment.
• If available, use a static-safe workstation.
• When not in use, store the equipment in appropriate static-safe
packaging.

Make sure that you have all the components you need
To use the S500-FBP Interface Module you should use at least the following parts:

Part Number Designation

1SAP220000R0001 DC505-FBP, Interface Module with 8DI/8DC 24 V DC
1SAP210000R0001 or TU505, FBP Terminal Unit with screw or TU506, FBP Terminal Unit with
1SAP212000R0001 spring
See the FBP Catalog FieldBusPlug module with desired Fieldbus protocol

You may also use these components with the S500-FBP Interface:

If you want to: Then use this component:

• connect a 24 V dc digital sensor or DI524 (32 DI ), DC522 (16DC), DC523 (24DC),
actuator to the device DC532 (16DI/16DC) or DX522 (8DI/8 DO-R) with
the corresponding terminal unit with screw-type or
spring connection TU515/516 or TU531/532
• connect a 115-230 V AC digital sensor or DX531 (8DI 115-230 V AC / 4 DO-R) +
actuator to the device corresponding Terminal Unit TU531/532 with
screw or spring technology
• connect a 24 V DC analog sensor or AI523 (16AI U/I/PT100), AO523 (16AO),
actuator to the device AX521(4AI/4AO U/I/PT100) or AX522 (8AI/8AO
U/I/PT100) + corresponding Terminal Unit
TU515/516
• Label the I/O Channels TA523 (Pluggable marking holder) + TA525
Markers for marking holder.

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 System planning
Consider the following when planning your S500-FBP system:

• The S500-FBP controller is always the left-most module in the system.

• The FieldBusPlug delivers the power supply for the FBP interface module DC505 and the connected
I/O bus; the additional I/O modules have to be installed to the right of the FBP Interface Module.
• The DC505-FBP Interface module supports as many as 7 I/O expansion modules.
• An additional process power supply has to be provided for the I/Os of each module. Each I/O
expansion module can be powered with its own power supply (isolation purpose) or the same power
supply can also be used.
• One FieldBusPlug can be used in a S500-FBP cluster.

Installation steps

√ Installation step: Further

information
1 Snap the FBP Terminal Unit onto DIN Rail or screw it (wall mounting)
2 Snap the additional Terminal Units for I/O modules onto DIN Rail
(optional) or screw them (wall mounting)
3 Make the sensor/actuator wire connections according to the dedicated
Electronic module you want to use (see dedicated pages), connect
also a Process Power supply to the modules.
4 Plug the different Electronic modules in the right place (FBP Interface
module on TU, and eventually also I/O modules onto dedicated TUs)
5 Make the FBP fieldbus connection acc. to the chosen FBP and use the (*)
dedicated FBP accessories (cables, master cable to M12, line
termination, power supply connector, etc...)
6 Plug the FBP-Plug on the M12 connector located on the Terminal Unit
of the S500-FBP Interface Module
7 Set the correct address onto the FBP Interface Module (rotary
switches)
8 Install the appropriate EDS/GSD files into the Fieldbus configurator (for
use with AC31 or AC500 Control Builder) or use a dedicated Fieldbus
Configurator tool using GSD/EDS configuration files of your Master
device
9 Set the power on (process power supply first and FBP power supply)
10 Start the communication

(*) Refer to the Installation Instructions of the used FBP device.

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 Assembling the System

The S500-FBP modules are not designed for removal or insertion under power.
WARNING Because of unforeseeable consequences, it is not allowed to plug or unplug
modules with the power being ON.

If you connect or disconnect the FBP plug while power is applied to this module
or the wiring while the process power supply is on, an electrical arc can occur.
This could cause an explosion in hazardous location installations.

Be sure that power is removed or area is non-hazardous before proceeding.

Using S500 I/O Modules

The S500 I/O modules could be used either directly connected to an AC500 CPU (central expansion) or
together with an FBP Interface Module DC505-FBP + an FBP (PROFIBUS DP, DeviceNet, etc.) as
decentralized expansion.

CM572 CM577 PM581 DC532 DC532

Figure: S500 I/O modules directly connected to an AC500 CPU (central I/O expansion)

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 DC505 DC532 DC532

Figure: S500 I/O modules connected to an FBP Interface Module DC505-FBP with an FBP
(decentralized expansion)

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 Minimum spacing

DC505 DC532 DC532

DIN rail,
earthed

Mounting
plate,
earthed

Cable duct

20 mm minimum distance between

the modules and the cable duct

DC505 DC532 DC532

DIN rail,
earted

Mounting
plate,
earthed

Figure: AC500/S500 module mounting into cabinets

Maintain spacing from enclosure walls, wireways, adjacent equipment, etc. Allow minimum 20 mm (1 in.)
of space on all sides, as shown. This provides ventilation and electrical isolation.

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 Important: Horizontal mounting is highly recommended. Vertical mounting is possible,
however, derating consideration should be made to avoid problems with poor air circulation and the
potential for excessive temperatures (see also the AC500 system data, operating and ambient
conditions, for reduction of ambient temperature).

Note: By vertical mounting, always place an end-stop terminal block (e.g. type BADL, P/N:
1SNA399903R0200) at the bottom and on the top of the modules to properly secure the modules.

By high vibration applications and horizontal mounting, we also recommend to place end-stop
terminals at the right and left side of the device to properly secure the modules, e.g. type BADL,
P/N: 1SNA399903R0200.

Mounting the System

During panel or DIN rail mounting of all devices, be sure that all debris (metal
ATTENTION chips, wire strands, etc.) is kept from falling into the controller. Debris that falls
into the controller could cause damage while the controller is energized.

Mounting and Demounting of the Terminal Unit and Electronic Module

Mounting on DIN rail

Step 1: Install the 7.5 mm or 15 mm DIN Rail

Step 2: Snap the FBP-Terminal Unit (TU505 or TU506)

Figure: Mounting of the FBP Terminal Unit (TU505 or TU506)

The FBP Terminal Unit will be placed on top of the DIN Rail and then snapped on the bottom. Follow the
reverse order to disassembly.

