AC500 – the scalable PLC for customized automation Technical information The scalable AC500 PLC – flexible, cost-efficient, future-friendly Customers’ requirements met to perfection Simple, consistent expandability, flexible when choosing a field bus, and designed for future market trends – those are some of the demands made on an automation platform, particularly in the mechanical engineering sector, but in plant engineering as well. These needs have been worked out in a close dialog with customers and end-users. And now, they have been realized in the design and high functionality of the new scalable AC500 PLC. Parallel connection to several buses The new AC500 consists of different devices that can be combined and flexibly expanded to suit the customer’s individual requirements. It is also possible, for instance, to operate several field buses simultaneously in any desired combination with a single control system. Customers can choose between different CPU performance classes, which can even be easily replaced subsequently to meet increasing requirements. Our common engineering tool AC500 Control Builder provides standardized programming of the entire platform according to IEC 61131-3, as well as further features and utilities. 2 Guarantees your safe investment in future Besides the high performance capabilities of the system regarding handling, reliability and ease of maintenance, also the long-term availability of the chosen system plays a decisive role: Your safe investment must be ensured in future. With the new AC500, ABB offers a modern high-performance platform which is suitable for future-oriented automation concepts and open for new trends and market requirements. AC500 – the first choice everywhere The AC500 is an optimum selection for applications like the following: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ packaging machines plastics machines printing presses crane engineering energy optimization building engineering pumping installations marine engineering wind power installations air-conditioning/refrigeration systems tunnel construction … 3 Everything you need for switching and control Flexible choice of the field bus Flexibility in the choice of a field bus without needing The FBP is the link to a communicative series of to replace any field devices: That’s the basic idea switching and automation components, which can behind the field bus plug (FBP). Thanks to this intelli- thus be combined with standard field bus systems gent plug connector, field devices „become“ field- in the easiest way. bus-neutral. Thus, changing the field bus (often due to end-user’s wishes), only requires the replacement of the plug connector itself – the field devices and terminal wiring can be retained. Bus-neutral field devices: Circuit-breaker 4 Universal Motor Controller Motor Starter AC500 Slave Complete product portfolio ABB offers a complete range of low-voltage devices from one source: PLC, devices for switching and protection, such as soft starters, contactors, and circuit-breakers, up to standard sensors. Many of these ABB components have already been integrated into the innovative system concept involved. Examples here include the UMC22-FBP Universal Motor Controller for effective motor protection and particularly user-friendly motor control, the interactive circuitbreakers Tmax T4, T5, the PSS soft starter and the wireless proximity switch. With the AC500, the FBP product range has been extended by field-bus-neutral I/ O modules and a CPU which can also be used as a field bus slave via the FBP. S500 remote I/Os Soft Starters Wireless Automation 5 Clear advantages thanks to clear structures Flexibility as program Thanks to its scalability, the AC500 PLC can be adapted to the most different automation tasks: The devices concerned can be used and combined in a flexible way. The number of different parts to be kept in stock is correspondingly minimized. The AC500’s system architecture The CPUs are available in different performance classes, can all be programmed in five different languages, and provide an LCD display, an operator keypad, an SD card slot, and two inte-grated serial interfaces. The CPUs can be simply plugged onto the CPU terminal base. Optionally, they are also available with integrated Ethernet or ARCNET. The communication modules For connection to standard field bus systems and integration into existing networks. Up to four communication modules in any desired combination are allowed at one CPU, resulting in a high degree of communication. 6 The CPU terminal base The FBP interface module Available in three different versions, enables easy With embedded digital I/Os and a field-bus-neutral plugging of the CPU and one, two or four communi- interface for connecting the chosen FBP connec- cation modules. tor. For decentralized expansion by up to seven I/O modules. The I/O modules Digital and analog in different versions. Can be simply The SD card plugged onto the terminal units – for local expansion Optional for data logging, downloading and uploa- of the CPU (max. seven local I/O modules) and ding the user program without a PC or a firm- decentralized expansion via the FBP interface. ware update for all devices (CPU, couplers or I/O Flexible use thanks to configurable channels. modules). The terminal units Multi-purpose usage for both digital and analog I/Os, for 1, 2 and 3-wire designs. Enable simple prewiring 1 Back-lighted LCD display and keypad without electronics. For 24 V DC and 230 V AC, 2 SD card slot optionally for spring or screw-type terminals. 3 Plug-in communication modules (1 to max. 4) 4 Optionally with integrated Ethernet 1 or ARCNET 2 5 FBP interface (for slave and for 3 programming) 1 6 Two serial interfaces for programming, 4 ASCII, Modbus or CS31 field bus (master) 5 7 6 7 Expandable by up to seven local I/O modules 7 AC500 grows to meet requirements Control + communication: Centralized expansion: Decentralized expansion: 8 Networked and communicative Network Modem 9 Programming Control Builder AC500, Programming Tool PS501 Control Builder AC500 is the engineering tool for all CPU performance classes of the AC500, designed for standardized IEC 61131-3 programming in five different languages. Other features of this tool are: Configuration of the overall system including field buses and interfaces, extensive diagnostic functions, alarm handling, integrated visualization and open software interfaces. The Programming Tool PS501 also allows to select between different languages such as English, German, Spanish, French, Italian, Russian and Chinese. Member of Automation Alliance 10 Programming in conformity with IEC 61131-3 ■ Five standardized programming languages: Besides the suitable hardware, a high-performance, Function Block Diagram (FBD), Instruction List (IL), user-friendly and convenient engineering tool is Ladder Diagram (LD), Structured Text (ST), Sequential indispensable for simple planning, programming, Function Chart (SFC) testing and commissioning of an automation applica- ■ Free graphical function chart (CFC) tion. AC500 Control Builder provides the following ■ Debugging functions for the program test: functionalities: • Single step • Single cycle • Breakpoint 11 Programming Offline simulation Watch and Recipe Manager, and stored in memory IEC 61131-3 commands can be simulated without a there (“Read recipe). These functions are also helpful, for PLC being connected, including the relevant mal- example, for setting and entering control parameters. functions. 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. Visualization Includes color change, moving elements, bitmaps, Recipe management and watch lists text display, allows input of setpoint values and Values of selected variables are displayed. Pre- display of process variables read from the PLC, defined values can be assigned to variables which dynamic bar diagrams, alarm and event manage- can then be downloaded to the control system all at ment, function keys and ActiveX elements. The once (“Write recipe”). Ongoing values from the control visualizations package is also available individually as system can also be pre-assigned for reading into the a separate software-licence (PS501-HMI). 