ABB AC500 Product Series: Installation and Connection Guide

ABB AC500 Product Series: Installation and Connection Guide

This document provides comprehensive installation and connection instructions for various modules within the ABB AC500 product series. It covers terminal bases (TB51x-TB54x, TB56xx-2ETH), CPU modules (PM5xx, PM595, PM56xx-2ETH), communication modules (CM582-DP, CM589-PNIO(-4)), and I/O modules (TU5xx, DC522, DC523, DC532, DI524, DO524, DO526, AI523, AI531, AO523, AX521, AX522, CI5x1, CI5x2, CI541-DP, CI542-DP). The document emphasizes safe handling, proper installation, and detailed connection specifications for each component.

General Safety and Installation Guidelines

Throughout the document, a critical warning is reiterated: "Risk of injury to personnel and damage to PLC modules!" Improper installation and maintenance can lead to personal injury and module damage. Therefore, all installation and maintenance work must be performed by skilled electricians in accordance with technical regulations, specifications, and relevant standards (e.g., EN 60204-1).

Dimensions for all modules are provided in millimeters, with inches in parentheses. For screw mounting, it is crucial to use wall mounting accessories (TA526 or TA543 for PM595) to prevent modules from bending and damage. These accessories snap into the rear of the module, similar to DIN rails, and the module is then tightened with M4 screws (max torque 1.2 Nm) from the front.

Terminal Bases (TB51x-TB54x and TB56xx-2ETH)

These sections detail the assembly, disassembly, dimensions, and connection specifications for various terminal bases.

• TB51x-TB54x: Features I/O bus, processor module slots, communication module slots, fieldbus plug interface (not for TB523-2ETH), 24V DC power supply, serial interfaces (COM1, COM2), Ethernet, and ARCNET network interfaces. Pin assignments for power (L+, M, FE), COM1 (RS-485, RS-232 signals), COM2 (RS-232, RS-485 signals, 5V supply), ARCNET, and Ethernet (RJ45) are provided.

• TB56xx-2ETH: Specifically designed for PM56xx-2ETH processor modules. It includes I/O bus, processor and communication module slots, CAN interface, 24V DC power supply, serial interface COM1, and Ethernet network interfaces. Detailed pin assignments for CAN (CAN_GND, CAN_L, CAN_SHLD, CAN_H), power (L+, M, FE), COM1 (RS-485, RS-232 signals), and Ethernet (RJ45) are given.

For both terminal base types, a crucial note advises keeping terminal boards connected even if interfaces are unused to prevent corrosion, especially for "XC" (extreme condition) versions in salt spray environments, where TA535 protective covers should be used.

Processor Modules (PM5xx, PM595, PM56xx-2ETH)

These sections describe the assembly, disassembly, dimensions, and connection interfaces of the CPU modules.

• PM5xx (-y): Includes models like PM572, PM573-ETH, PM582, PM583-ETH, PM585-ETH, PM590-ARCNET, PM590-ETH, PM591-ETH, PM592-ETH. Connection details include status displays (7-segment), triangular and square displays for "project" and "status," status LEDs, function keys, SD memory card slots, and a label area. Specific compatibility notes are provided, e.g., PM591-2ETH only with TB523-2ETH, and PM57x/58x/59x-ETH modules with specific TB5xx terminal bases.

• PM595: Includes PM595-4ETH-F and PM595-4ETH-M-XC. Features I/O bus for I/O modules, LEDs for fieldbus status, battery cover and display, LEDs for processor module status, RJ45 interfaces for fieldbus and Ethernet, memory card slot, reset button, and run/stop switch.

• PM56xx-2ETH: Includes PM5630-2ETH, PM5650-2ETH, PM5670-2ETH, PM5675-2ETH. Similar to PM5xx, it details status displays, LEDs, function keys, and memory card slots. It explicitly states that PM56xx-2ETH processor modules must only be used with TB56xx-2ETH terminal bases.

All processor modules have a warning regarding incorrect battery use potentially causing fire or explosion.

Communication Modules (CM582-DP, CM589-PNIO(-4))

These modules facilitate communication with various fieldbus systems.

• CM582-DP: Assembly, disassembly, dimensions, and connection details for PROFIBUS DP communication. It features status LEDs and rotary switches for setting PROFIBUS ID. Pin assignments for PROFIBUS (RxD/TxD-P/N, CNTR-P, DGND, VP) are provided.

• CM589-PNIO(-4): Assembly, disassembly, dimensions, and connection details for PROFINET IO communication. It includes status LEDs and rotary switches for setting I/O device identifiers. Ethernet network interface pin assignments (TxD+/-, RxD+/-, NU) are detailed.

For unused connectors on communication modules, TA535 accessories are recommended in corrosive environments.

I/O Modules (TU5xx, DC522, DC523, DC532, DI524, DO524, DO526, AI523, AI531, AO523, AX521, AX522, CI5x1, CI5x2, CI541-DP, CI542-DP)

The document covers a wide range of I/O modules, each with specific connection details, LED indicators, and process voltage considerations.

• Terminal Units (TU5xx): TU515, TU531, TU541, TU516(-XC), TU532(-XC), TU542(-XC), TU516-H. These are terminal devices for I/O modules. "H" suffix indicates hot-swappable I/O modules (from index F0), provided communication interface modules (CI5xx) are also from index F0. A warning is given against hot-swapping modules below index F0.

• Digital I/O Modules (DC522, DC523, DC532, DI524, DO524, DO526): These modules handle digital inputs and outputs. They feature yellow LEDs for signal status, green LEDs for process voltage (UP, UP3, UP4), and red LEDs for errors. All I/O channels are protected against reverse polarity, reverse supply, and continuous overvoltage up to 30 VDC. Specific models vary in the number of I/O channels (e.g., DC522 has 16 configurable digital I/O, DI524 has 32 digital inputs, DO524 has 32 digital outputs, DO526 has 8 digital outputs).

• Analog I/O Modules (AI523, AI531, AO523, AX521, AX522): These modules manage analog inputs and outputs. Similar to digital modules, they feature yellow LEDs for signal status, green LEDs for process voltage, and red LEDs for errors. All channels are protected. AI523 has 16 analog inputs, AI531 has 8 analog inputs, AO523 has 16 analog outputs. AX521 and AX522 are mixed analog I/O modules, with AX521 having 4 analog inputs and 4 analog outputs, and AX522 having 8 analog inputs and 8 analog outputs.

• Communication Interface Modules (CI5x1, CI5x2, CI541-DP, CI542-DP): These modules combine analog and digital I/O with communication capabilities. CI5x1 and CI5x2 series (e.g., CI501-PNIO, CI511-ETHCAT, CI521-MODTCP) feature various combinations of analog/digital I/O, Ethernet network interfaces, and rotary switches for I/O device identifiers. CI541-DP and CI542-DP are specifically for PROFIBUS DP communication, including rotary switches for PROFIBUS ID.

For all I/O modules, process voltage must be considered in the control system's grounding scheme.

Cleaning and Recycling

The document provides consistent instructions for cleaning and recycling across all module types.

• Cleaning: Devices should only be cleaned with a damp cloth; no cleaning agents should be used.

• Recycling: Products and their packaging bear the WEEE (Waste Electrical and Electronic Equipment) symbol, indicating that they must be disposed of separately from household waste. End-users are responsible for delivering the product to a designated WEEE collection facility for proper recycling, which helps conserve natural resources and protect human health and the environment.

This comprehensive guide ensures proper handling, installation, and maintenance of the ABB AC500 product series, contributing to the longevity and reliable operation of the PLC modules.