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 Figure: Disassembly of the FBP Terminal Unit (TU505 or TU506)

Step 3: Mounting of the I/O Terminal Unit (TU515, TU516, TU531 or TU532)

Figure: I/O Terminal Unit assembly (TU515, TU516, TU531 or TU532)

The I/O Terminal Unit is installed on the DIN rail in the same way as the FBP Terminal Unit. Once
secured on the DIN rail, slide the I/O unit to the left until it fully locks into place creating a solid
mechanical and electrical connection.

Up to 7 I/O Terminal Units could be combined with a FBP Terminal Unit.

When attaching the FBP, FBP Interface and I/O modules, make sure the bus
ATTENTION connectors are securely locked together to ensure proper electrical connection.

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 1 2 ... 7

Figure: Maximum configuration (1 FBP Terminal Unit plus 7 I/O Terminal Units)

Disassembly of a Terminal Unit

Figure: I/O Terminal Unit disassembly (TU515, TU516, TU531 or TU532)

A screwdriver is inserted in the indicated place to separate the Terminal Units.

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 Step 4: Module assembly

DC505

Figure: Mounting of the module

The module will be plugged on the Terminal Unit. And will be locked in place.

The disassembly is done in reverse order.

Figure: Module disassembly

For disassembly, press top and bottom, then pull out the module.

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 Panel mounting
If the Terminal Unit should be mounted with screws, a Wall Mounting Accessory TA526 must be inserted
at the rear side first. This plastic part prevents bending of the Terminal Unit while screwing on.

Holes for
Rear view wall mounting
1 Rear view

1 2 3
Front view

Figure: Fastening with screws of the Terminal Unit TU516 (as an example)

1 The Wall Mounting Accessory TA526 is snapped on the rear side of the Terminal Unit like a DIN rail.
The arrow points to the right side.

2 Accessory for wall mounting inserted

3 Terminal Unit, fastened with screws. Use two screws per module. Use M4 or #8 pan head screws.
Mounting screws are required on every module.

By wall mounting, the Terminal Unit is earthed through the screws. It is necessary that

• the screws have a conductive surface (e.g. steel zinc-plated or brass nickel-plated)
• the mounting plate is earthed
• the screws have a good electrical contact to the mounting plate

The following procedure allows you to use the assembled modules as a template for drilling holes in the
panel. Due to module mounting hole tolerance, it is important to follow these procedures:

1. On a clean work surface, assemble no more than three modules.

2. Using the assembled modules as a template, carefully mark the center of all module-mounting
holes on the panel.

3. Return the assembled modules to the clean work surface, including any previously mounted
modules.

4. Drill and tap the mounting holes for the recommended M4 or #8 screw.

5. Place the modules back on the panel and check for proper hole alignment.

6. Attach the modules to the panel using the mounting screws.

TIP: If mounting more modules, mount only the last one of this group and put the others aside.
This reduces remounting time during drilling and tapping of the next group.

7. Repeat steps 1 to 6 for any remaining modules.

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 Grounding considerations
This product is designed to be mounted to a well-grounded mounting surface such as a metal panel.
Additional grounding connections from the S500 mounting tabs or DIN rail (if used), are not required
unless the mounting surface cannot be grounded. Refer to appropriate Chapter of the S500-FBP User's
Manual, for additional information.

This product is grounded through the DIN rail to chassis ground. Use zinc
ATTENTION plated yellow-chromate stell DIN rail to assure proper grounding. The use of
other DIN rail materials (e.g. aluminium, plastic, etc.) that can corrode, oxidize,
or are poor conductors, can result in improper or intermittent grounding.

S500 system dimensions

57.7
(2.27)

DC505

59 (2.32)
70.5 (2.78)
135 (5.31)

67.5 (2.66) 67.5 (2.66) Dimensions:

135 mm
TU505/506 TU515/516/531/532 (5.31) inches

Figure: Dimensions of the Terminal Unit (front view)

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 84.5 (3.33)
77 (3.03)
75 (2.95)
21 (0.83)
70.5 (2.78) 54 (2.13)
59 (2.32)

76 (2.99)
135 (5.31)
DIN rail 15 mm
DIN rail 7.5 mm

Dimensions:
135 mm
28 (1.10) (5.31) inches

View on the left side View on the right side

Figure: Dimensions of the Terminal Unit with module (lateral view)

Note: All dimensions are in mm (in.). Hole spacing tolerance: ±0.4 mm (0.016 in.)

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 Setting of the slave address of the FBP plug onto the S500-FBP interface module
The FieldBusPlug needs to get an address to be used into a fieldbus as a slave module. The S500-FBP
Interface Module gives them an address at power-up of the system. The address should be set
according to 2 rotary switches located on the top of the module.

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

DC505 DC532

PWR 1.0 I0 2.0 C8 1.0 I0 2.0 I8 3.0 C16 4.0 C24

FBP 1.1 I1 2.1 C9 1.1 I1 2.1 I9 3.1 C17 4.1 C25
S-ERR 1.2 I2 2.2 C10 1.2 I2 2.2 I10 3.2 C18 4.2 C26
I/O-Bus 1.3 I3 2.3 C11 1.3 I3 2.3 I11 3.3 C19 4.3 C27
1.4 I4 2.4 C12 1.4 I4 2.4 I12 3.4 C20 4.4 C28
1.5 I5 2.5 C13 1.5 I5 2.5 I13 3.5 C21 4.5 C29
ADDR
Rotary switch for setting x10 1.6 I6 2.6 C14 1.6 I6 2.6 I14 3.6 C22 4.6 C30
1.7 I7 2.7 C15 1.7 I7 2.7 I15 3.7 C23 4.7 C31
the FBP slave address ADDR 1.8 UP 2.8 UP 1.8 UP 2.8 UP 3.8 UP 4.8 UP