12 Configurators of the communication interfaces For PROFIBUS DP, CANopen, DeviceNet, Ethernet, Modbus and CS31. Open interfaces as Visual Source Safe, can be used in order to DDE and OPC. ensure data consistency of the program code for several different users and projects. Programming Serial or via Ethernet or ARCNET networks. Miscellaneous • Comprehensive libraries. Engineering interface • Windows 32-bit standard. Provides access from the programming system to an • Operating systems Windows NT, 2000 and XP external project database in which the program source code of one or several automation projects is managed. Optionally, a version control system, such 13 CP400 and CP500 – the operator interfaces Obvious Human-machine communication ABB offers an extensive range of human machine interfaces (HMIs). The two families CP400 and CP500 provide many different displays to choose from, which satisfy application-specific demands regarding required operator actions and information density. Whether it’s a simple device for displaying text, a graphic-capability device or a touch-panel with color display, the entire range of control terminals meets the requirements for maximized transparency and efficiency for the automation task. 14 Simple handling Functionalities in line with demand Users can communicate with the AC500’s CPUs via the Depending on the used device type, the operator panels various operator panels, read and write access on feature the following functions: device data is possible. ■ real-time clock The configuration of the operator panels can be done ■ alarm management in several different groups easy and fast with the programming software CPsoft. ■ trend curves and datalogger With regard to frequently harsh conditions at the place of ■ recipe management installation, all operator panels fulfill IP65 protection at ■ report printouts the front. Operator panels and automation devices are ■ password protection linked either simply via serial interfaces, or in case of ■ Flash memory up to 1600 kB complex applications via Ethernet. 15 Operator Terminals CP400 Performance Quick and easy project creation and management Quickly view and easily manage your project components using the screen manager (detailed list or screen miniatures). Simplify the creation, modification, sorting and identification of your project data via the cross-references function. Easy testing and use Simplified adaptability and connectivity Test your projects, screens and alarms as well as SConnect your HMIs to the various automation your communication and controller functions quickly equipment: via on- and off-line simulation. Change language ■ via the various possible protocols for ABB AC31, quickly and easily using the multi-language support series 40&50, series 90, AC500 PLCs and more function. than 100 leading PLCs on the market, where the display acts as gateway. The multi protocol also Secured data and operations allows data to be exchanged between the various Protect your files and machine configurations using controllers. global and object-specific passwords (9 protection levels) to prevent downloading of the application. ■ via multi-channel communication (Connecting a controller to each available port via different protocols, transferring values between drivers via macros, using the values of various controllers in the calculations). ■ via the multiple connection media (RS232, RS485, RS422or Ethernet…) increasing connection capacities. 16 Comfort Simplified creation Simplify the creation of your projects using: ■ the Macro and Ladder functions, providing you with ready-to-use modules such as arithmetic functions ■ quick and easy retrieval of your PLC’s variables by variable import. Easy template choice Satisfy your requirements by choosing the HMI which is most adapted to your needs in terms of dimensions, colours, functions and connection. Enhanced visual comfort Embellish your screens by using available or imported fonts and by importing animated Gif images. 17 Communication – Ethernet Ethernet Ethernet operates with a data rate of 10 MBit/s and as FastEthernet 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 (CarrierSense 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 Transmission media Star- or ring-shaped using Ethernet hub or switch. Twisted-pair cables with RJ45 connector. The maximum cable length is 100 m for 100 MB/s. Data transmission Max. 10 MB/s with 10 Base T and max. 100 MB/s Diagnostics with Fast-Ethernet. Detailed diagnostic messages for rapid troubleshooting are shown on the CPU display. In addition, the device status is indicated at the communication module by four LEDs. 18 Ethernet - Functionality at a glance Ethernet functionality AC500 CPU with integrated Ethernet interface AC500 with communication module CM577-ETH Protocols supported Modbus TCP/IP Ethernet TCP/IP yes (client/server), up to 8 client/server connections simultaneously. Supported functions: 1, 2, 3, 4, 5, 6, 7, 15, 16 for programming only, not for communication UDP/IP yes, using special function blocks and with ABB header BOOTP yes DHCP yes ARP yes ICMP yes Associated libraries for Modbus/TCP and UDP/IP communication Diagnosis Error indication Online diagnosis on LCD display of the CPU LED's on the communication modul using SYCON.net tool (part of programming software) Error code yes Physical layer Connection RJ45 10Base-T oder 100Base-TX Baud rate 10 / 100 Mbit/s Number of sockets Ethernet switch integrated Configuration Station address configuration up to 16 no yes using SYCON.net tool (part of programming software) yes using display and keypad of CPU yes, via rotary switch on the communicating coupler 19 Communication – 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-busneutral FBP devices (decentralized I/Os and intelligent switching devices) via the PROFIBUS-FBP connector. Communication basic functions in accordance with EN 50170. Each The masters rule data traffic on the bus. When in master has full write and read access to its assigned possession of the bus access authorization (token), slaves, but only read access to the slaves assigned to the masters can transmit data without an external other bus masters. There is no direct data exchange request. The passive devices, known as slaves, do between masters. Acyclical services (DP-V1) for not receive any bus access rights; they acknowledge parameterization and diagnostics between master and messages received, or respond to a query from a slave are also available. This is performed in parallel to master. Baud rates from 9.6 kBaud to 12 MBaud are the master’s cyclical user data traffic. supported. A maximum of 126 devices can be operated on the bus. Diagnostics Detailed diagnostic messages for rapid trouble- Data exchange shooting are shown on the CPU display. In addition, This is handled predominantly in cyclical mode be- the device status is indicated at the communica-tion tween master and slave. The requisite communication module by four LEDs. functions have been specified by the PROFIBUS DP 20 PROFIBUS DP - Functionality at a glance Profibus DP functionality Profibus master Multi master AC500 CPU with CM572-DP AC500 CPU with Profibus FieldBusPlug (FBP DPV1) S500 I/Os with bus interface DC505-FBP and Profibus FieldBusPlug (FBP DPV1) yes no no yes, bus access via token no no no yes yes Profibus DP V0 yes yes yes Profibus DP V1 with service MSAC1_read (read data) + MSCA1_write (write data) yes no yes via LEDs on the communication module via LCD display of the CPU and via LEDs on the FBP via LED on the interface module and the FBP Profibus slave Protocols supported Diagnosis Error indication Online diagnosis using SYCON.net tool (part of the programming software) Error code yes no no Associated function blocks yes no no Physical layer Connection no 9-polig D-Sub M12 FBP (standard) Baud rate up to 12 Mbit/s Distance up to 1200 m at 90 kbit/s Max. number of subscribers Configuration Using GSD file Station address configuration 126 subscribers max. (via amplifier) and max. 32 subscribers (master/slave devices) per bus segment using SYCON.net tool (part of programming software) yes, using the specific GSD file of the slave device no using SYCON.net tool (part of programming software), if another AC500 is the master yes, using the AC500 GSD file Yes using display and keypad of CPU (99 max.) yes, via rotary switches (99 max.) 21 Communication – 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 Data transfer By polling, i.e. the master transmits a request to the Max. 115.2 kB/s. Each telegram has a 16-bit CRC slave and then receives the response. Both interfaces appended. The telegrams permit process data (input/ COM1 and COM2 can operate simultaneously as output data) to be written and read, either individually Modbus interfaces. The Modbus operating mode of or in groups. The data are packed in the RTU format. an interface is set using the engineering tool. Transmission media Topology May vary. One widely used option is the RS485 bus Point-to-point via RS232 or multi-point via RS485. physics, a twisted-pair, shielded cable with termina- With RS232, a maximum of one master and one tors. slave is possible, while with RS485 one master and a maximum of 31 slaves can be operated. The maxi- Diagnostics mum cable length is 15 m with RS232 and 1.2 km Detailed diagnostic messages for rapid trouble-shoot- with RS485. ing are shown on the CPU display. 