x1 1.9 ZP 2.9 ZP 1.9 ZP 2.9 ZP 3.9 ZP 4.9 ZP

CH-ERR1 CH-ERR2 CH-ERR1 CH-ERR2 CH-ERR3 CH-ERR4

A screwdriver with a FBP 8 DI 8 DC 16 DI 16 DC

Input 24 V DC Input 24 V DC
width of 2.5 mm to 3 mm Output 24 V DC 0.5 A Output 24 V DC 0.5A

is required 1.0 2.0 1.0 2.0 3.0 4.0

1.1 2.1 1.1 2.1 3.1 4.1

1.2 2.2 1.2 2.2 3.2 4.2

1.3 2.3 1.3 2.3 3.3 4.3

ADDR 1.4 2.4 1.4 2.4 3.4 4.4

1.5 2.5 1.5 2.5 3.5 4.5

x10 1.6 2.6 1.6 2.6 3.6 4.6

1.7 2.7 1.7 2.7 3.7 4.7

1.8 2.8 1.8 2.8 3.8 4.8

1.9 2.9 1.9 2.9 3.9 4.9

ADDR
x1

Figure: Setting the FBP slave address

The two rotary switches labelled ADDR x 1 and ADDR x 10 are used to assign an address to the
FieldBusPlug.

For example: to assign the address 25 to the station, turn the rotary switch ADDRx10 to the position 2
and the ADDRx1 to the position 5, then the resulting address is 2x10 + 5x1 = 25.

Same example but for the address 6: turn the ADDRx10 to 0 and the ADDRx1 to 6, then the resulting
address is 0x10 + 6x1 = 6.

If the address set on the FBP Interface Module is different from those assigned
ATTENTION into the Fieldbus configurator software of the Master device for that station, the
station could not be accessed and the complete fieldbus could not work
properly or be completely down!

Make the Connection of the FieldBusPlug to the Fieldbus Master Device

The FieldBusPlug module has to be connected to the master device and the power supply has to be
provided. Please use the dedicated accessories to the FBP used for the desired Fieldbus.

Refer to the FBP documentation for the installation instructions.

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 LEDs on S500-FBP modules
All S500 modules have LEDs for the display of operating statuses and error messages. They indicate:

LED Meaning Color LED = ON LED = OFF LED flashes

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

For the meaning of the different LEDs and their behaviour when the system is running, please refer to
the S500 System Data of the S500 User’s manual for further information.

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 FBP LEDs – PROFIBUS DP

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 S500-FBP Modules Specifications
Please refer to the S500 User’s Manual chapter System Data.

S500-FBP Modules Certifications

Please refer to the S500 User’s Manual chapter System Data.

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 Examples
Examples for introduction

Getting started
We will introduce you to the system using a simple example.

PM581 DC532
L+ +24 V DC UP
L+ +24 V DC UP
M 0V ZP
M 0V ZP
FE FE Functional Earth
1
2
3
4
5
6
7
8
9

+ 24 V DC
–

24 V DC TK501

The following components are required for this example:

• One basic unit (e.g. PM581) and one terminal base (e.g. TB511-ETH).

• One digital I/O module DC532 (DX522 or DX531 as an alternative) and one I/O terminal unit (e.g.
TU516).

• One 24 VDC power supply.

• A PC with the programming software PS501 installed.

• One cable (TK501) to connect the PC to the basic unit.

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 Task: Assign an input signal to an output.

In this example, we are using the programming language FBD.

Preparations
• Connect the PM581 controller to 24 V DC. Connect the DC532 I/O module to 24 V DC. Connect
the COM2 interface of the controller to the COM1 interface of the PC or use an USB RS-232
converter and connect it to the USB interface of the PC.

• Start the PS501 software. The project last edited is opened. If necessary, close this project by
selecting "File/Close".

• Familiarize yourself with the main window of the software.

For a correct operation of the system, it is important to completely specify

ATTENTION (configure) the device configuration in the programming software. Otherwise
the system will bring up corresponding error messages! In case of errors,
please refer to the chapter "System Technology / Diagnosis System in AC500"
for required information.

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 Creating a new project
Select "File/New".

Select the desired CPU in the appearing window. In our example, select PM581.

In the appearing window confirm with OK.

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 A window appears where you can select the POU name, type and language. For the name and the type
keep the settings "PLC_PRG" and "Program". Select "FBD" for the language and confirm with "OK".

You have now opened a new project.

Note: All necessary libraries are loaded automatically.

Saving the project to the PC

First of all save the project by selecting the menu item "File/Save as".

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 Select the desired directory and enter the project name. Complete your input with "Save".

In our example the project is saved under the name "First_Steps" to the folder "Projects". The file
extension "pro" is automatically created by the software.

Specifying the hardware configuration

The software has to be informed about the hardware configuration, i.e. the hardware configuration has to
be specified in the software (e.g. the I/O devices). Click on .

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 Double click the object "PLC Configuration". If the AC500 folder in the PLC configuration tree is closed,
click on the symbol.

Click on "I/O-Bus[FIX]" and then press the right mouse button.

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 Select "Append Subelement" -> "DC532" (or the I/O module You use).

Configuring the digital I/O module DC 532

Configuring the I/O parameters

Click on . Double click the object "PLC Configuration". By clicking on the I/O symbol, the
module parameters are displayed and can be changed. Example for DC532: The input delay is changed
from 8 ms (default) to 1 ms.

This way you can also configure the inputs and outputs of the S500-FBP interface module DC505-FBP
in order to use them as decentralized inputs and outputs.

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 First click on the symbol in front of the entry "DC532" and then click on this symbol in front of the entry
"Digital Inputs 0-15[FIX]". The I/O address mapping in the CPU is displayed:

In our example, it is possible to access the digital inputs of the DC532 module as word using the address
%IW0 (simultaneous access to the 16 inputs I0…I15) or as bytes (inputs 0 - 7 using the address %IB0,
inputs I8 - I15 using the address %IB1) or as individual bits (addresses %IX0.0 to %IX0.7 for inputs I0 -
I7 or %IX1.0 to %IX1.7 for the inputs I8 - I15).