22 Modbus - Functionality at a glance Modbus functionality AC500 CPU with integrated Modbus interface Master or slave at COM1 yes Master or slave at COM2 yes Slave at FBP interface Protocols supported no Modbus RTU Diagnosis Error indication Online diagnosis on LCD display of the CPU yes Physical layer RS485 Connection 9-pole D-Sub (COM2) or plug (COM1) Baud rate up to 115.2 kbit/s Distance up to 1200 m (at slow baud rate) Configuration Station address configuration using configuration tool (part of programming software) using configuration tool (part of programming software) 23 Communication – CANopen and DeviceNet CANopen (Controller Area Network) and DeviceNet The CAN protocol was originally developed for the European automotive industry, so as to replace expensive cabling by an affordable network cable. 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). Data transmission Bus access for subscribers Two types of message have been defined: I/O data The connection ID with the lower address has higher transfer and direct link. I/O data transfer is used for priority on the bus. Data is transmitted by the source, time-critical process data, while the direct link can while the sinks (i.e. receivers of the data) have like- be, for example, used for diagnostic messages. wise been specified during the configuration phase. 24 CANopen DeviceNet The bus operates on the master/slave principle with The bus operates on the multi-master and/or the one master and up to 127 slaves. A shielded twisted- master/slave principle, with up to 64 bus subscribers. pair cable is used, according to ISO 11898. Cable Two types of shielded twisted-pair cables are used: lengths and transmission rates: from max. 40 m at trunk cable for the main line and drop cable for the 1 MBit/s to 1000 m at 20 kBit/s. branch line. Transmission rate 125 kBit/s 250 kBit/s 500 kBit/s Max. cable length of trunk line Trunk cable 500 m (1610 ft) 250 m (820 ft) 100 m (328 ft) Max. cable length of trunk line Drop cable 100 m (328 ft) 100 m (328 ft) 100 m (328 ft) Max. cable length per branch line Trunk cable/Drop cable 6m (20 ft) 6m (20 ft) 6m (20 ft) Max. cable length total branch line Trunk cable/Drop cable 156 m (512 ft) 78 m (256 ft) 39 m (128 ft) Diagnostics Detailed diagnostic messages for rapid troubleshooting are shown on the CPU display. In addition, the device status is indicated at the communication module by four LEDs. 25 Communication – CANopen and DeviceNet CANopen - Functionality at a glance CANopen functionality Master AC500 with communication module CM578-CN AC500 CPU with CANopen S500 I/Os with bus interface FieldBusPlug (FBP) DC505-FBP and CANopen FieldBusPlug (FBP) yes (client) no no no yes yes CAN 2.0A (11 bit identifier) yes yes yes CAN 2.0B (29 bit identifier) yes no no CiA DS401 integrated device profile yes no no CiA DS402 integrated device profile yes no no CiA DS406 integrated device profile yes no no Event triggered yes yes yes Synchronous yes yes yes Cyclic yes yes yes Remote PDO transmission yes yes yes Node guarding yes yes yes Heartbeat yes yes yes using LEDs on the communication module via LCD-Display of the CPU and the LEDs on the FBP via LEDs on the interface module and on the FBP Slave Protocols supported Data transfer Diagnosis Error indication Online diagnosis using SYCON.net tool (part of programming software) Error code yes no no Associated function blocks yes no no Physical layer ISO11898 Connection Baud rate yes yes yes 5-pole Combicon M12 M12 up to 1 Mbit/s up to 500 kbit/s up to 500 kbit/s Distance up to 1000 m at 20 kbit/s Configuration Configuration using EDS file Station address configuration 26 using SYCON.net tool (part of programming software) yes, using the specific EDS file of the slave device; non-modular EDS files only yes, EDS-file of the AC500 yes, EDS file to be configured according the existing HW (EDS Generator part of the programming software) no yes, via display and keypad of the CPU (max. 99) yes, via rotary switch on the interface module (max. 99) DeviceNet - Functionality at a glance DeviceNet Functionality AC500 with communication module CM575-DN AC500 CPU with DeviceNet FieldBusPlug (FBP) S500 I/Os with bus interface DC505-FBP and DeviceNet FieldBusPlug (FBP) Master yes no no Slave no yes 3 different fixed configurations: 16 bytes + 16 words I/O or 16 bytes I+O or 16 words I+O yes 1 fixed configuration for DC505 or EDS file configured according the existing HW (EDS Generator part of the programming software) DeviceNet (server) no yes yes DeviceNet (client) yes no no Polling yes yes yes State changes yes yes yes Cyclic yes yes yes Bit strobe yes no no Peer-to-Peer (acyclic) yes no yes using LEDs on the communication module via LCD display of the CPU and LEDs on the FBP via LEDs on the interface module and the FBP Protocols supported Data transfer Diagnosis Error indication Online diagnosis using SYCON.net tool (part of programming software) Error code yes no no Associated function blocks yes no no Physical layer ISO11898 Connection Baud rate yes yes yes 5-pole Combicon M12 M12 up to 500 kbit/s up to 500 kbit/s up to 500 kbit/s Distance Configuration Using EDS file Station address configuration up to 500m at 125 kbit/s using SYCON.net tool (part of programming software) yes, using the specific EDS file of the slave device; non-modular EDS files only yes, using AC500 EDS file yes, EDS file to be configured according the existing HW (EDS Generator part of the programming software) yes, using display and keypad of the CPU (99 max.) yes, via rotary switches on the communication module (max. 99) 27 Communication – 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 Bus assignments ARCNET is one of the few networks that can be ARCNET operates on the token-passing procedure, operated in every conceivable topology. Options where each subscriber has equal rights. include bus, star, or tree topologies, or mixtures of these. This means that ARCNET can be used for a Configuration mechanisms broad field of different applications. ARCNET allows to add and to remove subscribers from the network during runtime. When a new subscriber is added, the entire network will be reconfigured. ARCNET functionality ARCNET for programming ARCNET for communication Collision-free data transmission AC500 CPU with integrated ARCNET interface yes in preparation yes Guaranteed response times yes Real-time support through token passing yes Handshake protocol between sender and recipient yes Variable network topology: Bus, tree and star topologies incl. mixed topologies yes Variable use of media for networking: Coax cable, twisted-pair cable and optical fibre yes Automatic connect/disconnect of subscribers yes Diagnosis Error indication Online diagnosis on LCD display of the CPU yes Error code yes Physical layer Token-passing system Connection Coax cabel, type RG62/U 93Ω Baud rate Max. number of stations Maximum length of segments Hub/switch integrated Configuration Station address configuration 28 2.5 Mbit/s 255, with max. 8 stations per segment 300m no using configuration tool (part of programming software) using display and keypad of the CPU ARCNET Security mechanisms The permissible twisted-pair cables are specified in A 16-bit CRC is appended to every data packet, and IEEE 802.3i-1990. At 2.5 MBit/s and with coaxial checked by the recipient. If the token is lost, a recon- cables, for example, the maximum length of a bus figuration routine will be initiated, and the network will segment is 300 m with eight subscribers and without automatically be restructured. Additionally, diagnostic a hub. With twisted-pair cables, under the same registers are available. conditions, a maximum length of approximately 120 m can be achieved. The maximum transmis- Physical characteristics sion length depends on the number of connected ABB recommends coaxial cables as transmission subscribers. With coaxial cables, a maximum of medium, for direct connection to the CPU. But also 16 km can be achieved; with twisted-pair cables twisted-pair cables or (glass, plastic) fiber-optic cables approximately 6 km, in each case at 2.5 MBit/s. The can be connected via bus converters. The line lengths fiber-optic link provides the highest degree of inter- that can be achieved without any intermediate ampli- ference immunity. With glass fiber-optics, distances fiers depend not only on the used medium, but also of up to 3 km are possible at 2.5 MBit/s; with plastic on the selected baud rate and the number of subscri- fiber-optic cables only small distances of up to approx- bers. The ranges per segment vary from approximate- imately 100 m. The baud rate plays no significant role ly 120 m for a simple two-wire bus, up to 3 km for in fiber-optic cable transmission. Here, the range can fiber-optics, in each case at 2.5 MBit/s. By providing as well be extended using hubs. appropriate hubs, different topologies and transmission media can be combined with each other and the Diagnostics transmission distance can be increased. The coaxial Detailed diagnostic messages for rapid trouble- cables used are a type with 93 Ohm, e.g. RG 62. shooting are shown on the CPU display. 29 Communication – CS31 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 Data transmission Is handled using polling, i.e. the master sends a Is performed at 187.5 kB/s. Each telegram has an 8-bit request to the slave and then receives the response. CRC appended. The telegrams enable process data The CS31 operating mode of COM1 is set using the (input/output data) to be written and read. engineering tool. Transmission medium Topology Primarily a twisted-pair, shielded cable with termina- Multi-point line, RS485, approved without branch tors. Other transmission media: fiber-optic cables via lines. A system consists of one master and up to 31 a converter (glass fibers max. 3 km, plastic max. slaves. The maximum cable length is 500 m, or 2 km 100 m), contact lines, slip rings (bus length max. with an amplifier. Slaves are primarily decentralized 50 m) and data photocells. input/output modules with integrated CS31 bus connection. Diagnostics Detailed diagnostic messages for rapid troubleshooting are shown on the CPU display. 30 CS31 CS31 functionality Master Slave AC500 CPU with integrated CS31 interface S500-FBP I/O with bus interface DC551-CS31 yes, at COM1 no no Protocols supported yes ABB CS31 protocol Diagnosis Error indication on LCD display of the CPU Online diagnosis Error code erros are recorded in the diagnosis system of the CPU Associated function blocks yes Physical layer Connection via module LEDs yes RS485 plug at COM1 screw-type or spring-type terminals Baud rate 187.5 kbit/s Distance up to 500 m; up to 2000 m using a repeater Max. number of modules on fieldbus Configuration Station address configuration 31 modules max. Please note: The DC551 bus interface occupies one or two module addresses (if counters are configured onboard). Depending on the configuration, connected extension modules can occupy further module addresses. using configuration tool (part of programming software) no using rotary switches (99 max.) 31 Scalable automation system AC500 Details/Type: Supply voltage PM571 PM571-ETH 24 V DC PM581 PM581-ETH PM581-ARC 24 V DC Program memory Flash EPROM and RAM [kB] 64 256 Integrated data memory [kB] 21, incl. 4 KB RETAIN 288, incl. 32 KB RETAIN Plug-in memory card [SD card] 128 MB 128 MB Cycle time for 1000 instructions in ms binary word floating-point 0.3 0.3 6 0.15 0.15 3 Max. number of centralized inputs/outputs Digital inputs Digital outputs Analog inputs Analog outputs 320 240 160 160 320 240 160 160 Max. number of decentralized inputs/outputs Data buffering depends on the used standard fieldbus CS31 field bus only: up to 31 stations with up to 120 DIs / 120 DOs per station battery battery Real-time clock (with battery back-up) x x Program execution cyclical time-controlled multi tasking x x x x x x User program protection by password x x x terminal block x x terminal block x x SUB-D x x SUB-D x Internal interfaces COM1: RS232/RS485 configurable Connection Programming, Modbus, ASCII, CS31 COM2: RS232/RS485 configurable Connection Programming, Modbus, ASCII Integrated Ethernet coupler Ethernet connection x RJ45 x RJ45 Integrated ARCNET coupler ARCNET connection Display and 8 function keys x Coax x RUN/STOP status, diagnosis x RUN/STOP status, diagnosis Timers unlimited unlimited Counters unlimited unlimited x x x x x x x x x x x x Function Function Block Diagram (FBD) Instruction List (IL) Ladder Diagram (LD) Structured Text (ST) Sequential Function Chart (SFC) Continuous Function Chart (CFC) 32 Details/Type: Supply voltage PM582 PM582-ETH PM582-ARC 24 V DC PM590 PM590-ETH PM590-ARC 24 V DC PM591 PM591-ETH PM591-ARC 24 V DC Program memory Flash EPROM and RAM [kB 512 2056 4096 Integrated data memory [kB] 288, incl. 32 KB RETAIN 3072, incl. 512 KB RETAIN 3072, incl. 512 KB RETAIN Plug-in memory card [SD card] 128 MB 128 MB 128 MB Cycle time for 1000 instructions in ms binary word floating-point 0.15 0.15 3 0.02 0.01 0.02 0.02 0.01 0.02 Max. number of centralized inputs/outputs Digital inputs Digital outputs Analog inputs Analog outputs 320 240 160 160 320 240 160 160 320 240 160 160 Max. number of decentralized inputs/outputs Data buffering depends on the used standard fieldbus CS31 field bus only: up to 31 stations with up to 120 DIs / 120 DOs per station battery battery battery Real-time clock x x x Program execution cyclical time-controlled multi tasking x x x x x x x x x User program protection by password x x x x terminal block x x terminal block x x terminal block x x SUB-D x x SUB-D x x SUB-D x x RJ45 x RJ45 x RJ45 Internal interfaces COM1: RS232/RS485 configurable Connection Programming, Modbus, ASCII, CS31 COM2: RS232/RS485 configurable Connection Programming, Modbus, ASCII Integrated Ethernet coupler Ethernet connection Integrated ARCNET coupler ARCNET connection Display and 8 function keys Function x Coax x RUN/STOP status, diagnosis x Coax x RUN/STOP status, diagnosis x Coax x RUN/STOP status, diagnosis Timers unlimited unlimited unlimited Counters unlimited unlimited unlimited x x x x x x x x x x x x x x x x x x Function Block Diagram (FBS) Instruction List (IL) Ladder Diagram (LD)) Structured Text (ST) Sequential Function Chart (SFC) Continuous Function Chart (CFC) 33 Scalable automation system AC500 Digital I/O modules Number of channels per module Digital inputs DI Digital outputs DO Configurable channels DC (configurable as inputs or outputs) Additional configuration of channels as DC522 DC523 DC532 DX522 DX531 DC541 DC505-FBP 32 – – – – – 16 – 8 8 8 4 – – 8 – 8 – – 16 24 16 – – 8 8 16 Configuration of max. 2 channels per module. Operating modes see table on page 33. fast counter pulse-width modulator rpm, time and frequency counter interrupt I/O Occupies max. 1 DO or DC when used as counter Connection via terminal block TB5xx Connection via CPU terminal base. Occupies one communication module slot. Digital inputs – – – – – x – – – x x – – – x x – – – x x – – – – x – – – – x – – – – – – Input signal voltage 24 V DC Frequency range Input characteristic acc. to EN61132-2 – Type 1 0 signal 230 V AC or 120 V AC 47 … 63 Hz Type 2 > + 5 V DC ... < + 15 V DC 1 signal + 15 V DC ... + 30 V DC Residual ripple, range for 0 signal – 3 V DC ... + 5 V DC Residual ripple, range for 1 signal + 15 V DC ... + 30 V DC Input time delay (0 -> 1 or 1 -> 0) – – – – – – x Configuration of max. 2 channels p. module. Operating modes see table on page 33. – – – x x x – – 24 V DC 24 V DC 24 V DC – Type 1 – Type 1 Yes. See table on page 34 for possible configurations – Type 1 – 3 V DC ... + 0 ... 40 V AC 5 V DC > 40 V AC ... > + 5 V DC ... < 74 V AC < + 15 V DC > + 5 V DC ... 74 ... 265 V AC < + 15 V DC – 3 V DC ... – + 5 V DC + 15 V DC ... + – 30 V DC 8 ms typically, 20 ms configurable typically from 0.1 up to 32 ms – 3 V DC ... + 5 V DC Undefined signal state Input current per channel at input voltage + 24 V DC at input voltage + 5 V DC at input voltage + 15 V DC at input voltage + 30 V DC at input voltage 159 V AC at input voltage 40 V AC Digital outputs Transistor outputs 24 V DC, 0.5 A Readback of output Relay outputs, supplied via process voltage UP, changeover contacts Switching of 24 V load Switching of 230 V load Interface modules DC551CS31 DI524 8 ms typically, configurable from 0.1 up to 32 ms 5 mA typ. > 1 mA > 5 mA < 8 mA – – – – – – – 3 V DC ... + 5 V DC > + 5 V DC ... < + 15 V DC + 15 V DC ... + 30 V DC – 3 V DC ... + 5 V DC + 15 V DC ... + 30 V DC 8 ms typically, configurable from 0.1 up to 32 ms > 7 mA < 5 mA 5 mA typ. > 1 mA > 5 mA < 8 mA – – 5 mA typ. > 1 mA > 5 mA < 8 mA – – – – – – x x x x x x – – – – x x x x x x – – – – x x – x – – – x – x – x – x x x x x – x – Process voltage UP minus 0.8 V – – x – Process voltage UP minus 0.8 V Output voltage at signal state 1 Process voltage UP minus 0.8 V Output current Nominal current per channel – 500 mA at UP = 24 V Maximum (total current of all channels) Residual current at signal state 0 Demagnetization when switching off inductive loads – – 8A < 0.5 mA – by internal varistors 34 500 mA at UP = 24 V 8A < 0.5 mA by internal varistors 500 mA at UP = 24 V 4A 8A < 0.5 mA by internal varistors DI524 DC522 Digital I/O modules DC523 DC532 DX522 Switching frequency for inductive load – 0.5 Hz max. for lamp load – 11 Hz max. at max. 5 W Short-circuit / overload proofness – Overload indication (I > 0.7 A) Output current limiting Proofness against reverse feeding of 24 V signals – – x x DX531 2 Hz max. 11 Hz max. at max. 5 W by external fuse / circuit breaker. 