In our example, the DC532 I/O expansion module used has digital inputs
ATTENTION and also digital configurable inputs/outputs. These configurable I/Os are
displayed in the I/O mapping either as inputs or as outputs according to
how the channel will be used by the user!

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 The I/Os will have the following CPU addresses in the CPU mapping table:

Channels Address in Comment

the mapping /
programming
software
Digital inputs 0-15 %IW0 All the 16 digital inputs combined as Word from the
DC532 module
Digital inputs 0-7 %IB0 All the 8 first digital inputs combined as Byte
Digital inputs 8-15 %IB1 All the 8 following digital inputs combined as Byte
Single digital input 0 %IX0.0 Single digital input as a bit for the input 0 to the input 7
to to
single digital input 7 %IX0.7
Single digital input 8 %IX1.0 Single digital input as a bit for the input 8 to the input 15
to to
single digital input 15 %IX1.7
Digital configurable %IW1 All the 16 digital configurable I/Os as inputs in combined
inputs 16-31 as Word from the DC532 module
Digital configurable %IB2 All the 8 following digital configurable I/Os as inputs
inputs 16-23 combined as Byte
Digital configurable %IB3 All the 8 following digital configurable I/Os as inputs
inputs 24-31 combined as Byte
Single digital %IX2.0 Single digital configurable I/Os as input as a bit for the
configurable input 16 input 16 to the input 23
to to
single digital
configurable input 23 %IX2.7
Single digital %IX3.0 Single digital configurable I/Os as input as a bit for the
configurable input 24 input 24 to the input 31
to to
single digital
configurable input 31 %IX3.7
Digital configurable %QW0 All the 16 digital configurable I/Os as outputs combined
outputs 16-31 as Word from the DC532 module
Digital configurable %QB0 All the 8 following digital configurable I/Os as outputs
outputs 16-23 combined as Byte
Digital configurable %QB1 All the 8 following digital configurable I/Os as outputs
outputs 24-31 combined as Byte
Single digital %QX0.0 Single digital configurable I/Os as output as a bit for the
configurable output 16 output 16 to the output 23
to to
single digital
configurable output 23 %QX0.7
Single digital %QX1.0 Single digital configurable I/Os as output as a bit for the
configurable output 24 output 24 to the output 31
to to
single digital
configurable output 31 %QX1.7

For more details concerning the I/O mapping, please refer to the AC500 User's manual.

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 Symbolic names for I/Os
In our example we use one digital input and one digital output. We want to label them with symbolic
names. Proceed as follows: Click on the symbol in front of "DC532" in order to display the I/O
configuration:

Now define a symbolic name for the digital input (digital input 0) as follows. First click on the symbol in
front of "Digital Inputs 0-15[FIX]":

In the line of input 0, click twice on "AT". Then enter the symbolic name, e.g. I0dig.

Complete your input by pressing the <Enter> key (displayed entry: I0dig AT %IX0.0 …). Now the
program can access this input by its symbolic name. Using the same procedure, we then have to label
the digital output with a symbolic name. Click on the symbol in front of the entry "Digital In/Outputs -
outputs 16-31 [FIX]".

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 In the line of output 16, click twice on "AT". Then enter the symbolic name, e.g. O0dig, and complete
your input by pressing <Enter>.

Opening the Function Block Diagram editor

From the Resources we now want to switch to the Function Block Diagram editor: Click on the
tab and then double click on the entry PLC_PRG (PRG). The Function Block Diagram editor is opened.

Position the mouse cursor into the insertion mark of network "0001" and press the right mouse
button. Select "Assign".

The display is as follows:

Now we have to enter the symbolic names previously assigned to the input and the output. Click on the
left-hand question marks (???) and press <F2>. The Help Manager appears. Select "System Variables".

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 Select "I0dig" and confirm with "OK". Proceed in the same way for the output. At the end, click into the
free area of network "0001".

Compiling the project

The definition of the project is now completed and the project can be built. For this purpose, select the
menu item "Project/Rebuild all".

If no errors were detected, the message "0 errors, 0 warnings" is displayed in the message box.

Setting the communication parameters

In order to establish the connection between the PLC and the PC, the communication parameters have
to be set. We are using the COM2 interface of the PLC and the COM1 interface of the PC or the COM
interface of the PC assigned by the USB RS-232 converter. Switch to the tab. Double click
the object "PLC Configuration". In the configuration tree, click on the symbol in front of the
"Interfaces[FIX]" element.

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 Click on the entry "COM2 - Online access[SLOT]" in order to display the default values of the PLC's
COM2 interface.

Then we have to define the PC interface settings. Select the menu item "Online/Communication
Parameters".

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 In the "Communication Parameters" dialog, click on the "Gateway" button and then select the entry
"Local" from the "Connection" list box in the appearing dialog. Then confirm your settings with "OK".

Now the "Communication Parameters" dialog displays the PC interface. Press the "New" button. Enter
any name for the new channel, e.g. COM1_PC, and select "Serial [RS232]" for the "Device" (driver).

Confirm your settings with "OK".

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 Now we have to specify the corresponding parameters in the "Communication Parameters" dialog.
Specify the serial interface of the PC with the parameter "Port": double click on the value of “Port”,
possibly several times. Click on the "Baudrate" value and then double click the value until "19200" is
displayed. Proceed in the same way to change the "Motorola byteorder" setting from "No" to "Yes".
Confirm your settings with "OK".

Testing the program with PLC hardware connected

Proceed as follows to test the program with PLC hardware connected:

Downloading the program to the PLC

First we have to load the program to the controller. To do this, select the menu item "Online/Login".

The software checks whether the project on the PLC is identical to the project on the PC. If the PLC
does not yet contain a user program, the message "No program available in the controller. Should the
new program be loaded" is displayed. If the project on the PLC differs from the project on the PC, the
following message is displayed:

Select "Yes". Then the program is downloaded from the PC to the PLC. When starting the download
process, the PLC changes to the STOP mode.

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 Now we are going to store our program in the Flash memory of the PLC to protect it against voltage
breakdown. To do so, select "Online/Create boot project".