6 A gL/gG per channel – – – – xx Hz max. x after approx. 100 ms 0.7 A typ. DC541 Interface modules DC505-FBP DC551-CS31 0.5 Hz max. 11 Hz max. at max. 5 W 0.5 Hz max. 11 Hz max. at max. 5 W x – 0.7 A typ. x x after approx. 100 ms Automatic reclosure – x x x – – x x x for resistive load, max. – – – – 3 A at 230 V AC 2 A at 24 V DC – for inductive load, max. – – – – 1.5 A at 230 V AC 1.5 A at 24 V DC – – – for lamp load – – – – 60 W at 230 V AC 10 W at 24 V DC – – – Lifetime (switching cycles) Mechanical lifetime – – – – – – – Lifetime under load – – – – – – – Spark suppression for inductive AC load – – – – – – – Demagnetization for inductive DC load – – – – – – – Contact rating Process voltage UP Nominal voltage 24 V DC 24 V DC Maximum ripple 5% 5% Reverse polarity protection x x Fuse for process voltage UP Connections for sensor voltage supply. Terminal + 24 V and 0 V for each connection. – 8 Permitted load for each group of 4 or 8 connections: 0.5 A Short-circuit and overload proof – x 24 VDC sensor supply voltage Maximum cable length for connected process signals Shielded cable [m] 1000 1000 Unshielded cable [m] 600 600 Potential isolation per module x x between the input channels – – between the output channels – – Voltage supply for the module 24 V DC 24 V DC 5% 5% x x 10 A miniature fuse 24 V DC 5% x 24 V DC 24 V DC 5% 5% x x 10 A miniature fuse – – – – – – x – – – – – – 1000 600 1000 600 1000 600 1000 600 1000 600 1000 600 1000 600 x – – x – – x – x x – x x – – internally via backplane bus via AC500 CPU x – – x – – by external 24 V DC voltage via terminal CS31 field bus, via terminal by code switch on the front side via AC500 CPU or interface module Address setting 24 V DC 5% x 4 internally via extension bus interface (I/O bus) Field bus connection Operating state indicators Yellow LED for I/O state Green LED for voltage supply Red LED for module and group errors Mounting position Cooling 24 V DC 5% x 300.000 300 000 at 24 V DC/ 2 A 200 000 at 120 V AC/ 2 A 100 000 at 230 V AC/ 3 A External measure depending on the switched load External measure: Free-wheeling diode connected in parallel to the load – via software via software via FBP via FBP via FBP 32 1 4 16 24 32 16 12 8 16 24 1 1 1 1 1 1 1 1 4 4 4 2 2 1 2 1 1. Horizontal mounting. 2. Vertical mounting possible with restrictions (max. output load per group: 50 % at 40 °C). Cooling by natural convection must not be obstructed by cable ducts or other interior components of the switchgear cabinet. 35 Scalable automation system AC500 Analog I/O modules AX522 AI523 AX521 Number of channels per module Analog inputs AI, individual configuration Analog outputs AO, individual configuration Signal resolution for channel configuration – 10 V ... + 10 V: 12 bits + sign 0 ... 10 V: 12 bits 0 ... 20 mA, 4 ... 20 mA: 12 bits Temperature: 0.1 °C Monitoring configuration per channel Plausibility monitoring Wire break & short-circuit monitoring Analog Inputs AI Signal configuration per AI 0 ... 10 V – 10 V ... + 10 V 0 ... 20 mA 4 ... 20 mA Pt100, – 50 °C ... + 400 °C (2-wire) Pt100, – 50 °C ... + 400 °C (3-wire), occupies 2 AIs Pt100, – 50 °C ... + 70 °C (2-wire) Pt100, – 50 °C ... + 70 °C (3-wire), occupies 2 AIs Pt1000, – 50 °C .. .+ 400 °C (2-wire) Pt1000, – 50 °C ... + 400 °C (3-wire), occupies 2 AIs Ni1000, – 50 °C ... + 150 °C (2-wire) Ni1000, – 50 °C ... + 150 °C (3-wire), occupies 2 AIs 0 ... 10 V using differential inputs, occupies 2 AIs – 10 V ... + 10 V using differential inputs, occupies 2 AIs Digital signals (digital input) Input resistance per channel Time constant of the input filter Conversion cycle Overvoltage protection Data when using the AI as digital input Input time delay Input signal voltage 0 signal 1 signal Analog outputs AO Possible configuration per AO – 10 V ... + 10 V 0 ... 20 mA 4 ... 20 mA Output resistance (burden) when used as current output Output loading capability when used as voltage output 36 AO523 4 4 8 8 16 – 16 x x x x x x x x x x x x x x x x x x x x x x x x Max. number per module and with regard to the configuration: AIs / Measuring points (depending on the use of 2/3-wire connection or differential input) 4/4 8/8 16 / 16 – 4/4 8/8 16 / 16 – 4/4 8/8 16 / 16 – 4/4 8/8 16 / 16 – 4/4 8/8 16 / 16 – 4/2 8/4 16 / 8 – 4/4 8/8 16 / 16 – 4/2 8/4 16 / 8 – 4/4 8/8 16 / 16 – 4/2 8/4 16 / 8 – 4/4 8/8 16 / 16 – 4/2 8/4 16 / 8 – 4/2 8/4 16 / 8 – 4/2 8/4 16 / 8 – 8/8 16 / 16 Voltage: > 100 kΩ, Current: approx. 330 Ω Voltage: 100 µs, Current: 100 µs 2 ms (for 8 AI + 8 AO), 1 s for Pt/Ni... x x – – – – – 4/4 x 8 ms typ., configurable from 0.1 up to 32 ms 24 V DC – 30 V ... + 5 V + 13 V ... + 30 V 4 4 4 – – – – Max. number of AOs per module and with regard to the configuration: 8 – 16 4 – 8 4 – 8 0 ... 500 Ω – 0 ... 500 Ω max. ± 10 mA – max. ± 10 mA Process voltage UP Nominal voltage Maximum ripple Reverse polarity protection Max. line length of the analog lines, conductor cross section > 0.14 mm² Conversion error of analog values caused by non-linearity, calibration errors ex works and the resolution in the nominal range Potential isolation per module between the input channels between the output channels Voltage supply for the module Operating state indicators Yellow LED for I/O state Green LED for voltage supply Red LED for module and group errors Mounting position Cooling AX521 Analog I/O modules AX522 AI523 AO523 24 V DC 5% x 24 V DC 5% x 24 V DC 5% x 24 V DC 5% x 100 m 0.5 % typ., 1 % max. x – – x x – – – – internally via extension bus interface (I/O bus) x – – 8 1 2 16 16 16 1 1 1 2 2 2 1. Horizontal mounting. 2. Vertical mounting possible with restrictions (max. output load per group: 50 % at + 40 °C). Cooling by natural convection must not be obstructed by cable ducts or other interior components of the switchgear cabinet. Table: Digital I/O modules, „fast counter“ operating modes. Not applicable for DC541 Operating mode, configured in the user program of the AC500 0 1 2 3 4 5 6 7 8 9 10 No counter One count-up counter with „end value reached“ indication One count-up counter with „enable“ input and „end value reached“ indication Occupied inputs DI or DC 0 1 Occupied outputs DO or DC 0 1 Maximum counting frequency – 50 kHz Notes – Note for input module DI524: It is not possible to set an output directly. As an alternative, the status byte should be evaluated and applied to another output in the system. 2 1 50 kHz Two up/down counters Two up/down counters with 1 counting input inverted One up/down counter with „dynamic set“ input One up/down counter with „dynamic set“ input One up/down counter with directional discriminator. For synchro transmitters using two counting pulses with an offset of 90° (track A and B). 2 2 0 0 50 kHz 50 kHz 2 0 50 kHz 2 0 50 kHz 2 0 50 kHz – One up/down counter with directional discriminator and double evaluation. For synchro transmitters using two counting pulses with an offset of 90° towards each other (track A and B). 0 2 0 0 – 30 kHz Acts to the rising signal edge (0->1). „End value“ interrogation via status byte. Acts to the falling signal edge (1->0). „End value“ interrogation via status byte. For synchro transmitters with 24 V signals. Incase of 5 V synchro transmitters, the signal has to be increased to 24 V. The zero track of the synchro transmitter is not processed. Interrogation of the „end value“ indication via the status byte. Single evaluation. – See operating mode 7. One up/down counter with directional discriminator and fourfold evaluation. For synchro transmitters using two counting pulses with an offset of 90° towards each other (track A and B). 2 15 kHz Difference: Double evaluation, i.e. evaluation of the rising edge and the falling edge of track A -> higher accuracy due to the double number of counting pulses. See operating mode 7. 0 „End value“ interrogation via status byte. Difference: Fourfold evaluation, i.e. evaluation ofthe rising edge and the falling edge of track A and track B -> higher accuracy due to the fourfold number of counting pulses. 37 Scalable automation system AC500 Table: Possible configurations for the multifunctional module DC541 Max. no. of chanRemarks and notes regarding possible alternative nels combinations of the remaining channels (a and b) for this function Mode 1: Interrupt functionality, mutually exclusive with mode 2 (counting functionality) Each channel can be configured individually as interrupt 1 1 1 1 4 8 Digital input Interrupt input or interrupt output. 1 1 1 1 4 8 Digital output Mode 2: Counting functionality and multifunctional I/Os, mutually exclusive with mode 1 (interrupt functionality) Usual input. 1 1 1 1 4 8 Digital input Usual output. 1 1 1 1 4 8 Digital output PWM, resolutiOutputs a pulsed signal with an adjustable on-off ratio. 1 1 1 1 4 8 on10 kHz *1) a) Both channels (0 and 1) configured as 50 kHz counters => channels 2 to 7 can be configured as digital I/Os. Up/down OK OK OK b) Only one channel (0 or 1) configured as 50 kHz counter counter, 50 kHz 1 1 2 *1) *1) *1) => the second channel can be configured as counter < 50 kHz or for time/frequency measurement with a max. resolution of 200 µs. The remaining channels (2 to 7) can be configured as digital I/Os. *2) a) Four channels (0 to 3) configured as 5 kHz counters => channels 4 to 7 can be configured as digital I/Os. Up/down b) Not all of the four channels 0 to 3 configured as 5 kHz OK counter, 5 kHz 1 1 1 1 4 counter => the remaining channels (of chan. 0 to 3) can be *2) configured as counters for 2.5 kHz or for time/frequency measurement with a max. resolution of 200 µs as desired. The remaining channels (4 to 7) can be configured as digital I/Os. Up/down counter, 1 1 1 1 4 8 2.5 kHz Time/frequency *3) measurement, OK OK OK OK Channel 0 configured for a max. resolution of 50 µs 1 1 resolution *3) *3) *3) *3) => channels (1 to 7) can be configured as digital I/Os. 1 µs *4) a) Both channels (0 and 1) configured for a max. resolution Time/frequency of 50 µs => chan. 2 to 7 can be configured as digital I/Os. measurement, OK OK OK b) Only one channel (0 or 1) configured for a max. resolution resolution 1 1 2 *4) *4) *4) of 50 µs => the second channel can be configured as 100 µs counter < 50 kHz or for time/frequency measurement with a max. resolution of 200 µs. The remaining channels (2 to 7) can be configured as digital I/Os. Time/frequency measurement, Times, frequencies and rotational speeds are measured 1 1 1 1 4 8 resolution with a maximum resolution of 200 µs. 200 µs For connection of an incremental transmitter. For signals up to 50 kHz (corresponds to a motor with a rotational Bidirectional Channels 0 to 3: speed of 3000 rpm). The counter always occupies the first OK 32 bit counter, track A, track B, zero track, 1 4 channels (0 to 3). *6) 50 kHz max. touch trigger *6) The remaining channels (4 to 7) can be configured as limit values, as 5 kHz counters, for time/frequency measurement with a resolution of 200 µs or as digital I/Os. „Endless“ forward counting. An overflow occurs corresponding to the 32 bit value. Shaft (endless OK 1 1 *7) The remaining channels can be configured as counting) *7) limit values, as 5 kHz counters, for time/frequency measurement with a resolution of 200 µs or as digital I/Os. *8) The remaining channels can be configured as 32 bit counter OK 1 1 limit values, as 5 kHz counters, for time/frequency incl. sign *8) measurement with a resolution of 200 µs or as digital I/Os. Various counting values of the 32 bit counter can be Limit values for OK 1 1 displayed directly via these outputs. 32 bit counter *9) *9) In this case, the channels 0 to 3 are used as 32 bit counters. Fast counter Multifunctional I/Os, digital I/Os, PWM, counter, time and frequency measurement Configuration as 38 Function/ Configuration Chan. for channel no. 0 Chan. 1 Chan. 2 Chan. 3 Chan. 4-7 Operating and environmental conditions / System data Voltages according to EN 61131-2 24 V DC Process and supply voltage Absolute limits Residual ripple Polarity reversal protection 24 V DC (–15%, +20% without residual ripple) 19.2 V ... 30 V incl. residual ripple < 5% 10 s 120 V AC Supply voltage Frequency 120 V AC (–15%, +10%) 47 Hz ... 62.4 Hz/50 ... 60 Hz (–6%, +4%) 230 V AC Supply voltage Frequency 230 V AC (–15 %, +10%) 47 Hz ... 62.4 Hz/50 ... 60 Hz (–6%, +4%) 120–240 V AC Wide voltage input Voltage Frequency 102 V ... 264 V/120 V ... 240 V (–15%, +10%) 47 Hz ... 62.4 Hz/50 ... 60 Hz (– 6%, +4%) Power failure bridging time according to EN 61131-2 DC supply AC supply Failure < 10 ms, time between 2 failures > 1 s, PS2 Failure < 0.5 periods, time between 2 failures > 1 s Temperature Operation Storage Transport 0 °C ... +60 °C for horizontal mounting -25 °C ... +75 °C -25 °C ... +75 °C Operation Storage > 800 hPa / < 2000 m > 660 hPa / < 3500 m Humidity Air pressure 95% max., no condensation Creepage distances and clearances The creepage distances and clearances correspond to Overvoltage Category II, Pollution Severity 2 Electromagnetic compatibility Interference immunity against electrostatic discharge (ESD) interference voltage with air discharge interference voltage with contact discharge acc. to EN 61000-4-2, Zone B, Criteria B 8 kV 6 kV Interference immunity against radiated interferences (CW radiated) Test field strength acc. to EN 61000-4-3, Zone B, Criteria A 10 V/m Interference immunity against transient interference voltages (burst) acc. to EN 61000-4-4, Zone B, Criteria B Interference immunity against conduction-bound interferences (CW conducted) Test voltage acc. to EN 61000-4-6, Zone B, Criteria A 3V Zone B Impulse voltage acc. to EN 61000-4-5, Zone B, Criteria B Emitted interferences acc. to EN 55011, Group 1, Class A Mechanical data Connection type / terminals Mounting Degree of protection Housing Vibration resistance Vibration resistance with SD card plugged in Shock resistance Device mounting DIN top-hat rail acc. to DIN EN 50022 Screw mounting Torque horizontal IP 20 acc. to UL 94 all three axes 2 Hz ... 15 Hz, continuously 3.5 mm 15 Hz ... 150 Hz, continuously 1 g (4 g in preparation) 15 Hz ... 150 Hz, continuously 1 g all three axes 15 g, 11 ms, semi-sinusoidal 35 mm, overall height 7,5 mm or 15 mm Screws with 4 mm diameter 1.2 Nm 39 Operating and displaying Operator panels CP500 – Overview CP501 CP502 CP503 CP511 CP512 1SBP 260170 R1001 1SBP 260171 R1001 1SBP 260172 R1001 1SBP 260173 R1001 1SBP 260174 R1001 STN-LCD with backlight STN-LCD with backlight STN-LCD with backlight STN-LCD with backlight S/W-STN-LCD with backlight Text Text Text graphics and text graphics and text Display size 2 lines x 16 characters 2 lines x 20 characters 4 lines x 20 characters 240 x 64 pixels 240 x 128 pixels Display area W x H (mm) 55.7 x 11.0 73.5 x 11.5 70.4 x 20.8 5.2" 127.2 x 33.9 5.3" 120.0 x 64.0 5 5 5 variable variable 5 (2 colors) 16 (2 colors) 16 (2 colors) 4 3 / 20 5 / 22 (with labels) 8 (with labels) 16 (8 with labeling strip) Web functions ● ● Buzzer ● ● Ident. Nr. Display type Display Text height (mm) LEDs Function keys/ other keys 1 group 4 groups 4 groups Time channel Alarm management ● ● ● ● Real-time clock ● ● Trend curves ● ● real-time historical Data logger Recipe management ● ● ● ● Report printing ● ● ● ● 8 levels 8 levels 8 levels 8 levels ● ● ● ● Password protection Multilanguage support Application memory 16 kB Flash 64 kB Flash 64 kB Flash 400 kB Flash 400 kB Flash Voltage supply 5 / 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 150 mA 450 mA 450 mA Current consumption Ambient temperature 0 – 50 °C 0 – 50 °C 0 – 50 °C 0 – 50 °C 0 – 50 °C Communication interfaces RS232 oder RS422 RS232, RS422 RS485 RS232, RS422 RS232, RS422 Ethernet RS232, RS422 Expansion slot – – – 1 1 IP65 IP65 IP65 IP65 IP65 104 x 69 x 38 142 x 100 x 29 147 x 163,5 x 38 211 x 198 x 69 214 x 232 x 87 0.2 0.5 0.7 1.5 1.4 Degree of protection front cover Dimensions W x H x D (mm) Weight (kg) 40 CP551 CP552 CP554 1SBP 260176 R1001 1SBP 260177 R1001 1SBP 260178 R1001 Touch-S/W-STN with backlight Touch-LCD 16 gray levels 256 Colors TFT touch display graphics and text graphics and text graphics and text 320 x 240 pixels 320 x 240 pixels 320 x 240 pixels 3.8" 78.0 x 58.5 5.7" 115.2 x 86.4 5.7" 115.2 x 86.4 variable variable variable ● ● ● ● ● ● 4 groups 5 groups 5 groups ● ● ● ● ● ● historical historical historical ● ● ● ● ● ● ● ● ● 8 levels 8 levels 8 levels ● ● ● 400 kB Flash 400 kB Flash 400 kB Flash 24 V DC 24 V DC 24 V DC 450 mA 400 mA 450 mA 0 – 50 °C 0 – 50 °C 0 – 50 °C Ethernet RS232, RS422 RS485 RS232, RS422/RS485 RS232, RS422/RS485 - 1 1 IP65 IP65 IP65 138 x 100 x 30 200 x 150 x 69 200 x 150 x 69 1.4 1.5 1.5 41 Operating and displaying Operator panels CP400 – Overview ■ 32-Bit-RISC-Prozessor ■ 4 MB Flash Memory ■ Graphic and Text ■ 24 V DC ± 15% supply voltage ■ Macro and Ladder ■ Ambient temperature: 0 bis 50 °C ■ Online- and Offline-Simulation ■ Protection class IP65 ■ Real Time Clock ■ Conform to RoHs ■ Password protection Reference Screen type Screen size Display resolution (pixels) Helligkeit (cd/m2) Contrast adjustment Backlight type Backlight life time (h) Touch screen life time (number of touch operations) Function keys CP410M CP420B CP430B CP430-ETH 1SBP 260 181 R1001 1SBP 260 182 R1001 1SBP 260 183 R1001 1SBP 260 184 R1001 LCD 16 gray