Starting the program

Now we want to run the program. Select the menu item "Online/Run":

In order to test the program we are going to force input I0dig to TRUE: Double click to the input "I0dig":

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 In order to set this value permanently, the Force function has to be used. With this function, the user
defined value is set in the runtime system each time at the beginning and at the end of the program
cycle.

This way, the input is assigned to the output (i.e. set to TRUE) in each program cycle. The CoDeSys
software displays the TRUE state in blue color (the FALSE state is displayed in black).

This way, the input I0dig is assigned to output O0dig.

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 Note: The status of the I/Os can also be displayed in the PLC configuration. Click on .
Double click on “PLC configuration”.

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 Using "Online/Logout", the connection to the PLC is disconnected and the Force function is canceled. To
exit the CoDeSys software, select the menu item "File/Exit".

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 Examples for decentralized systems connected by network
On principle, the configuration of decentralized systems connected by network is done in two steps:

• The CPU has to be informed about which couplers are assigned to it (internal and/or external
couplers).

• The couplers have to be informed about which peripheral devices are connected to them.

This is done using the tool SYCON.net (opened via the tab Resources -> Tools -> SYCON.net). This tool
is also used to create the variables lists for the individual peripheral devices. The symbolic names
created therein are directly (online) made available for the programming software. Thus, these created
variables are located in the Global Variables folder.

Example with an AC500 CPU PM581 as PROFIBUS DP Master and a DC505-FBP as

PROFIBUS DP slave with a FieldBusPlug PDP22-FBP

AC500 PM581-ETH + CM572-DP as

master + DC532 + AX522
CM572 PM581 DC532 AX522

PDA11-FBP.050
+ 24 V DC
–
from COM2/PLC to PC
+/– 24 V DC +/– 24 V DC

DC505 DC532 AX522

PDP22
-FBP
+ 24 V DC
–
DC505-FBP + DC532 + AX522

PDR11-FBP.150

Figure: Example with an AC500 CPU as PROFIBUS DP master and a DC505-FBP as PROFIBUS DP
slave. Note: “to PC” – either COM1 interface of PC, directly, or corresponding COM interface of PC,
allocated via USB RS-232 converter.

The following example will guide you through the installation and the configuration of a small PROFIBUS
DP fieldbus using an AC500 PLC as PROFIBUS DP master and a S500-FBP remote I/O station with a
modular FBP.
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 This example could be used as starting point to develop your own application.

Refer to the dedicated User's manuals or Installation guides of the

ATTENTION FieldBusPlug and the AC500 PLCs and programming software.

Needed products

amount product description order number

1 PM581-ETH, CPU 1SAP 1401 00 R0170
1 CM572-DP, Communication Module PROFIBUS DP 1SAP 170 200 R0001
Master 12 Mb/s
1 TB521-ETH, CPU Terminal Base AC500, 1x CPU Slot, 1SAP 1121 00 R0170
2x Coupler Slots, Ethernet RJ45 Connector
1 TA524, Dummy Coupler Module 1SAP 1806 00 R0001
1 TK501, Programming Cable, D-Sub / D-Sub 1SAP 1802 00 R0001
1 PDA11-FBP.050, Adapter M12-Dsub9-M12, cable length 1SAJ 9240 09 R0005
0.50 m (field bus + power supply)
1 PDP22-FBP.050 PROFIBUS DP-V0/V1-FBP 0.5 m, 1SAJ 2401 00 R1005
modular (FieldBusPlug)
1 PDR11-FBP.150 Terminating resistor 150 Ohm 1SAJ 9240 07 R0001
1 DC505-FBP with 8DI/8DC 1SAP 2200 00 R0001
2 DC532 with 16DI/16DC 1SAP 2401 00 R0001
2 AX522 with 8AI/8AO 1SAP 2500 00 R0001
1 TU506, FBP Terminal Unit, Spring Terminals 1SAP 2100 00 R0001
4 TU516, I/O Terminal Unit, 24 V DC, Spring Terminals 1SAP 2120 00 R0001
1 GSD file for FBP module ABB_091F.GSD
1 PS501-PROG, Control Builder AC500, Programming 1SAP 1901 00 R0001
Software

Before starting with the following example, please:

• Use the previous installation instructions to assemble and mount the system, also refer to the
dedicated Users manual of the PROFIBUS DP FBP, S500-FBP and AC500 PLCs.
• Make the wiring and provide supply power to the system (process supply) and to the FieldBusPlug
(use dedicated accessory, e.g. PDA11-FBP.050 which allows connecting a PROFIBUS DP master
with a 9 pins D-Sub and provides power supply for the FBP through a M12 connector).
• Set the slave address of the FBP to 2 with the front rotary switches of the S500 FBP-Interface
module (chosen for this example; see also S500-FBP Getting started).
• Install the AC500 Control Builder programming software for AC500 PLCs
• Install the SYCON.net fieldbus configurator
• Install GSD and EDS files
• Connect the programming cable TK501 from the PC to the AC500 PLC
• Review all of the hardware instructions for your specific system to be sure you have completed all of
the required preliminary steps prior to beginning the system configuration with the AC500 Control
Builder programming software.
• Power up the system

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 Starting the programming software
Start the AC500 Control Builder programming software. Select "File/New" to create a new project.

Select the desired CPU in the appearing window. In our example, select PM581.

In the appearing window confirm with "OK".

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 A window appears where you can select the POU name, type and language. For the name and the type
keep the settings "PLC_PRG" and "Program". Select "ST" for the language and confirm with "OK".

The ST editor is opened.

First, save the project under a specific name. Select the menu item "File/Save as".

Select the desired directory and enter the project name (in our example: "Test3"). Complete your input
with "Save".

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 Specifying the hardware configuration
The software has to be informed about the hardware configuration, i.e. the hardware configuration has to
be specified in the software. Click on .

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 Double click the object "PLC Configuration". If the AC500 folder in the PLC configuration tree is closed,
click on the symbol.

First the I/O devices connected directly to the I/O bus of the CPU will be entered: Click on "I/O-Bus[FIX]"
and then press the right mouse button.