Touch 16 blue, STN Touch 16 blue, STN Touch 16 blue, STN 3'' 4.7'' 5.7'' 5.7''l 160 x 80 320 x 240 320 x 240 320 x 240 36 110 110 110 via rotary switch via touch panal via touch panel and via rotary switch on the back via touch panel and via rotary switch on the back LED CCFT CCFT CCFT 75.000 50.000 50.000 50.000 > 500.000 > 1.000.000 > 1.000.000 > 1.000.000 16 (10 can be used as function keys) - 5 function keys + 1 menu key 5 function keys + 1 menu key Ethernt - - - ● Alarm management - ● ● ● Recipe management - - - ● Memory - - - 512 KB Trend curves - ● ● ● Data storage (CF card – Compact Flash) - - - - Communication interface 1 2 2 2 - - - - USB 2.0 Printer port Voltage supply Housing dimensions (W x H x D) in mm Weight (kg) 42 - - - ● < 330 mA < 500 mA < 840 mA < 840 mA 173 x 106 x 52 170 x 103 x 45 195 x 145 x 60 195 x 145 x 60 0,65 0,47 0,81 0,81 CP430C CP430B-ETH CP440C-ETH CP450T CP450T-ETH 1SBP 260 185 R1001 1SBP 260 186 R1001 1SBP 260 187 R1001 1SBP 260 188 R1001 1SBP 260 189 R1001 Touch 256 colors, STN Touch 256 colors, STN Touch 64.000 colors, STN Touch 64.000 colors, TFT Touch 64.000 colors, TFT 5.7'' 5.7'' 7.5'' 10.4'' 10.4'' 320 x 240 320 x 240 640 x 480 640 x 480 640 x 480 300 300 350 350 350 via touch panel and via rotary switch on the back via touch panel and via rotary switch on the back via touch panal - - CCFT CCFT CCFT CCFT CCFT 75.000 75.000 45.000 50.000 50.000 > 1.000.000 > 1.000.000 > 1.000.000 > 1.000.000 > 1.000.000 5 function keys + 1 menu key 5 function keys + 1 menu key 6 function keys + 1 menu key 7 function keys + 1 menu key 7 function keys + 1 menu key - ● ● - ● ● ● ● ● ● ● ● ● ● ● 512 KB 512 KB 512 KB 512 KB 512 KB ● ● ● ● ● - - ● ● ● 2 2 3 3 3 - 2 Master + 1 peripheral device 2 Master + 1 peripheral device 2 Master + 1 peripheral device ● ● USB USB USB < 840 mA < 840 mA <1A < 1,25 A < 1,25 A 195 x 145 x 60 195 x 145 x 60 231 x 176 x 47 297 x 222 x 52 297 x 222 x 52 0,81 0,81 1,20 1,90 1,90 43 Ordering data AC500 The AC500 CPU´s ■ 2 serial interfaces integrated, RS232/RS485 configurable ■ Display and 8 function keys for diagnosis and status ■ Centrally expandable with up to 7 expansion modules locally ■ Up to 4 external communication modules simultaneously and in any desired combination ■ Optional: SD card for data storage and program backup ■ Can also be used as slave on Profibus DP, CANopen and DeviceNet via FieldBusPlug ■ Available with communication processors for Ethernet and ARCNET (PM5xx-ARC; PMxx-ETH) AC500 CPUs, type PM571 Type Program memory Cycle time in ms 1000 instructions Bit/Word/Float. point Integrated coupler Order code Weight per piece/kg PM571 PM571-ETH 64 KB 64 KB 0.3 / 0.3 / 6 0.3 / 0.3 / 6 Ethernet 1SAP 130 100 R0100 1SAP 130 100 R0170 0.135 0.15 AC500 CPUs, type PM581 and PM582 Type Program memory Cycle time in ms 1000 instructions Bit/Word/Float. point Integrated coupler Order code Weight per piece/kg PM581 PM581-ETH PM581-ARCNET PM582 PM582-ETH PM582-ARCNET 256 KB 256 KB 256 KB 512 KB 512 KB 512 KB 0.15 / 0.15 / 3 0.15 / 0.15 / 3 0.15 / 0.15 / 3 0.15 / 0.15 / 3 0.15 / 0.15 / 3 0.15 / 0.15 / 3 Ethernet ARCNET – Ethernet ARCNET 1SAP 140 100 R0100 1SAP 140 100 R0170 1SAP 140 100 R0160 1SAP 140 200 R0100 1SAP 140 200 R0170 1SAP 140 200 R0160 0.135 0.15 0.16 0.135 0.15 0.15 AC500 CPUs, type PM590 and PM591 Type Program memory Cycle time in ms 1000 instructions Bit/Word/Float. point Integrated coupler Order code Weight per piece/kg PM590 PM590-ETH PM590-ARCNET PM591 PM591-ETH PM591-ARCNET 2048 KB 2048 KB 2048 KB 4096 KB 4096 KB 4096 KB 0.02/ 0.01/ 0.02 0.02/ 0.01/ 0.02 0.02/ 0.01/ 0.02 0.02/ 0.01/ 0.02 0.02/ 0.01/ 0.02 0.02/ 0.01/ 0.02 Ethernet ARCNET Ethernet ARCNET 1SAP 150 000 R0100 1SAP 150 000 R0170 1SAP 150 000 R0160 1SAP 150 100 R0100 1SAP 150 100 R0170 1SAT 150 100 R0160 0.135 0.15 0.16 0.135 0.15 0.16 Ethernet communication module 10/100 Mbit/s, full/half duplex with auto-sensing. 2-port switch integrated. Transport protocols TCP/IP, UDP/IP, Modbus TCP. CPU interface: 8 kB dual-port memory. Contains a separate communication processor, 256 kB RAM memory and 512 kB fl ash memory. No external power supply required. Type Interfaces Order code Weight per piece/kg CM577-ETH 2 x RJ45 1SAP 170 700 R0001 0.115 44 Profibus DP communication module For Profi bus DP master V0/V1. Multi master funcitonality. Transfer rate: 9.6 kbit/s up to 12 Mbit/s. Max. no. of subscribers: 126 (V0) or 32 (V1). CPU interface: 8 kB dual-port memory. Contains a separate communication processor and 256 kB RAM memory. No external power supply required. Type Interface Order code Weight per piece/kg CM572-DP Sub-D socket 1SAP 170 200 R0001 0.115 DeviceNet communication module For DeviceNet master. Transfer rate: 125 kbit/s, 250 kbit/s, 500 kbit/s. CPU interface: 8 kB dual-port memory. Contains a separate communication processor, 256 kB RAM memory and 512 kB fl ash memory. No external power supply required. Type Interface Order code Weight per piece/kg CM575-DN Plug-in terminal block, spring-type terminals 1SAP 170 500 R0001 0.115 CANopen communication module For CANopen master. Transfer rate: 10 kbit/s up to 1 Mbit/s. CPU interface: 8 kB dual-port memory. Contains a separate communication processor, 256 kB RAM memory and 512 kB fl ash memory. No external power supply required. Type Interface Order code Weight per piece/kg CM578-CN Plug-in terminal block, spring-type terminals 1SAP 170 800 R0001 0.115 Weight per piece/kg Terminal base For mounting and connection of the CPUs and communication modules 1 to 4 plug-in communication modules Connection for communication coupler integrated in the CPU I/O interface for direct connection of up to 7 expansion modules Fieldbus-neutral FieldBusPlug-Slave interface Connection COM1: 9-pole pluggable terminal block Connection COM2: 9-pole SUB-D (socket) Type Number of coupler slots Connection for coupler integrated in the CPU Order code TB511-ETH TB511-ARCNET TB521-ETH TB521-ARCNET TB541-ETH 1 1 2 2 4 Ethernet RJ45 ARCNET COAX Ethernet RJ45 ARCNET COAX Ethernet RJ45 1SAP 111 100 R0170 1SAP 111 100 R0160 1SAP 112 100 R0170 1SAP 112 100 R0160 1SAP 114 100 R0170 Interface modules For decentralized I/Os DC505-FBP DC551-CS31 0.215 Communication via FieldBusPlug with Profi bus DP or DeviceNet (in preparation: CANopen) Fieldbus-dependent FieldBusPlug required Communication via internal interface with CS31 system bus Plug-in electronic modules, terminal block TU551 or TU552 required DC: Channels can be confi gured individually as inputs or outputs Type Number of DI/DO/DC Input signal Output signal Order code Weight per piece/kg DC505-FBP DC551-CS31 8/–/ 8 8/ –/16 24 V DC 24 V DC Trans. 24 V DC, 0.5 A Trans. 24 V DC, 0.5 A 1SAP 220 000 R0001 1SAP 220 500 R0001 0.3 0.3 45 Ordering data AC500 Digital input/output modules - For central expansion of the AC500 CPUs (up to 10 digital or analog modules in any combination) - For decentralized expansion in combination with interface module DC505-FBP or DC551-CS31 (up to 7 digital or analog modules with a maximum of 4 analog modules) - Plug-in electronic modules, terminal block required (refer to table below) - Exception: DC541 (occupies one communication module slot on the CPU terminal base, no terminal block required) - DC: Channels can be confi gured individually as inputs or outputs. Type Number of DI/ DO/ DC Input signal Relay/ transistor outputs Output signal Order code Weight per piece/kg DI524 DC522 DC523 DC532 DX522 DX531 DC5412) 32 /–/– –/–/16 –/–/24 16/–/16 8/8/– 8/4/– –/–/8 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 230 V AC 24 V DC – Transistor Transistor Transistor Relay Relay Transistor – 24 V DC, 0.5 A 24 V DC, 0.5 A 24 V DC, 0.5 A 230 V AC, 3 A1) 230 V AC, 3 A1) 24 V DC, 0.5 A 1SAP 240 000 R0001 1SAP 240 600 R0001 1SAP 240 500 R0001 1SAP 240 100 R0001 1SAP 245 200 R0001 1SAP 245 000 R0001 1SAP 270 000 R0001 0.2 0.2 0.2 0.2 0.3 0.3 0.1 1) 2) Relay outputs, changeover contacts Multifunctional module, refer to table on page 29 for details Analog input/output modules - For central expansion of the AC500 CPUs (up to 10 digital or analog modules in any combination) - For decentralized expansion in combination with interface module DC505-FBP or DC551-CS31 (up to 7 digital or analog modules with a maximum of 4 analog modules) - Plug-in electronic modules, terminal block required (refer to table below) - Each channel can be confi gured individually - Resolution: 12 bits + sign Type Number of AI / AO Input signal Output signal Order code Weight per piece/kg AI523 AX521 AX522 16 / 0 4/4 8 / 8 (max. 4 current outputs) 0 / 16 (max. 8 current outputs) 0 ... 10 V, ±10 V 0 /4 ... 20 mA Pt100, Pt1000 Ni1000 - - 1SAP 250 300 R0001 1SAP 250 100 R0001 1SAP 250 000 R0001 0.2 0.2 0.2 1SAP 250 200 R0001 0.2 AO523 ±10 V 0 /4 ... 20 mA Terminal blocks For digital and analog expansion modules and interface modules. Please note: For modules with relay outputs, terminal blocks for 230 V AC (TU531/TU532) are required! For the module-terminal block assignments, please consult the table! DI524 DC522 DC523 DC532 DX522 DX531 AI523 AX521 AX522 AO523 DC505-FBP DC551-CS31 46 TU515 screw-type x x x x x x x x for I/O modules TU516 TU531 spring-type screw-type x x x x x x x x x x TU532 spring-type TU505-FBP screw-type for interface modules TU506-FBP TU551-CS31 spring-type screw-type TU552-CS31 spring-type x x x x x x Type for TU505-FBP TU506-FBP TU515 TU516 TU531 TU532 TU551-CS31 TU552-CS31 FBP interface modules FBP interface modules I/O modules I/O modules I/O modules AC / relay I/O modules AC / relay CS31 interface modules CS31 interface modules Supply Connection type Order code Weight per piece/kg 24 V DC 24 V DC 230 V AC 230 V AC 24 V DC 24 V DC Screw-type terminals Spring-type terminals Screw-type terminals Spring-type terminals Screw-type terminals Spring-type terminals Screw-type terminals Spring-type terminals 1SAP 210 200 R0001 1SAP 210 000 R0001 1SAP 212 200 R0001 1SAP 212 000 R0001 1SAP 217 200 R0001 1SAP 217 000 R0001 1SAP 210 600 R0001 1SAP 210 400 R0001 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 Accessories for AC500 Type for Description Order code Weight per piece/kg TK501 Programming cable Sub-D/Sub-D, length 5 m Programming cable Sub-D/ terminal block, length 5 m Connection to PC via USB interface. Includes USB extension cable and installation CD. 1SAP 180 200 R0001 0.4 1SAP 180 200 R0101 0.4 1SAJ 929 400 R0001 0.1 MC502 TA521 TA523 AC500 CPUs COM2 AC500 CPUs COM1 Cable for programming the AC500 via the integrated fieldbus neutral interface AC500 CPUs AC500 CPUs I/O modules 1SAP 180 100 R0001 1SAP 180 300 R0001 1SAP 180 500 R0001 0.1 0.1 0.3 TA524 TA525 TA526 Terminal base I/O modules CPU terminal base 1SAP 180 600 R0001 1SAP 180 700 R0001 1SAP 180 800 R0001 0.1 0.2 TA527 CPU terminal base 1SAP 181 100 R0001 0.2 TA528 CPU terminal base 1 SAP 181 200 R0001 0.2 TK502 UTF21-FBP Memory card (SD card) 128 MB Lithium battery for data buffering Pluggable marker holder for I/O modules, packing unit incl. 10 pcs. Communication module, dummy housing White labels, packing unit incl. 10 pcs. Accessories for back plate mounting, packing unit incl. 10 pcs. 5-pole power plug for AC500. Spare part. Can be plugged to CPU terminal base TB5x1. Packing unit incl. 5 pcs. 9-pole COM1 plug for AC500. Spare part. Can be plugged to CPU terminal base TB5x1. Packing unit incl. 5 pcs. Programming package PS501 Control Builder For all AC500 CPUs All programming languages according to IEC 61131-3 Contains: 5 programming languages, sampling - trace, debugging, offline simulation, integrated visualization, trace recording (multi-channel), recipe management, Continuous Function Chart Languages: German / English / French Scope of delivery: Software, libraries and documentation (PDF) on CD-ROM Type for Description Order code Weight per piece/kg PS501 all AC500 CPUs Programming package PS501 Control Builder AC500 License for runtime visualization package. For installation and visualization of images created with the programming package PS501. Delivery includes license code and documentation. 1SAP 190 100 R0002 0.3 1SAP 190 500 R0001 0.3 PS541-HMI 47 Ordering data CP400 Operator panels with graphics display LCD screen with backlight Type Pixels Display Order code Weight p. piece/kg CP410 M 160 x 80 3", 16 gray levels 1SBP 260 181 R1001 0.65 Operator panels with touch display Type Pixels Display Order code Weight p. piece/kg CP420 B CP430 B CP420 B-ETH CP430 C CP430 C-ETH CP440 C-ETH CP450 T CP450 T-ETH 320 x 240 320 x 240 320 x 240 320 x 240 320 x 240 640 x 480 640 x 480 640 x 480 4,7", 16 blue levels 5,7", 16 blue levels 5,7", 16 blue levels 5,7", 256 color STN 5,7", 256 color STN 7,7", 64.000 color STN 10,4", 64.000 color TFT 10,4", 64.000 color TFT 1SBP 260 182 R1001 1SBP 260 183 R1001 1SBP 260 184 R1001 1SBP 260 185 R1001 1SBP 260 186 R1001 1SBP 260 187 R1001 1SBP 260 188 R1001 1SBP 260 189 R1001 0.47 0.81 0.81 0.81 0.81 1.20 1.90 1.90 Programming cables CP400 Type Plug on CP400 side Description Order code Weight p. piece/kg TK401 SubD9 1SBN 260 216 R1001 0.18 TK402 SubD25 Connection to COM1 of CP400. Length: 4 m Connection to COM2 of CP400. Length: 4 m 1SBN 260 217 R1001 0.23 Communication cables CP400 (connection operator panel <-> PLC) Type Plug on PLC side PLC Order code Weight p. piece/kg TK403 TK404 TK405 MiniDin SubD9 SubD9 AC31 Series 40..50 AC31 Series 90 AC500 1SBN 260 218 R1001 1SBN 260 220 R1001 1SBN 260 221 R1001 0.12 0.12 0.13 Programming software Type Description Order code Weight p. piece/kg CP400Soft Programming software for CP400 operator panels. Delivery includes the programming software and corresponding documentation on CD-ROM. 1SBS 260 284 R1001 0.07 48 Ordering data CP500 Operator panels with text display Type Lines Charact. per line Function LEDs keys / other keys Interfaces Order code Weight p. piece/kg CP501 CP502 CP503 2 2 4 16 20 20 4 3 / 20 5 / 22 5 RS232 or RS422 RS232, RS422, RS485 RS232, RS422 1SBP 260 170 R1001 1SBP 260 171 R1001 1SBP 260 172 R1001 0.1 0.5 0.7 Operator panels with graphics display Type Pixels Function keys / other keys LEDs Interfaces Order code Weight p. piece/kg CP511 CP512 240 x 64 240 x 128 8 / 22 6 / 22 16 16 RS232, RS422 RS232, RS422 1SBP 260 173 R1001 1SBP 260 174 R1001 1.5 1.4 Operator panels with touch display Type Pixels Display Interfaces Order code Weight p. piece/kg CP551 CP552 CP554 320 x 240 320 x 240 320 x 240 B/W - STN B/W - STN Color TFT RS232, RS422, RS485 RS232, RS422, RS485 RS232, RS422, RS485 1SBP 260 176 R1001 1SBP 260 177 R1001 1SBP 260 178 R1001 1.4 1.5 1.5 Weight p. piece/kg Programming cables Type Interface Order code CAB5 CAB6 RS232 RS232/RS422 converter 1SBN 260 210 R1001 1SBN 260 211 R1001 Communication cables Type Controller Order code CAB45 CAB90 CAB8 CAB57 Series 40 / 50 MiniDin Series 90 RS422/RS485 converter Series AC500 SubD9 1SBN 260 213 R1001 1SBN 260 214 R1001 1SBN 260 212 R1001 1SBN 260 215 R1001 Weight p. piece/kg Programming software for operator panels CP5xx Type Description Order code CPsoft Software, documentation on CD 1SBS 260 283 R1001 Weight p. piece/kg 49 Dimensions CPU terminal base TB511, TB521 and TB541 I/O expansion and interface module terminal unit 50 Relevant approvals Like all ABB products, the AC500 components, are In harmony with the natural environment tested in conformity with the applicable European, Protection of the natural environment is integral to North American and international guidelines, and ABB’s corporate philosophy. This includes both approved by the organizations responsible. For the resource-economy and the avoidance of problematical applicable approvals please refer to our ABB web substances, plus recycling-friendly construction and site or contact your local ABB representative. long-lived products. These aspects are taken fully on board by an integrated eco-management system Certified quality conforming to ISO 14001, whose implementation is The entire process involved in creating an ABB repeatedly verified by regular eco-audits. And for product – from the original idea to the actual sale – is, newly developed products ABB now conducts a of course, monitored by a quality management lifecycle assessment as well. process certified under DIN ISO 9001. 51 Subject to alteration Comprehensively customer support ABB draws upon its long years of experience in low-voltage engineering to provide you with a comprehensive range of support services available worldwide. You can call upon contact persons in engineering you can also contact our consultants by phone or fax. Special seminars and training courses are offered for many ABB products and systems, not least covering the automation of machinery and production lines. On request, we will also be pleased to provide on-the-spot training at your own premises. Just talk Printed in the Federal Republic of Germany (04.08 · 5 · VCM) our country sales offices. For all questions to do with automation Publication Number: 2CDC 125 002 B0206 to your regional consultant. 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/stotzkontakt ABB France Automation Products Division Export Department 10, rue Ampère Z.I. - B.P 114 F-69685 Chassieu cedex / France Tel.: 33 (0)4 7222 1722 Fax.: 33 (0)4 7222 1935 ABB Global Contact Directory The ABB Contact Directory (http://www.abb.com/contacts/) helps you find local contacts for ABB products in your country. Please select the relevant product group from the dropdown menu to the right or from the page.
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