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 Select "Append Subelement" -> "DC532".

Repeat this procedure to append the analog module AX522.

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 Now we are going to append the PROFIBUS DP communication module. In the configuration tree, click
on "Couplers[FIX]" and then press the right mouse button. Select Append Subelement -> CM572 and
then click to append the element.

The coupler is appended to the tree. As the CPU also comprises an integrated Ethernet coupler we are
going to replace ‘Couplers – Internal none’ by an Ethernet coupler.

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 Configuring the decentralized S500-FBP I/O station using the SYCON.net fieldbus
configurator
Now we are going to configure the decentralized S500-FBP I/O station. Proceed as follows:

• In the left-hand window, click on the symbol in front of the Tools entry. Then double click the
entry SYCON.net.

• The SYCON.net fieldbus configurator is opened. Using this configurator, you can configure the
decentralized I/O station.

In the "Fieldbus" tab, open the folder 'PROFIBUS DPV 0' by clicking on the symbol. Do the same with
file "Master". With the left mouse button, click on CM572-DPM. Keep the left mouse button pressed and
drag the object into the left window to append it to the green line (this line represents the connection to
the CPU). Release the left mouse button.

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 In the appearing window, leave the "Board No. 1" unchanged (counting mode: CPU-internal coupler =
Board No. 0, first coupler left of the CPU = Board No. 1, second coupler = Board No. 2).

Click on "Accept". The coupler is now connected to the CPU.

Recommendation: You can choose the symbolic coupler name according to your plant (mark coupler
with left mouse button; the coupler is displayed with a blue rectangle; press right mouse button ->
symbolic name. Example for symbolic name: DPM1_AC500).

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 The parameter settings of the communication coupler can be easily modified by double clicking on the
coupler symbol (surrounded by a blue line). A window opens - click on "Configuration -> Bus
Parameters". With that you can change the parameters.

Change the desired parameters and then click OK.

The same procedure is used to append a slave to the PROFIBUS DP master CM572-DPM. Open the
"Slave" folder in the "Fieldbus" tab. Drag the PROFIBUS DP FieldBusPlug PDP22-FBP (DPV1 modular)
into the left-hand window to append it to the purple line (this line represents the PROFIBUS DP fieldbus).

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 The FieldBusPlug slave is now appended to the PROFIBUS DP line. The symbolic name has been
changed to DPS2_FBP_S500.

The slave has to be correctly software configured and mapped to precisely match the true hardware
configuration. Double click on the PDP22-FBP symbol to open a new configuration window. In this
window the hardware configuration is described and some parameter settings can be defined.

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 The slave station has to be set up. Click on "Configuration -> Modules" in the 'Pages Tree View'. First
select the FBP interface module DC505-FBP from the list of available modules. Click on "Append". Thus
the selected module is added to the list of configured modules.

The order of the modules in the list of configured modules must match the actual
ATTENTION order of hardware modules. Otherwise, the decentralized station and the
network cannot work properly!

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 Repeat this procedure to append the modules DC532 and AX522. Then, the list of configured modules
looks as follows:

Proceed as follows to configure the module parameters. Click on "Configuration -> Parameters". Select
the corresponding module from the list.

Click on the corresponding module.

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 The available parameters are displayed.

Example: Changing the input delay of the module DC532.

Highlight the line of the desired parameter: move the cursor to that line and press the left mouse button.
Double click with the left mouse button onto the highlighted line. Click with the left mouse button on
to display the values available. Select the desired value by clicking with the left mouse button on that
value. Click with the left mouse button into the area with the empty lines. Thus the change has been
adopted.

After you have changed all the desired parameters, click on OK to exit the parameter configuration.

The configuration of the fieldbus modules is finished. Now the names of the communication variables
used for data exchange between coupler and CPU program have to be specified. Proceed as follows to
specify the variables (these variables are automatically forwarded to the AC500 Control Builder software
in order to have them available there):

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 The upper part of the netConnect area contains a tree structure showing the master communication
coupler CM572-DPM and the slave PDP22-FBP (DPV1 modular) with the sorted list appended. Click on
the symbol in front of the entry PDP22-FBP to open this branch of the tree. For each I/O module, a
separate folder is displayed containing the corresponding data exchange variables.

Click on the first folder 2 byte input. This folder represents the digital inputs of the DC505-FBP module
(8 DI + 8 DC as input). The corresponding variables are listed in the appended list (with Name of signal,
Data type, I/O identifier (I = input, O = output) and Name of variable (can be entered)).

Enter a corresponding “Name of variable“ for each “Name of signal” .To do this, double click into the
Name of variable field of the corresponding signal. Enter the desired variable name and press the
<Enter> key to complete your entry. These names are used in the AC500 Control Builder software. In
our example, we use the following system for the variable name:
bytePROFIBUSDpslaveAddress2_S500(system)_DC505(device)_Input8_to15 (by - byte; b - bit; w -
word).

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 Recommendation: For the planning of your plant we recommend to use symbolic names according to
your plant.

Assign a name to each variable. For the 8 DC (as outputs) of the DC505-FBP module:

For the 16 DI + 16 DC (as inputs) of the DC532 module:

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 For the 16 DC (as outputs) of the DC532 module:

For the 8 analog inputs of the AX522 module:

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 For the 8 analog outputs of the analog module AX522:

After completion of the variables configuration, the fieldbus configuration is finished.

Store the project via “File -> Safe”.

Loading the configuration from SYCON.net to the coupler

Now the configuration has to be loaded from SYCON.net to the coupler CM572-DP. Proceed as follows:
In the netDevice window, click on the coupler to highlight it with a blue frame:

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 Double click on the coupler icon and select "Settings -> Driver -> 3S Gateway Driver".

Select "Gateway Configuration".

In the Communication Parameters window, you can set the parameters for the communication between
the PC and the PLC (port: serial interface of the PC).

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 Confirm the settings with "OK". Select "Settings -> Driver -> Device Assignment" and click on "Scan".
The configuration tool SYCON.net searches for PROFIBUS couplers connected to the stated interface.

Select the device "CM572-DP" and confirm with "OK". Then press the right mouse button and select
"Connect".

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 The coupler entry CM572-DPM is now highlighted in green, indicating that the connection is established:

Press the right mouse button and select "Download".

ATTENTION: To do this the CPU must be in ‘Stop’ state.

A safety inquiry is displayed. Confirm with "Yes".

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 This downloads the configuration to the coupler. Progress of data transfer is displayed.

After the download is completed, SYCON.net has to be disconnected. Press the right mouse button and
select "Disconnect".

In SYCON.net, the configuration has to be saved to a file. The system adopts the project name (in our
example: "Test3"). Select "File/Save".

Exit SYCON. Select "File/Exit".

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 Return to the AC500 Control Builder by clicking on the button in the Windows task bar on
the bottom of the screen.

The AC500 Control Builder software is opened again and the fieldbus variables are automatically
transferred to the Global Variables list of the programming software.

Open the Global Variables in the "Resources" tab. Double click on Slot 1 <R>. The previously
configured variables are displayed and available in the programming software.

Testing the system

In order to test the system, we are going to create a small user program according to the procedure used
in the Getting Started example. We are using the ST programming language (structured text). The
program should read an input of the decentralized station (DC505-FBP) and output the value to the
DC532 device located next to the CPU. The output byte %QB0 at DC532 (located next to the CPU) is
named with the symbolic name by_AC500_DC532_Out16_23.

The program looks as follows:

The input byte with the variable name byDps1_S500_DC505_In0_7 (signals I0 to I7 at DC505) is read
and applied to the output byte by_AC500_DC532_Out16_23 (signals C16 to 23 at DC532).

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 New GSD file(s)

If you install additional GSD files to the installation of the Control Builder CD's
Note GSD files they have to be added to the device catalog of SYCON.net. To do
this apply subsequent procedure.
The GSD files have to be copied to the corresponding directory beforehand
(\ProgramFiles\HilscherGmbH\SYCONnet\ABBPBGenericSlaveDTM\GSD).

Attention: Handling of GSD files only works that way in case of an empty
project!

Click on . Open the 'Tools' folder. Double click on the entry SYCON.net.

Click into the window next to netDevice and select "Network/Device Catalog…" from the menu.

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 Click on . This integrates the new GSD file. Click on OK and close SYCON.net.

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 For AC1131 experts –
connection S500-FBP I/O module to series 90
Example with an AC31 Series 90 CPU as PROFIBUS DP Master and a DC505-FBP as
remote I/Os

+/– 24 V DC

PDA11-FBP.050

RUN

STOP
COM2

07 KT 98

AdvantController31
BasicUnit

COM1

PC

07 KT 97/98 DP
+
24 V DC
DC505 DC532 AX522

PDP22-FBP
+ 24 V DC
–
DC505-FBP + DC532 + AX522

PDR11-FBP.150

Figure: Example with an AC31 series 90 CPU as PROFIBUS DP master and a DC505-FBP as remote
I/Os

The following example will guide you through the installation and the configuration of a small PROFIBUS
DP fieldbus using an AC31 PLC as PROFIBUS DP Master and a S500-FBP remote I/O station with a
modular FBP.

This example could be used as starting point to realize your own application.

Refer to the dedicated User's manuals or Installation guides of the

ATTENTION FieldBusPlug and the AC31 PLCs and programming software.

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 Needed products

Quantity Product description Order number

1 CPU 07 KT 97/98 with PROFIBUS DP
here: 07 KT 97 with Ethernet and PROFIBUS DP GJR5 2530 00 R0272
coupler
1 Programming cable 07 SK 90 GJR5 2502 00 R0001
1 PDA11-FBP.050 adapter for FBP, power supply and 1SAJ 9240 09 R0005
field bus
1 PDP22-FBP.050 PROFIBUS DP-V0/V1-FBP 0.5 m, 1SAJ 2401 00 R1005
modular (field bus plug)
1 PDR11-FBP.150 terminating resistor 1SAJ 9240 07 R0001
1 DC505-FBP with 8DI/8DC 1SAP 2200 00 R0001
1 DC532 with 16DI/16DC 1SAP 2401 00 R0001
1 AX522 with 8AI/8AO 1SAP 2500 00 R0001
1 TU506 FBP terminal unit for FBP interface 1SAP 2100 00 R0001
2 TU516 I/O terminal unit for I/O modules 1SAP 2120 00 R0001
1 GSD file for FBP modules ABB_091F.GSD
1 Programming software 907 AC 1131 GJP5 2070 00 R0102

Before starting:
• Use the previous installation instructions to assemble and mount the system, also refer to the
dedicated User's manual of the PROFIBUS DP FBP and AC31 series 90 PLC.
• Make the wiring and provide power supply to the system (process supply) and to the FieldBusPlug
(use dedicated accessory, e.g. PDA11-FBP.050 which allows to connect a PROFIBUS DP master
with a 9-pin D-Sub and provide power supply for the FBP through an M12 connector).
• Set the slave address of the FBP to 1 with the front rotary switches of the S500-FBP module (see
Getting Started with S500-FBP, "Setting the FBP slave address").
• Install the AC1131 programming software for AC31 PLCs
• If you want to configure the fieldbus using the fieldbus configurator software 907 FB 1131, install this
software. As an alternative, you can also use the fieldbus configurator included in the programming
software.
• If you want to use the fieldbus configurator 907 AC 1131 for configuration, copy the PROFIBUS GSD
file ABB_091F.GSD to the folder \Program Files\AC1131\FB1131\Fieldbus\PROFIBUS\GSD. If you
want to configure the fieldbus using the fieldbus configurator included in the programming software,
copy the GSD file to the folder \Program Files\AC1131\Library\PLCConf.
• Connect the PC (COM1) to the AC31 CPU (COM1) using the programming cable 07 SK 90.
• Connect the CPU to the DC505-FBP module via the FieldBusPlug.
• Switch on voltage.
• Perform the steps given in the following instructions.

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 Variant A: Configuration using the fieldbus configurator included in the
programming software

First, we have to specify the hardware. Click on . Double click the object "PLC
Configuration". Click on "Hardware Configuration". Press the right mouse button. Select "Append
Subelement/DP Master…".

Set the "Card number" in the appearing window. The following rule applies: The slot number (= card
number) can be gathered from the identification number of the CPU. Furthermore, we can also
determine the coupler form the identification number. The following applies:

• GJR5 253x 00 Rxxyz with

y = slot number = card number = 1
z = slot number = card number = 2
• Furthermore, the following code applies to y and z: 2=PROFIBUS DP / 5=DeviceNet / 6=ARCNET /
7=Ethernet / 8=CANopen / 9=Interbus
• For our example: CPU with identification number R0272 -> slot number 1 -> Ethernet; slot number 2
-> PROFIBUS DP
• Since we are using the PROFIBUS coupler in our example, the resulting card number is 2.

Confirm with "OK".

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 Press the right mouse button and select "Append DP Slave".

In the appearing window, select "PDP22-FBP (DPV1 modular) (Default)" in the File Name list box.

Confirm with "OK".

Click on the entry "PDP22-FBP (DPV1 modular). Press the right mouse button and select "Properties".

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 Select "Input/Output". Click on the entry DC505-FBP in the left-hand window and then click on
"Select >>". Proceed in the same way for DC532 and AX522.

Click on “OK”. The hardware is now specified.

When a user program is loaded to the CPU, the configuration data of the coupler (the data are a definite
element of a project) are loaded as well. The operating system of the PLC transfers the configuration
data to the coupler. In addition, the configuration data can be saved together with the user program in
the Flash memory of the controller. The configuration data stored in the Flash memory are automatically
loaded the next time the power is switched on.

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 Variant B: Configuration using the fieldbus configurator software FB1131
Start the fieldbus configurator software 907 FB 1131 and select "File -> New". A window appears where
you can select a fieldbus system.

Select PROFIBUS and click on OK. Now you have to configure the master.

Select Insert -> Master from the menu bar. The mouse pointer changes to an arrow with an 'M'. Left
click with the mouse on that position on the screen where you want to place the DP Master. Another
window appears.

In this window, select 07KT97 DPM and click on Add >> to add the selected master to the network. The
selected master is now displayed on the right-hand side of the window. You can change the default
address of the master and enter a comment in the 'Description' field.

Click on OK and continue.

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 Now append a slave to the PROFIBUS DP line. Click below the master surrounded by a frame. A
rectangle indicates the area where the slave will be inserted.

Select Insert -> Slave from the menu bar.

The mouse pointer changes to an arrow with an 'S'. Proceed as already described for the master in
order to place the slave. A new window appears.

Left click with the mouse on that position on the screen where you want to place the Slave. Another
window appears. Scroll down in the left-hand area and select PDP22-FBP (DPV1 modular) as the
slave. Then click on ADD >>. Your selection is displayed on the right-hand side of the window.

In this window, you can also change the default station address and enter a description for the device.
Then click on OK.

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 The configured fieldbus is displayed.

Double click inside of the rectangle surrounding the slave in order to configure the slave. A new window
named Slave Configuration appears.

The modular station has to be configured in order to specify the used hardware. First, select the FBP
interface module DC505-FBP (list of available modules ('Module' column) in the window shown above;
the selected module is highlighted by a rectangle). Click on Append Module to insert it into the list of
configured modules.

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 The following information is given for the selected modules: Slot number (Slot), module type (Module)
and definition of the input bytes/words IB/IW and the output bytes/words QB/QW. Then we have to
specify the expansion modules of the used hardware. In our example this is a digital input/output module
DC532 and an analog input/output module AX522.
After you have added all required modules into the configuration list, click on OK to apply the
configuration.

Call the address table before you specify the parameter data (via View -> Address Table) in order to
update the addresses of the input/output variables.
If you want to change the device parameters of the slave, select the device entry to highlight it by a
rectangle. Press the right mouse button and select Parameter Data from the context menu.

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 A new window appears, showing all PROFIBUS DP parameters:

For instance, click on Module if you want to change the delay time of all inputs of the module DC532.

Select dc532 1sap240100r0001 and click on OK. The corresponding module parameters are displayed
and can be changed now.

Example: In order to change the delay time of the inputs, double click on Input Delay.

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 A new window appears, showing all available values. Select the desired value, e.g. 1 ms, and click on
OK.

The new value is applied.

After you have changed all the desired parameters, click on OK to exit the parameter configuration. The
following configuration is displayed:

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 In order to test the configured fieldbus, the configuration has to be downloaded to the master. Select the
master (click on the master to highlight it by a surrounding rectangle). Select the menu item Online ->
Download.

Select 3S Gateway Driver as gateway for the download to the CPU coupler and click on OK.

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 A new window named 3S Gateway Driver Assignment is opened for setting the gateway parameters
for the address assignment of the DP coupler in the CPU (this is only done when the gateway is used
the first time).

Click on Gateway Configuration and then select the default channel COM1_PC in the appearing
window.

Apply the selection by clicking on OK.

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 The window is closed and the software tries to establish the connection via the gateway. If the
connection establishment is successful, the couplers are displayed in the Device Information area.

Click into the field next to the coupler name to select the desired coupler (DPM) and confirm with OK.

To perform the download, select the menu item Online -> Download. A safety inquiry is displayed.
Answer with Yes. The configuration is then transferred to the controller.

The address data used can be displayed using the menu item View -> Address Table.

The digital inputs can be accessed via IB0 to IB5, the digital outputs via QB0 to QB2 and the analog
outputs via QW3 to QW11.

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 Testing the system
In order to test the system, we are going to create a small user program. We are using the programming
language FBD. The program should read an input of the decentralized station (DC505-FBP) and output
the value at the CPU. The program looks as follows:

The first byte on the DC505-FBP is read at address %IB2.0 and output at the CPU via the address
%QB124 (outputs A62,00 to A62,07).

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